Tag Archives: Oklahoma

Placed on Light Duty at the Power Plant

The 40th “Rest Of” Power Plant Post

Originally posted July 19, 2013:

In another profession being put on light duty may mean that you don’t have to work as hard as everyone else.  When an electrician is put on light duty it means something else entirely.  I think I calculated the number of lights and it was well over 10,000 light bulbs in the coal-fired power plant in North Central Oklahoma.  Ideally you would think that every one of the lights should be in good working order.

Electricians don’t call a light bulb a light.  The light is the fixture.  The bulb is called a “lamp”.  So, for the rest of this post I’ll call the light bulbs “lamps”.

You may think that it’s pretty straight forward to go change out lights (oh.  I mean… lamps), but it’s not.  You see, it isn’t like in your house where you have the regular light bulbs everywhere with just different shapes and wattage.  Sure, there were different Watts for the different lamps, but for a good number of the lights, they varied by voltage as well.

Not only that, but these lamps were different types of lights.  Most of which are not incandescent (well… now that the government has seen fit to force the lighting industry to stop making incandescent lamps altogether, I guess it wouldn’t seem odd to the younger folks).

A descriptive picture of an Incandescent lamp found at www.techlinea.com

A descriptive picture of an Incandescent lamp found at http://www.techlinea.com

In the office areas and places like the main switchgear 4 foot fluorescent lamps were used.  Each 4 foot fluorescent lamp is 40 watts.  Just because it is 40 watts, it doesn’t mean that the voltage is low.  It can take up to 650 volts to start up a fluorescent lamp.  A Fluorescent lamp actually has a gas in it that causes a coating on the glass to glow when a current flows across the gas.

A fluorescent Lamp

A fluorescent Lamp

Besides the typical fluorescent lamps, the majority of the rest of the lamps in the plant were various sizes of Mercury Vapor lamps.  (now replaced with Sodium Vapor).

Before you become all twisted about using Mercury Vapor to light up a power plant because of the environmental impact, I think I should point out that even though a fluorescent lamp is filled with an inert gas like argon, it is mixed with Mercury vapor as well, and the phosphorous coating on the glass has mercury in it also.

So, if you have fluorescent lamps in your house…. Well, there you go.  And you know those lamps that are used to replace your old incandescent light bulbs….. Yep… and they have other kinds of hazardous metals as well.  I suppose it is good for the environment to take those hazardous materials out of the earth and put them in lamps in your houses.  Isn’t that improving the environment?

The thing about using Fluorescent lamps and Mercury Vapors and Sodium Vapor lamps is that they all use different voltages.  So, in order for them to start up and stay running, the voltages have to change from the start up voltage to the operating voltage.  Each lamp has it’s own transformer designed just for that one type of lamp.  It is placed in the light fixture for the lamp.

You can tell this is a 100 Watt Mercury Vapor lamp because of the 10. If it had a 25, then it would be a 250 watt lamp. Following the same logic if it has a 75 on it, then it is a 75 watt lamp..... oh...well.. the logic is there somewhere

You can tell this is a 100 Watt Mercury Vapor lamp because of the 10. If it had a 25, then it would be a 250 watt lamp. Following the same logic if it has a 75 on it, then it is a 75 watt lamp….. oh…well.. the logic is there somewhere

If the light glows blue, then it is mercury vapor.  If it is orange then it is a sodium light.  Your street lights are the same way.  Well.  Now there is also Halogen lamps which shine white.

Besides these different type lamps, we also had some super special lights.  We have the flashing lights on the smoke stack and the red blinking light on the top of the radio tower.  The lights that flash on the smoke stacks are really flashbulbs.

A flash tube used in a smoke stack beacon that can easily be seen 50 miles away at night. Especially when the day time setting is still on

A flash tube used in a smoke stack beacon that can easily be seen 50 miles away at night. Especially when the day time setting is still on

Our smoke stacks are 500 feet tall with beacons at the 250 foot level and the 500 foot level.  Not only did you have to change out the bulb, but you often had to change out the large capacitors and the circuit boards that had been fried by a passing lightning storm.

You may have heard that with the older style Television sets that had a picture tube (before the flat screen TVs came around), that you could electrocute yourself by taking the cover off the back of the TV and working on it, even though you unplugged the set from the wall before you started.  A few movies used this in the plot.  Robert T. Ironside even used it once in an episode during the first season.

Robert T. Ironside played by Raymond Burr

Robert T. Ironside played by Raymond Burr

Well.  The Stack lights are like that.  When we opened up the light fixture to work on the flash tube or the circuits inside the first thing you did was take a metal rod with a wooden handle and a wire attached with a clip on the end and clipped the wire to the handrail.  Then turning your head the other way, you placed the metal rod across each of the large capacitors in the box.   Invariably, one of the capacitors would let out a loud pop (or should I spell that “pow!”) that would echo across the lake…. oh, and leave your ears ringing.

Once the voltage was discharged from all the capacitors, you knew it was safe to go to work fixing the light.  The lights had a day and a night mode, and the difference was how many times the flash tube flashed when it discharged.  What I mean to say is that it wasn’t just one flash.  It is really a series of flashes closely timed to look like one flash.  The number of flashes and the timing between the flashes determine how bright the flash is.

At night the flash was much dimmer because it didn’t need to be so bright.  When it was stuck in the day mode at night the farmers for a 30 mile radius would be calling saying they can’t sleep because every 6 seconds their bedroom would light up as the smoke stack lights would blink.

The Lake on a hill with the power plant in the distance at sunset

The Lake on a hill with the power plant in the distance at sunset

I thought I would just put that picture in there so you could see how pretty the plant looked from across the lake at sunset.  To me it looked like a big ship on the horizon.

I mentioned above that there was a radio tower that had a light on it that needed to be changed when it burned out.  The actual lamp looked a lot like a regular incandescent bulb in your house, but it was different.  It was designed just for this job.  It didn’t burn out very often.  Ok.  I can see your look of disbelief, so here is a picture of one:

A radio tower light bulb

A radio tower light bulb

Yeah, looks just like something in your house.  Doesn’t it?

Anyway.  I changed out the light at the top of our radio tower which is only about 200 feet tall.  It looked like the following picture:

Our tower was like this only it didn't have a safety pole up the side for a lanyard.

Our tower was like this only it didn’t have a safety pole up the side for a lanyard.

I had to climb to the top of this tower to replace the red flashing light.  I was by myself when I did it.  Bill Bennett handed me the bulb that had been specially ordered and asked me if I would do it.  If not, they could call Oklahoma City and have the line crew come down and change it.  I told him I could do it.  The tower wasn’t that tall, and I had shimmied around the top of the smoke stack before at 500 feet with only a slight urge to panic.

I changed the lamp out without incident.  I know that some people have a much more interesting job changing these lights out than I had.  Our radio tower was only 200 feet tall.  Here is a video of someone that had to climb a tower 1768 feet high.  You can see the beacon when they reach the top of this radio tower:

if your browser doesn’t play the video from the picture try this link:  “Climbing a 1768 foot tower“.

Ok.  That is crazy!  Wouldn’t dropping someone from a helicopter onto the tower using a safety line be safer?

My last story about being on light duty at a power plant is about when Ted Riddle and I were working at the gas-fired power plant near Mustang, Oklahoma.  I talked about the time that Ted and I worked at this plant in the post “Working Power Plant Wonders with Willard Stark

While we were there after they found out that we were electric conduit running fools, they gave us all sorts of jobs running conduit all over the plant.  One job they showed us was in an area that was dark.  All the lights were out in this area.  The foreman explained where the light bulbs were kept.  They were just the regular incandescent lights like the normal lights you would have in your house.

Well… Ted and I had both been put on Light Duty at our plant, and we knew that when we went to change out one light, we were supposed to change out all the lights that were out.  So, Ted and I each grabbed a box and a ladder and headed up to the boiler enclosure to change lights.

After lunch, the foreman came running up to us yelling, “What did you do?  You used up all of the light bulbs!”  Well.  Yes.  We had used up the lights, but now when you go up on the boiler you can see where you are going.  The foreman then explained to us  that this little plant didn’t have the same kind of budget that the new big plants had.  They couldn’t afford to just go around replacing all the lights whenever they burned out.  They only put in a light when someone has to work in that area.  We had lit the entire place up like a Christmas tree.

Ok.  Take a note Jan… Don’t replace all the lights if they are incandescent.

Ok (again), that wasn’t quite the last story.  Let me tell you some more about replacing Fluorescent lamps in our Coal-fired power plant.  When we were placed on Light Duty, we would grab a couple of boxes of 30 lamps from the pallet in the main switchgear and go to work.

In the main switchgear the lights were up high, so we used a 10 foot ladder with a stand on the top of it (No.  I don’t mean like a Deer stand…. geez… Power Plant men…. always thinkin’ ’bout huntin’).  Actually it is called a Platform ladder:

This is a 6 foot platform ladder. Ours was 10 foot and very wobbly

This is a solid 6 foot platform ladder. Ours was 10 foot and very wobbly

I didn’t like using this wobbly ladder when I was by myself.  besides being wobbly, the thing weighed a ton.  So, I would take a smaller ladder and put it on top of the breaker cabinets and climb on top of them.  The only problem here was that I couldn’t get directly under the lights, so I would end up reaching out to one side to change a light while I was standing on a ladder on top of a seven foot cabinet.  Not a pretty sight if someone safety minded walked in.

I felt safer doing this than standing way up in the air on a 10 foot wobbly platform ladder.  I always had the feeling that if I sneezed, the ladder would topple over.  The rule of thumb was to keep your belt buckle within the rungs on the ladder.

When we were done changing out fluorescent lamps, we usually had a stack of boxes of burned out lamps.  We couldn’t just throw them in the dumpster because they were a safety hazard as they were.  We had to break each bulb.  We found that we could take a box of 4 foot fluorescent lamps and back the truck over it and it would let out a low but loud boom that sounded like a cannon going off.

The ingenious electricians invented a bulb busting barrel where you slid one 4 foot bulb into a tube and then lifted a handle quickly, and it would explode the lamp in the safe confines of the metal barrel.  The end of the lamp may at times come shooting out the end of the tube, so you never wanted to be standing to that side of the barrel.  I would show you a picture of one, but I’ve never found another one like it.

So, if you were into breaking glass, this was the best part of being placed on Light Duty.  After a hard day of changing out lamps all over the plant, you could stand around in front of the electric shop and slide the lamps down a tube like mortar shell and pull the rod and…. Boom! A puff of Mercury Vapor released into the atmosphere a small cloud of dust…. repeat.

Comment from original post:

  1.  

    Ron Kilman July 24, 2014

    I remember being on “Light Duty” at the Mustang Power Plant as a summer student in 1967. We changed the 1000 watt bulbs in the top of the turbine room. It was so hot, we had to wear gloves.

Power Plant Lock Out – Tag Out or Just Tag Out

The 39th “Rest Of” Power Plant Post

Originally Posted July 12, 2013:

All safe electricians worth their salt know about OSHA regulation 1910.147(c)(3). Only Power Plant electricians have learned more about OSHA regulation 1910.147(a)(1)(ii)(C). Section 147 has to do with locking out and tagging a power source in order to protect the employees working on the circuit. 147(a)(1)(ii) says that Power plants are exempt from section 147. In other words, if you are working in a power plant it is all right to have a less stringent lock-out/tag-out procedure in place than if you didn’t work in a power plant.

One of the first things I learned from Charles Foster, my foreman when I became an electrician was how to remove the “heaters” from a breaker relay in order to protect myself from an “unauthorized” operation of the breaker. That means…. in case someone accidentally turned on the breaker and started up the motor or whatever else I was working on. “Heaters” are what we called the overloads that trip a 480 volt breaker when the circuit uses more power than it is supposed to be using. They are called heaters, because they literally “heat up” in order to trip the breaker.

typical 480 volt overload heaters

typical 480 volt overload heaters

Charles Foster told me the following story about my bucket buddy Diana Lucas (later Diana Brien):

Dee was wiring up a sump pump at the bottom of the coal dumper. The motor had been taken out while the pump had been repaired. Once back in place Dee was sent to wire it back up. The proper clearance had been taken to work on the motor. That is, she had gone to the Shift Supervisor’s office in the Control Room to request a clearance on the motor. Then later she had witnessed the operator opening the 480 volt breaker and place the clearance tag on the breaker.

A typical Clearance Tag. Our tags had the word

A typical Clearance Tag. Our tags had the word “Clearance” at the top. We called them a “Hold Tag”

The tag is signed by the Shift Supervisor and is only to be removed by an operator sent by the Shift Supervisor. It is placed through a slot in the handle on the breaker that keeps the breaker from closing unless the tag is removed first…. well… that’s the theory anyway.

Dee had just finished hooking the three leads in the junction box together with the cable coming into the box using two wrenches. She reached down into her tool bucket that she was using as her stool to get some rubber tape to begin wrapping the connections. The three bare connections were sticking out in front of her face.

A large vertical pump motor

A large vertical pump motor

The Junction box is the box on the right side of this motor. At this point the cover would be off and the wires would be sticking straight out. As she reached into the bucket, the motor turned on and began running.

Startled, Dee stopped what she was doing. I suppose she also pinched herself to make sure she wasn’t dreaming. Then I suppose she checked her diaper to make sure it was still dry. Then I suppose she may have said a few choice words whether anyone was around to hear them or not. Maybe not all in that order.

For those of you who don’t realize what this meant. It meant that if the motor had started running about 5 to 10 seconds later, someone, some time later may have made their way down to the west end of the dumper sump only to find one charred Diana Lucas (who never would have later become Diana Brien). They might not have recognized her at first. I can assure you. It wouldn’t have been pretty.

You see… someone had removed the Hold Tag and purposely started up the motor totally disregarding the clearance. I won’t mention any names, but his initials were Jerry Osborn.

So, after Charles told me this story, he showed me what to do to prevent this from ever happening to me.

Charles and I went to the Shift Supervisor’s office to take a clearance on a motor. Then we followed the operator to the breaker and watched him open the breaker and put the tag on the handle. Then we signed something and the operator left.

After the operator left, Charles told me to open the breaker and slip the hold tag through the slot in the door so that the door could open without removing the tag. I followed his directions.

Once the door was open, he told me to remove the three heaters on the bottom of the relay and hide them at the bottom of the breaker box.

480 volt relay with the 3 heaters at the bottom. That white square is an overload reset button. in front of the first heater

480 volt relay with the 3 heaters at the bottom. That white square is an overload reset button. in front of the first heater.  The black squares with the W 34 on them are the heaters.

You see… with the heaters removed, even if someone were to close the breaker and try to start the motor, the electricity would never leave the breaker box because I had just created an open circuit between the relay and the wires going to the motor.

Well… If you don’t learn from history you are bound to repeat it. No. I’m not going to change subjects and start talking about making it illegal to own guns.

Anyway, there is always a chance for something to go wrong. The Peter Principle demands it. So, at one point, someone forgot to replace the heaters in the relay before returning their clearance. When the motor was tested for rotation, it didn’t work. At that point the electrician knew that they had forgotten to re-insert the heaters. So, they had to return to the breaker to install the heaters before the motor would run.

This didn’t set well with the Shift Supervisor, who has supreme power at the power plant…. well… besides the janitor who had total control over the toilet paper supply.

Technically we were not going around the hold tag by removing the heaters because they were downstream from the breaker handle which cut off the power to the relay. The Shift Supervisor on the other hand believed that the hold tag included everything in the breaker box, including the relay and heaters (which really was stretching it).

An argument ensued that pitted the shift supervisors and the supervisor of operations, Ted Holdges with the electricians. Ted argued that we should not be removing the heaters to keep ourselves from becoming electrocuted accidentally when someone inadvertently removes a hold tag and turns the breaker on and starts up a motor. Electricians on the other hand argued that if we were going to be exposed to the possibility of being electrocuted, we would rather not work on any circuit. Without being completely assured that we would not occasionally be blown to pieces when someone or something accidentally caused the circuit to become hot, we concluded it wasn’t worth it.

So, a compromise was reached. We could remove the heaters, but they had to be put in a plastic bag and attached to the hold tag on the outside of the breaker. That way, when the clearance was returned, not only were the heaters readily available the operator would know to contact the electrician to re-install the heaters. The electricians didn’t really like this alternative, but we agreed. We were assured that there wasn’t any way that a breaker was going to be turned on and operated with the heaters in them when someone was actually working on a circuit.

Fast forward three years. 1992.

Bill Ennis and Ted Riddle were working on replacing a large electric junction box on the stack out tower. The Stack Out Tower is the tower that pours the coal out on the coal pile. Halfway up this tower there is a large junction box where most of the electric cables passed through going to the top of the tower. Bill Ennis had taken a clearance on a number of motor and control breakers.

Bill returned from lunch one day to work on the junction box, removing the old cables. Putting new lugs on them and placing them in the new junction box. As he began working, he decided to take out his multimeter and check the wires he was about to work on….

We had a couple of these Simpson Analog Multimeters in the shop

We had a couple of these Simpson Analog Multimeters in the shop

Bill was surprised to find that one set of cables were hot. They had 480 volts on them. Everything in this box should have been dead. I suppose he pinched himself to make sure he wasn’t dreaming. Then I suppose he checked his diaper to make sure it was still dry. Then I suppose he said a few choice words that Ted may have heard if he was standing close by.  Maybe not all in that order.

What had happened was that there had been two clearances on this one particular motor. One of the electricians had returned his clearance, and had installed the heaters that were in the plastic bag on the front of the breaker and the motor had been tested for rotation and put back in service. The operator had taken both clearances off of the breaker by mistake.  So, when the electrician arrived at the motor to test it, there were no hold tags on the breaker.

Ok. It was time for another meeting. Something had gone wrong. If it had not been for the guardian angels of both Diana Brien and Bill Ennis, at this point we would have had at least two dead electricians, and believe me…. I know that when an operator had later climbed the stack out tower to check the equipment, if he had run across the body of Bill Ennis… it definitely wouldn’t have been pretty (even on a good day).

I attended this meeting with Ted Holdges as did most of the electricians. I began by telling Ted that when we had met three years earlier I was newly married and wouldn’t have minded so much if I was killed by being electrocuted because I was young and only had a wife who knew how to take care of herself. But now it was different. I had a little girl at home and I need to be around to help her grow up.

Ted looked surprised by my remark. I had just told him the way I felt about this whole situation. The argument that we were making was that we should be able to place locks on the breakers just like OSHA demanded from the other industries. We had demonstrated that we didn’t have a system that would protect us from human error. We needed something that definitely kept us safe.

We told Ted that even if we had locks, and for some reason the breaker just had to be closed and the electrician had forgotten to remove his lock, the shift supervisor could keep a master key in his office to remove the lock. He finally agreed. His problem was a loss of control. The thought was that the Shift Supervisor had ultimate power.

If you don’t learn from history you are bound to repeat it. No. I’m not going to change subjects and talk about socialized healthcare and how it destroys all concepts of quality and privacy.

So, as electricians, we weren’t really happy with this situation. We had a secret weapon against human error. Sure we would place a lock on the breaker. But after the operator would leave, before we placed our lock on the breaker, we might just open up the breaker box and remove the entire face off of the relay. It was similar to removing the heaters only it was bigger. It completely opened the circuit no matter what.

I hadn’t really planned on talking about this next story for a couple more years, but I’ll tell it now because it fits with this story.

In the month of May, 2001. I had already given my notice to leave the plant to work for Dell as a software developer. I was asked to work on a job with my old bucket buddy Diana Brien (I don’t mean old as in Diana Brien was old.  I mean old in that she had been my bucket buddy years before).

Diana-Brien

My Bucket Buddy Diana Brien

The Shift Supervisor explained to us that the problem was that there was a grounded three phase circuit up on the Surge Bin tower. It had been tracked down to the dust collectors located below the surge bin conveyor floor.

Dee and I walked up to the Gravimetric feeder deck to look at the breaker to make sure it was turned off. It had a Danger tag on it that had been placed by the Shift Supervisor.

A typical Danger tag used at the plant

A typical Danger tag used at the plant

The breaker was open and the message on the tag said “Do not close this breaker. The circuit is grounded”.

Ok. We walked up to the surge bin tower through the counter weight room for belts 18 and 19. We opened up the big junction box that fed the power to the two large dust collector motors on the landing behind us. After taking the cover off of the box, I took out my multimeter and checked the circuit.

Like this. Ok. So the multimeters had become more sophisticated over the years.

Like this. Ok. So the multimeters had become more sophisticated over the years.

The big copper bus was dead (that means, there was no electricity present).

So, Dee and I worked on locating the grounded circuit. I had just removed the cover to the junction box on one of the motors while Dee was removing some wires from the control panel when Larry Tapp arrived on the landing through the same route we had taken from the gravimetric feeder deck.

Larry asked us what we were doing. We told him we were tracking down the ground on the Dust Collectors. Larry looked surprised.

You see… Larry explained that he had just come from the Gravimetric feeder deck where he had just closed the breaker for the dust collectors. This particular breaker didn’t have a relay, as it was controlled by the control panel where Dee had been working.

So, I rechecked the copper bus with my multimeter and it was hot. 480 volts hot.

I had just been looking through my tool bucket for two wrenches to remove a piece of the bus work just to make sure the ground wasn’t in the box itself when Larry had arrived. In other words, if Larry had arrived 5 to 10 seconds later, he would have probably arrived to find Dee looking down at my body, stunned that I had just been electrocuted by a circuit that we had just tested and found dead (and I can assure you.  It would not have been pretty).

If you don’t learn by history you are bound to repeat it.

You see… there is a difference between a Hold Tag and a Danger Tag. A hold tag is placed on a breaker after someone has requested a clearance by signing a form in the Shift Supervisor’s office in the control room. A Danger tag can be placed and removed at anytime by the person that placed the tag on the breaker.

So, I personally wrote this up as a “near” accident. We could have wiped our brow, pinched ourselves to make sure we weren’t dreaming. We could have checked our diaper to make sure it was still dry and then Dee could have said a few choice words that Larry Tapp would have agreed with (I have always had a mental block against expressing myself in that manner…. I found other ways). And we could have left this incident as a secret between Larry, Dee and I.

I thought it was a good time to remind the electricians throughout power production to follow the clearance procedures when working on high voltage circuits. Sure. Dee, Bill Ennis and I have powerful guardian Angels looking out for us…. but gee… I think we should be expected to look out for ourselves. So, I wrote up this incident to warn the rest of the team….. If we don’t learn from history, we are bound to repeat it.

I met with my roomie Steven Trammell, a month and a half later in Perkins Restaurant in Stillwater, Oklahoma to discuss his performance plan. I was a 360 Degree Assessment Counselor and my favorite roommate from 17 years earlier had chosen me to review his performance appraisal. During this meeting I asked Steven, who had driven from Harrah, Oklahoma from another power plant to meet with me, if he had read the near accident report about the dust collector at our plant.

My roomie told me that he had, and that he thought it seemed to unduly blame the electrician. I told him I was the electrician and that I wrote the report. After 18 years of being an electrician, I had become so relaxed in my job that I had become dangerous to myself and others. So, after I did a cause-effect analysis of the near accident, most of the cause had come from my own belief that I could circumvent clearance procedures and save time and still believe that I was being safe.

On my drive back to the plant after the meeting with my favorite roomie of all time, I had time to think about this…. I was going to be leaving the power plant in a little over a month to work for Dell as a programmer. I knew this when I had been negligent with the Danger tag. I could have caused the death of both Dee and I. I will sure be glad to be in Texas. — Only.. I will miss my friends most of all.

I leave the Power Plant with this one thought…. If you don’t learn from history, you are bound to repeat it. I mean it… This time I really do.

Comments from the previous posts:

  1. Ron Kilman July 13, 2013:

    This is a great story. I thank God for His guardian angels and I thank you for taking responsibility. It was always difficult investigating accidents because people are a little reluctant to share their mistakes with the world. But a wise man knows it’s better to have a bruised ego than a fried friend.

Larry McCurry July 13, 2013:

Kevin,

  1. As an old time operator and having followed in my fathers footsteps as a Shift Supervisor, The answer to all of these problems to add steps to the clearance procedure to make sure the heaters were removed and then replaced. The second was definitely an operator error, and I agree with you about it, The Shift supervisors did argue for it however the hubris of certain power hungry people managed to intimidate and control the situation. You do not ever work on equipment without your own clearance or a plan that includes the SS, as you mentioned He is the operating authority, or was until a person by the initials of Jim Arnold rewrote the procedures and made himself the Authority.

Jack Curtis August 12, 2013:
Good Story Indeed.
There is, I’m sure, a gene in human DNA labeled: “Murphy” that assures that anything that can happen, does. And in total ignorance, I’ll bet that some constant percentage of plant electricians were fried. I suppose the onset of computer controls has reduced that but that it still happens at a lower rate. The way you and your friends sort of automatically reached for your multimeters is a clue! These are shocking, highly-charged stories…
NEO July 16, 2014
Yep, and even c.3 rules fail on occasion. Most places I’ve worked the other key was at superintendent level, and required a veritable mountain of paperwork to acquire. G-d help anybody who lost his key! 🙂
Traditionally on distribution lines, we left our shotgun hanging on the (grounded) stinger to notify everyone since there is no (effective) way to LOTO a power line. Imagine my vocabulary one fine day up in Montana when I drove up to reenergize a tap to find it energized and a crew I had never seen putting my shotgun in their truck. That day, I got a profuse apology (and assurances) from the line superintendent in person, 50 miles from the office. I never worked dead again without three point grounding, and I require my people to use it as well, I don’t like funerals. Hot line is actually safer for most operations.
Dan Antion July 17, 2014
I have great respect for electricity, power tools and the threat of human error. That was a close call. Glad you had the presence of mind and experience to think to check again.

Working Power Plant Wonders with Willard Stark

The 38th “Rest Of” Power Plant Post

Originally posted on July 6, 2013:

Ted Riddle and I were working for an “Acting” foreman named Willard Stark during an overhaul at the plant outside Mustang, Oklahoma the spring of ’86.  Willard seemed much older than he was.  I would have guessed he was in his late 60’s or early 70’s, but it turned out he was only in his mid to lower 50’s.  I found out why he had aged as the overhaul unfolded.

I heard some slight grumblings from a few in the shop when Bill Bennett told me that I was going to the plant near Mustang, Oklahoma that spring.  I suppose it was because since I had become an electrician in the Fall of 1983, this was already going to be my third overhaul away from our plant, and all of them ended up being major overhauls.

The reason others were grumbling about this was because when you were able to go on an extended overhaul at another plant, it meant that you were going to earn not only a lot of extra overtime, but you also received travel time, mileage and a per diem (a daily amount of money for expenses).  I believe at the time the Per Diem rate was $32.00 each day.  This was supposed to pay for your hotel room and your meals while you were away from your family.  We lived in trailers to cut down on costs.

Others believed that I had received more than my share of the piece of this pie.  I had been sent on every available overhaul since just before I had reached my first year as an electrician.  So, by this time, most people would have saved up quite a sum of money.  I, however, was making around $7.50 my first year, and by the time 1986 had rolled around, I was still making just under $10.00 an hour.  So, overtime amounted to $14.50 an hour.

When you compared this to the first class electricians that were making around $19.00 an hour at the time, they would have been making $28.50 an hour overtime.  This was about twice what I was making.  So, I was a cheap date.

On December 21, 1985 I had been married (the day following my last day at Horseshoe Lake overhaul — see the post:  A Slap in the Face at a Gas-Fired Power Plant), and I had used every cent I had in the world to pay for our honeymoon.  I was even relying on paychecks I was receiving while I was away to finish paying for it.

So, it helped to come back and find that we were on a major overhaul at our plant on Unit 1 doing the 5 year checkout.  Then finding that I was going to a major overhaul at the plant in Mustang, Oklahoma where I could live with my wife in her apartment in Oklahoma City while she finished her last semester to obtain her nursing degree from Oklahoma University.  I went on the overhaul with Ted Riddle.

Ted was hired into the electric shop the previous summer.  He wasn’t on my crew so I hadn’t worked much with him.  He was a farmer that had an electric background.  He was a bigger man than I was and had a good sense of humor.  He had a steady temper and didn’t let much bother him.  He would laugh at things that might bother others.

I appreciated working with Ted, because his steady mood helped to teach me that blowing my top about little things did little to help the situation.  So, for this overhaul, I decided that I would try to emulate Ted Riddle by keeping up with his easy-going-ness (I know…. the dictionary couldn’t find that one).

Bob Kennedy was on this overhaul as well.  He had been my acting foreman during the  overhaul at Horseshoe Lake.  I had described our relationship in the post:  “Bobbin’ Along with Bob Kennedy“.  I was glad to be working with Bob again. As I mentioned, Willard Stark was our acting foreman during this overhaul.

For those that don’t know…. an acting foreman is someone that normally isn’t a foreman, but is appointed to lead a crew for a particular job.  These men usually are the best foremen to work for, because they haven’t attended any official “manager training”.  This usually made them better foremen, as the manager training had a tendency to destroy one’s character and moral integrity.  — I never could figure that one out.  Some people came back unscathed, but others came back with PTMD (Post-Training Manager Disorder).

The plant at Mustang was the smallest gas-fired power plant that had people permanently working there.  It had some smaller units that they wouldn’t run when the newer larger units weren’t running because the water treatment plant (that creates the boiler water) used more power than the small units could generate.  — That amazed me.  So, while we were there, I don’t think any of the units were running so they didn’t have to run the water treatment plant.

Willard Stark had spent a good portion of his life working at the plant and had a lot of stories about the plant manager and assistant manager at our plant.  He had been an electrician when Bill Moler had first come to the plant as a new green electrician like me.  I enjoyed sitting during lunch in Mark Thomas’s electric lab as Willard told us stories.

Willard had an incredible memory.  He could remember what he was doing on any specific day decades before. We would listen to Paul Harvey on the radio during lunch, and whenever Paul would say, “….noon news and comment.”  Willard would always finish the sentence by saying “…mostly comment.” I had spent a good part of my childhood listening to Paul Harvey on the radio because when I was young, we always had a radio playing in the house and the car.  So, Paul Harvey’s voice was always a comfort to me.  I was saddened a few years ago when he passed away.

Paul Harvey was one of a kind radio personality. No one will ever fill his shoes.

Paul Harvey was one of a kind radio personality. No one will ever fill his shoes.

Working with Ted Riddle cracked me up.  He would notice things that I was totally oblivious to (yeah.  I see it.  A preposition at the end of a sentence).  For instance, one day while we were working, Ted asked me if I ever noticed how Bob Kennedy drinks water out of his jar.  I told him I hadn’t noticed.

You see, Bob had this jar that looked like a pickle jar that he brought to work each day filled with water.  During lunch, he would drink out of this jar.  Ted said, “Watch Bob during lunch today.  Tell me what you think.” So as I was sitting next to Bob during lunch listening to Paul Harvey, and Willard Stark telling us what he did on any particular date in the past that Paul Harvey might mention, I kept one eye on Bob, which made me look a little like Marty Feldman.

Marty Feldman

As Bob lifted his jar to his mouth I watched as he began to drink.  I immediately knew what Ted had wanted me to see. As Bob took a drink, he  slowly tilted the jar up until the water reached his mouth.  As the jar was being tilted, Bob’s upper lip would reach way into the jar as far as it could, quivering in anticipation of a cool drink of fresh water.  The upper lip of a camel came to my mind.

Bob Kennedy's upper lip reaching into the water jar...

Bob Kennedy’s upper lip reaching into the water jar…

With all my might, I struggled to keep a straight face as I turned my head slowly to look over at Ted who had a grin from ear-to-ear….. ok.  I’ll show you the picture of Andy Griffith again that I included in my post from last week, just so you can see what I saw when I looked over at Ted:

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

I think I almost choked on my ham sandwich as I swallowed while trying to keep my composure.

Another day while Ted and I were cleaning ignitors on the shop work bench Ted asked me if I had noticed what Randy Oxley and Jimmy Armafio were working on.  I told him I hadn’t noticed.  Ted said that if he’s not mistaken Randy Oxley has been coming into the shop all morning with the same piece of conduit.  He bends it, then cuts a little off the end and re-threads it.

I don’t have a picture of Randy, but here is one of Jimmy:

So, the next time Randy came into the shop I noticed he had a piece of one and a half inch conduit in his hand.  It was about 3 1/2 feet long and had a couple of bends in it.  Randy hooked the conduit up in the large conduit bender and using his measuring tape carefully lined it up as Armafio stood back and watched.  He bent the conduit a little, then put it in the bandsaw and cut off a few inches.  Then he put it in the vice on the work bench and proceeded to thread the end of the conduit.

Then Jimmy and Randy left. Ted said that if he wasn’t mistaken, that’s the same piece of conduit Randy has been working on all morning.  So, as we continued the boring job of cleaning the 30 or so ignitors piled on our workbench, I told Ted about the time I was at the plant at Horseshoe Lake and Randy had told a Mechanical A foreman Joe Balkenbush (I think his first name was Joe), who was Randy’s uncle on his mom’s side, that Randy was the best electrician at the plant at Mustang, only he was the only one that knew it.

I mentioned this meeting and the reason for it in the post:  “Bobbin Along with Bob Kennedy” (See the link above). Sure enough, a little while later, Randy came back to the shop with the same piece of conduit and performed the same procedure of bending, cutting and threading and scadoodling.

A little while later the electrical B foremen came out into the shop (I can’t remember his name for the life of me… I can see his face – maybe something Campbell), and asked us if we knew how to run conduit.  We assured him that we did.  I had been thoroughly trained by Gene Roget and Ted, well, as it turned out, Ted was a crackerjack conduit hand.

The foremen took us up onto the boiler and asked us if we could run some conduit from one place to another.  He sounded apologetic when he asked if that would be all right.  We assured him it was no problem.  We would get right on it.

On the way back to the shop, as we were coming down from the boiler, Ted tapped my shoulder and pointed down to the bottom of a light fixture.  He said, “Hey!  Isn’t that the piece of conduit that Randy has been working on all morning?”  Sure enough.  There is was.  He finally bent it and cut it to fit! Well… The rest of this part of the story is that instead of running back and forth to the shop to bend and cut and thread conduit, Ted and I grabbed a conduit stand, and the appropriate tools and hauled them up on the boiler.

Conduit threader stand

Rigid Conduit threader stand

We carried about 40 foot of conduit up there and began bending, cutting and threading and mounting the conduit.  We finished just before lunch.  As I mentioned above, Ted was a heck of a conduit person.  He knew exactly what he was doing.  We carried all the equipment back to the shop.

After lunch Ted and I went back to cleaning ignitors.  The foreman saw us out of the window of the office and came out and asked us why we weren’t working on the conduit.  When we told him we were done, he had a look of disbelief.  He left the shop (to go check out our work).  Ted and I smiled at each other.

A little while later the foreman returned with the electric supervisor. The electric supervisor asked us if we wouldn’t mind working on some more jobs to run conduit.  Ted told him that we were there to do whatever they needed.  I nodded in agreement.

During the rest of the overhaul we worked to repair broken conduit, pull wire and install new conduit where needed. Mark Thomas, the electric specialist, that was about my age, asked if he could use us to pull and mount some new controls.  He said he wouldn’t let the others in the shop touch it because he would just have to follow through behind them and redo it when they were done.  So, we did that also.

We did get in trouble one day when we went to install some conduit over a control room just off of the T-G floor.  We noticed that all of the lights were out except a couple, so we found a couple of large boxes of light bulbs and replaced the burned out bulbs.  The Electric Foreman came running up to us a little while later and said, “What are you trying to do?  Run us out of business?”

With looks on our faces that conveyed that we didn’t understand what he meant, he explained that in small plants like this one, they don’t have a budget like the bigger plants.  They can’t afford to keep the lights burning all over the plant all the time.  So, we were only supposed to replace lights in the immediate area where we had to work.  Now the foreman had to figure out where he was going to find the money to buy another box of light bulbs.  — These were incandescent bulbs that don’t have a long life span.

I had mentioned in an earlier post called Resistance in a Coal-fire Power Plant that Bill Rivers had been given a bum deal when another person had accused him of cutting off the leads of electronic components so that no one could check them to see if they were really bad (which doesn’t make any sense given that you could still check them no matter how short the leads are).  Well, I found that the same situation had existed in this plant.

There was this one guy that sat in the electric shop Lab (not the same electric shop lab where Willard and Mark Thomas hung out), working on Gray Phones all day.  Ted had asked me if I had noticed how many gray phone boxes were missing gray phones (gray phones are the PA system in a plant.  You could go to any one of them and page someone).

Gaitronics Gray Phone

Gaitronics Gray Phone

Ted would point to empty gray phone boxes as we walked through the plant.  He told me that they have one electrician that doesn’t do anything else but sit in the electric lab working on gray phones.  That is all he does.  When we asked Willard about it, he told us this story.

Mark Thomas used to work on all the gray phones, and kept them all running in good working order.  When Mark worked on a gray phone, sometimes to make sure it is working, he would page himself.  Just to make sure that part worked.  I understood this.  When I was working on gray phones with Bill Rivers, he would page me, or I would page him, just to test it.

If you were working by yourself, it would make sense that you would page yourself instead of bugging someone else several times a day while you went from one gray phone to the next. Anyway, people accused Mark Thomas of trying to make himself more important by making others think that he was being paged all the time by paging himself.

Now, anyone with any sense would know how lame of an idea that is.  I mean, anyone would recognize Mark Thomas’s voice.  The plant wasn’t that big.  There weren’t that many people working there.  Everyone knew everyone else.  Mark was obviously just working on gray phones.

So, after the foreman accused him of trying to promote his self importance by paging himself several times a day, Mark said, “Fine!  Let someone else work on the gray phones!”  Mark was by far the most intelligent person at the plant.  He obviously didn’t need to artificially promote his reputation by making a fool of himself.

So, they gave the job of gray phone maintenance to someone that didn’t understand electronics.  They even bought an expensive gray phone test set to help him out.  So each day he would sit in the lab smoking his pipe staring at an ever-growing pile of gray phones.  At one point, Ted and I offered to fix them all for him.  He said, “That’s ok.  It keeps me in the air conditioning.

I know in later times, Mark Thomas went on to greater successes within the company.  I believe that Willard stayed around until there was a downsizing and he was able to early retire. I mentioned at the beginning that Willard looked a lot older than he really was.  Willard brought this to my attention.  He showed me a picture of himself a few years earlier.  It was of him standing by a car wearing a suit.

He reminded me of an actor from an old movie, though, I can’t remember the actor’s name at the moment. Willard said that in the past few years he aged rapidly.  It happened when the previous foreman had retired.  Willard had seniority in the shop and had been at the plant most of his life.  He knew what he was doing, and had filled in as foreman many times.  He really expected to become the foreman.

Nevertheless, they gave the job to someone from somewhere else who didn’t know the plant, or even much about being a foreman. This upset Willard so much that he said he just gave up.  He said the stress from that experience aged him.  Mark Thomas agreed.

Mark had his own encounter with this attitude when he decided to retreat to his lab off and away from the electric shop.  Willard and Mark, the two electricians that really knew what they were doing at the plant had sequestered themselves in their own hideaway where they would sit each day listening to Paul Harvey at lunch and biding their time until the next phase of their life came around.

Comments from Previous post

  1. Ron Kilman 

    I was a summer student at Mustang in 1967, 1968, and 1969. I remember Willard Stark as a happy guy in the Electric Shop (big smile) and fun to be around.

    The two older units at Mustang were around 50 MW each. They generated plenty of power to run the water plant. The reason they were not run much was because they were non-reheat units (900 psi, 900 F) with a very high “heat-rate” (very inefficient). If I remember right, they ran about 15,500 BTU/KW. Units 3 and 4 were around 10,500 – 11,000 BTU/KW. And it seems like the “modern” units (2400 psi, 1000F/1000F) at Seminole, Sooner and Muskogee ran a little over 9,000 BTU/KW.

    Promotions were always problematic with “help” coming from OKC Corporate Headquarters Human Resources experts. I am told that those who choose Plant Managers following the 1994 down-sizing were not even in Power Production or Generation Services, had never done a performance appraisal of a Plant Manager and made personnel decisions based on hearsay. I was tempted to “hideout” and retreat, but I decided to not go there. Instead I let OG&E pay for my next adventure (added “Instrument Rating” to my pilot’s license) and had a great time!

     

    Roomy 

    they revamped the two old units back in 2000 with the philosophy that they are only going to run two years. Well, here we are in 2013 and those two old units (60+years old) are still running today. They were put on two weeks ago and will run as long as it is hot. I must say I miss the old guys, maybe because since they are gone I am the old guy!!

Importance of Power Plant Backup Battery Preventative Maintenance

The 37th “Rest Of” Power Plant Post

Originally posted June 28, 2013.

The very last thing I ever learned in High School was the importance of Backup Battery Preventative Maintenance. In fact, the entire senior class of 1978 at Rockbridge High School in Columbia, Missouri learned this lesson at the same time. It was during the graduation ceremony in May while the students were walking across the stage to receive their diplomas.

I had already received mine and I was back in my seat sitting between Tracy Brandecker and Patrick Brier (we were sitting alphabetically. My last name is Breazile). Pat was sitting on my left and Tracy was on my right. We were grinning from ear-to-ear to be graduating. My friends from the second grade, Mark Schlemper, Russell Somers and Brent Stewart had just walked across the stage in the gymnasium while a storm raged outside. As my friend from the fifth grade forward, Matt Tapley was walking across the stage there was a loud crack of thunder and the sound of an explosion as the lights went out.

Matt Tapley has albinism, giving him white hair and skin. In his black robe, the entire class witnessed Matt’s head bobbing up and down in the faint light given off from the emergency lights to either side of the stage as he was bowing to his classmates. We all clapped. The clapping soon turned to laughter as the emergency lights quickly dimmed and went entirely out within a minute.

An emergency light

An emergency light

As we sat in total darkness waiting for some resourceful faculty member to make their way to the hidden fallout shelter in the basement of the school to retrieve the portable generator and a spotlight, I was amazed by how quickly the emergency lighting had failed. The transformer to the school had been destroyed by the lightning strike so we finished the ceremony by the light of the large spotlight from the back of gym. My thought was that the school is only 4 years old and already the emergency lighting is too old to stay lit long enough to even begin evacuating the building, if that was what we had intended to do.

Fast forward to the spring of 1984. I had become an electrician a few months earlier. As I was learning the electrical ropes, I learned the importance of Preventative Maintenance in a power plant setting. The majority of an electrician’s job when I first joined the electric shop was doing “Preventative Maintenance”. I have some horror stories of bad preventative maintenance that I will share much later. I will point out now that most Americans know of some stories themselves, they just don’t realize that the root cause of these major failures were from a lack of preventative maintenance.

A power plant, like the emergency lights in the High School, has a battery backup system, only it is on a grand scale. There are backup batteries for every system that needs to remain online when there is a total blackout of power. These batteries needed to be inspected regularly. We inspected them monthly.

At first, I had done battery inspections with various electricians. Some people didn’t seem to take this task very seriously. I remember that when I did the inspections with Mike Rose, he usually finished by taking a gallon of soda water (a gallon of water with a box of baking soda dissolved into it) and pouring it all over the batteries.

My bucket buddy, Diana Lucas (Dee), on the other hand, took a different approach. We carefully filled each cell with just the right amount of distilled water. Then she showed me how to meticulously clean any corrosion from the battery posts using a rag soaked in the soda water, and then she would paint the area on the post where the corrosion was with No-Ox grease.

A jar of No-Ox Grease (No-Ox means No Oxide)

A jar of No-Ox Grease (No-Ox means No Oxide)

When I say batteries, you may think that I’m talking about batteries like you have in your car, or even in a large piece of equipment like a big dirt mover. Some of the batteries were the size of a battery used in a large dozer or dirt mover:

A battery used in a large dozer

A battery used in a large dozer

Some of the batteries that we inspected were of this type. They were usually hooked up to generators that could be started up in case all the power was out and we needed to start up a diesel generator. However, this was just the puppies when it came to the Station Power Batteries. These were some serious batteries:

The battery shown on the left is about the size of a small file cabinet

These are the type of UPS Station batteries used at the plant. The battery shown on the left is about the size of a small file cabinet

As big as these batteries are, it takes 58 of them for each system to come up with a 130 volt circuit. That’s right. 58 of these batteries all in a series. The station batteries are all in rooms by themselves known as…. “Unit 1 and Unit 2 Battery rooms”. Smaller station battery sets are found at different locations. Today, those places include the relay house in the main substation, the Microwave room on the roof of #1 boiler. The River pumps, the radio tower building, the coalyard switchgear, Enid Turbine Generators and the Co-Generation plant in Ponca City. I’m sure I’m leaving some out. Maybe a current electrician at the plant can remind me of the others in a comment below. Each of these locations have approximately 58 station batteries.

While I was still a novice electrician, one morning in May I was told that I was going with Dee and Ben Davis to Enid to a Battery training class at an electric company office where the manufacturer (C&D) was going to go over the proper maintenance of the station batteries. Ben drove the pickup. I remember sitting in the middle between Dee and Ben both going and coming back from our lesson on Battery Preventative Maintenance….

Interesting that Ben was sitting to my left and Dee to my right that day… just like Pat and Tracy during the graduation ceremony 6 years earlier to the month when we first learned the impact of bad preventative maintenance on backup batteries. This time we were learning how to prevent the problem I had witnessed years before. I don’t know why I draw parallels like that. It just seem to make life a little neater when that happens. I don’t remember Ben and Dee grinning ear-to-ear like Pat and Tracy were the night we graduated from High School, but I can assure you, I was grinning the entire 45 minutes going to Enid and the 45 minutes going back to the plant.

Since I had been trained for battery maintenance, I suppose it was like Andy Griffith becoming the Permanent Latrine Orderly (PLO) in the movie “No Time For Sergeants”. I was able to go to town inspecting all kinds of backup batteries.

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

Gene Roget (pronounced with a french accent as “Row Jay” with a soft J) was a contract electrician when I first became an electrician in the shop. I wrote about him in the post New Home in the Power Plant Electric Shop. He was a great mentor that taught me a lot about how to be an electrician. He taught me how to use all the different tools in my tool bucket. He taught me how to bend conduit and make it come out the right length on both ends…

He especially taught me the importance of doing a “pretty” job when running wire or conduit or just rewiring a motor. I remember Gene stopping one day when we were walking to the precipitator and he paused to look up at the transfer tower. I asked him where he was looking. He said, “I’m just admiring the wonderful job someone did bending that set of conduit. that’s a perfect job! Just perfect!”

Anyway, Gene and I were given the task of checking all the batteries in the emergency lights throughout the plant. It happened that the emergency lights at the plant were all about 5 years old. Probably about the same age as the lights were in the high school the night of our graduation. The lights in the plant had wet cells. Which meant that you had to add distilled water to them like you do in your car, or in the station batteries. This amounted to a pretty large task as there were emergency lights stationed throughout the plant.

We found many of the lights that would never have been able to light up enough to cause a cockroach to run for cover. We took the bad ones back to the shop to work on them. A lot of the batteries had gone bad because they had never been checked. They have a built-in battery charger, and some of the chargers were not working. I drew a wiring diagram of the charger so that we could troubleshoot them and replace components that had gone bad.

All of this was like a dream to me. At the time I couldn’t think of any other place I would rather be. I loved taking things that were broken and fixing them and putting them back into operation. Eventually we decided to change the emergency light batteries to dry batteries. Those didn’t need water. We could pull out the six wet cells from each emergency light box and just plug the new batteries in place. This made a lot more sense. Who has time to go around regularly and check 50 or 60 emergency lights every 3 months? Not us. Not when we were trying to save the world.

Back to the Station Batteries:

Just to give you an idea of how important these batteries are, let me tell you what they are used for…. Suppose the power plant is just humming along at full power, and all of the sudden, the power goes out. It doesn’t matter the reason. When there is a blackout in a city, or a state, be assured, the power plant itself is in a blackout state as well. After all, the power plant is where the electricity is being created.

In the plant there is large equipment running. The largest and most valuable piece of equipment by far in a power plant is the Turbine Generator. The entire plant exists to spin this machine. As big as it is, it spins at 3600 revolutions per minute, or 60 times each second. In order to do that, oil has to be flowing through the bearings otherwise they would burn up almost instantly. This would cause the generator to come to a screeching halt — and I mean “screeching!”

A turbine Generator Room at a nuclear plant with a waxed floor!

A turbine Generator Room at a nuclear power plant with a waxed floor!  When I was a janitor I would wax the T-G floor.

So, in order to stop a turbine generator properly, when a unit is taken offline, once it has coasted to a smooth stop, the turbine has to be engaged to something called a “Turning Gear” which slowly rotates the turbine generator. This is turned off only when the shaft has cooled down. Without this, you might as well call General Electric and order a new one.

So, one of the most important things the station batteries do is run emergency oil pumps that engage immediately when the power is cutoff from the plant. This allows the turbine generator and other important equipment throughout the plant to slowdown and come to a stop gracefully in case the power is instantly gone.

I will write a story later about a day when this happened at our plant. The moments of confusion, and the quick decisions that had to be made to keep the unit 1 boiler from melting to the ground. Rest assured that throughout this time, the emergency oil pumps had kicked in. The station batteries did their job when they were called upon. While the control room operators were performing their emergency tasks to the letter and the electricians were scrambling to come up with a workable solution to an unforeseen problem, the turbine-generator, the PA (Primary Air) fans, the FD (Forced Draft) Fans, the ID (Induction) fans were all coasting down as the groundwork was being laid to quickly restore power.  See the post Runaway Fire Hydrant Leaves Power Plant in the Dark.

Someone in an office in the middle of Oklahoma City may have noticed their lights flicker for a moment. Maybe they dimmed slightly…

If not for the proper maintenance of the power plant station batteries, the lights would have possibly gone dark. Someone would have had to go looking for the portable generator and the spotlight. Ceremonies in progress may have to continued under candlelight.

Power Plant Phrases Fit for Mixed Company (almost)

The 36th “Rest Of” Power Plant Post

Original post June 8, 2013:

Great people in history are known for their great quotes. Take Albert Einstein for instance. We automatically think of the one most famous thing that Einstein said whenever we hear his name. We think of “E equals M C squared.” (which explains the direct relationship between energy and matter).

Albert Einstein

Albert Einstein

In more recent history, we have Gomer Pyle saying: “Golly”, only it was drawn out so that it was more like “Go-o-o-o-llyyyyyy” (which expresses the improbable relationship between Gomer and the real Marines).

Jim Nabors as Gomer Pyle on the virge of exclaiming his favorite word

Jim Nabors as Gomer Pyle on the virge of exclaiming his favorite word

Then there was the famous line by officer Harry Callahan when he said…. “Go Ahead. Make My Day!” (which demonstrates the exact relationship showing how guns don’t kill people. People kill people).

Clint Eastwood as Dirty Harry

Clint Eastwood as Dirty Harry

Even more recently, we heard the famous words of Arnold Jackson while talking to his brother when he said, “Whatchou talkin’ ’bout Willis?” (which supports the commonly held understanding that ‘Inquiring minds want to know”).

Gary Coleman as Arnold in Different Strokes

Gary Coleman as Arnold in Different Strokes

Great people are known for their great quotes.

This is true in the power plant kingdom as well. I have passed on the incomparable wisdom of Sonny Karcher in the post: Power Plant Invocations and Imitations of Sonny Karcher. When you told him something that he found totally amazing, he would look you right in the eye with an expression of total amazement and would say, “Well….. S__t the bed!” (only, he would include the word “hi” in the middle of that second word).

I had to run home and try it on my parents during dinner one night when I first heard this as a summer help…. at first they were too proud of me to speak. When they couldn’t contain their amazement any longer, they both burst out into laughter as I continued eating my mashed potatoes.

When I became an electrician, I belonged to a group of wise souls with a multitude of quotes. I would stare in amazement as I tried to soak them all into my thick skull. Every once in a while one would squeeze in there and I would remember it.

When talking about the weather, Diana Lucas (later Brien, formerly Laughery) would say, “Chili today, Hot Tamale”. I know there were a lot more like that one.

I invite any power plant men that remember these phrases to leave a comment at the bottom of this post with a list of phrases used, because I liked to forget them so that the next time I would hear them, it would be like hearing them for the first time all over again.

Andy Tubbs would say something like “Snot me. Statue” (I am not sure if I am even saying that right…). I know that Andy had a dozen other phrases like this one.

There was an old man named John Pitts that used to work at the old Osage Plant. I wrote about this plant in an earlier Post called Pioneers of Power Plant Fame Finally Find Peace. He would come out to our plant to work out of the electric shop on overhaul to make a few extra dollars.

One day at the end of the day, when we were all leaving for the parking lot, Andy Tubbs stepped out of the door shaking his head as if in disbelief. He had a big grin on his face, so I asked him why.

Andy said that he had asked John Pitts “What d’ya know.” John had said something that didn’t make sense, so Andy had asked him what he had said. When I asked Andy what John had said, Andy told me that John Pitts had said, “It takes a big dog to weigh a ton.” When this confused Andy, he asked him for clarification, and John had replied, “Well. You asked me what I know, and I know that it takes a big dog to weigh a ton.” — You can mark that one down as a famous quote from John Pitts.

Our A foreman was a tall thin black man named Bill Bennett. He would walk into the electric shop office during lunch and sit down next to me. He would look at me with a look of total disgust. Shaking his head with disappointment, he would say to me…. “You Scamp!” He might throw in another line like, “You disgust me.” (with the emphasis on the word “disgust) or he might say “You slut.” It was times like these that I knew that Bill really cared about me. I mean… he wouldn’t say those things to just anybody.

Bill accidentally said that last phrase to Diana when she had walked into the room just after he had graced me with those words. She stood there for about one second stunned that Bill had said that to her, then she turned around and walked right back out.

I asked him what he had said, because his back was to me at the time, and he had said it under his breath like he had to me and I couldn’t hear what he said…. but I did catch the look on Diana’s face, and it wasn’t a happy expression.

He told me, and he said he probably just made a terrible mistake. I’m sure once Diana thought about it twice she would have realized that this was Bill’s way of passing on his endearment toward you.

Charles Foster was my foreman for my first year as an electrician trainee. He was my friend for all 18 years I spent as an electrician. I had the habit when I was trying to think about something of starting my sentence with the word “Well….” and then pausing. Charles would invariably finish my thought with “…that’s a deep subject.”

The first time, my reaction was like Andy’s when John Pitt told him that it took a big dog to weigh a ton. I said, “What?” He replied. “Well…. That’s a deep subject.” Ok. I know…. I’m slow.

Each morning when Charles would walk into the electric shop office, or when I would walk in and Charles would already be there, I would say, “good morning.” Charles would say, “Mornin’ Glory.” In the time I was in the electric shop, I must have heard that phrase over 1,000 times.

One time we were on a major overhaul on Unit 1, and we were doing check out on all the alarms in the plant that weren’t specific to Unit 2. When you do that, you go to the various devices and mimic sending the alarm by either activating a device or putting a jumper across the contacts that would send in the alarm.

In order to perform this task, we found early on that there were two people in the shop that you couldn’t assign to this job. One person was Bill Ennis.

Bill Ennis was a middle aged (ok. well… older) fellow that owned a Coast-To-Coast store in Perry, Oklahoma.

Gee. This might be a picture of the actual store. Bill's store had a motel associated with it just like this one.

Gee. This might be a picture of the actual store. Bill’s store had a motel associated with it just like this one.

The reason you couldn’t assign Bill to do alarm checks was best put by Bill Ennis himself. He said it like this. “I’m blind in one eye, and I can’t see out of the other.” This was Bill’s famous power plant quote. What he meant was that he was color blind in one eye and he was literally blind in the other. So, he really was “blind” in one eye, and couldn’t see out of the other.

In order to do alarm checks, you needed to be able to locate wires some times by color. Well… Green and red both look the same to Bill Ennis.

If you are not color blind, you can see a number 62 in this picture.

If you are not color blind, you can see the number 62 in this picture.

If you are color blind, this is what you see.

So, you see, that wouldn’t be good.

The other person you didn’t want to have doing alarm checks was Charles Foster. As we found out later, this was because he has Dyslexia. So, even if he could read the 62 in the picture above, he might see it as a 26.

During alarm checks one person has to stay in the control room and watch the alarm monitor and the alarm printouts. So, as we would send in alarms to the control room the person in the control room would reply to us telling us which alarms came in. He would read the number on the screen or the printout.

In the spring of 1986, the person that was elected to sit in the control room all day and watch the alarm panel was Gary Wehunt. He was new at the plant, and didn’t know his way around much, so it was easier for him to perform this job.

The only problem was that Gary had a habit of not paying attention. He would either be daydreaming or he would be talking to someone in the control room about something other than the benefits of having a reliable alarm monitoring system.

So, while Dee (Diana), Andy and I were running around the plant sending alarms into the control room, we would be sitting there waiting for a response from Gary telling us what alarms he received. When he wouldn’t reply, we might call on the radio…. Gary, did you get an alarm?

Gary would always reply the same way. “Just now came in.” Well… we knew it didn’t take that long for an alarm to come into the control room, as the control room needed to know immediately when there was an alarm. So, some times we would send the same alarm about 20 times in a row one right after the other waiting for Gary to tell us that he received the alarm.

Finally we would just have to key the radio to call Gary, and he would jump in there and say, “Just now came in.” We had about 2,000 alarms to check, and you want to be able to move from alarm to alarm rapidly once you finally make it to a position where there are a number of alarms in the same area. But this was slowing us down.

We tried different ways to “remind” Gary that we needed to know immediately when the alarms came in, and we needed to have him give us the number of the alarm as well. But all during the overhaul, we would receive the same response from Gary…. “Just now came in.”

The last phrase that I will mention was said by Mike Rose. He was an Englishman that had moved to the U.S. from Canada where he had worked with the railroad. He pointed out that a Diesel Locomotive is really an electrical generator. A diesel engine on a train is really pulling the train using electricity generated by a turbine generator turned by a diesel engine.

I don’t remember the exact circumstances, but I remember the phrase well, as it became a well used phrase in our shop after we heard it for the first time from Mike Rose. The phrase was, “Ain’t my mota.” (in this case “mota” is a slang word for motor).

So, Mike was replying to a comment that some motor was not working properly, or had burned up all together by saying “Ain’t my mota.” Which meant, “it isn’t my worry.” Actually, this was pretty much Mike’s philosophy of life altogether.

Art Hammond and I would jokingly use the phrase, “Ain’t my mota.” When faced with an obvious task that was our worry. We might stop in the middle of our work and look at one another and say, “Well…. It ain’t my mota.” then continue working away while we giggled like little kids.

When I was working in Global Employee Services Support at Dell, where I work today (now I work for General Motors), during a particular project our project team had come up with the phrase, “Nobody’s gonna die.” Which meant that when we go live with our project, if something goes wrong, everything will be all right, because… “Nobody’s gonna die.” Meaning that it isn’t going to be so bad that we can’t fix it.

When the project was over we were given tee-shirts that said on the back, “Nobody Died”. This phrase reminds me of Mike Rose’s phrase “Ain’t my Mota.”

I tried to remember any phrases I came up with myself, but I’m either just not that creative, or I have just “forgotten more than I ever knew” (which is an actual phrase used by my mother once). I was more into singing songs like Richard Moravek, when he would sing “Nestle’s makes the very best Chocolate” with Jay Harris at the Muskogee Power plant each morning before going to work.

I would break out into song by belting out the Brady Bunch song, or the Beverly Hillbillies, or some such thing. I would also make some songs up like the one about Ronnie Banks on the Labor Crew to the tune of the William Tell Overture (The Lone Ranger galloping song for the more western educated readers)…. by singing, “Ronnie Banks, Ronnie Banks, Ronnie Banks, Banks, Banks.”

Or I would sing the Wizard of Oz like this. “We’re off to see the Wizard, the wonderful wizard of Oz, because because because because…. because because because because…” No… no great quotes from me.

Ok. I do remember borrowing a phrase from the movie, “Trouble with Angels.” with Haley Mills, when she would say, “Another Brilliant Idea.”

Trouble With Angels

Trouble With Angels

Only when I said it, it was usually for a very sarcastic reason…. For instance, (and I will write about this much later), I remember announcing on the radio on an open channel one day that this was “Another one of Jasper’s ‘Brilliant’ Ideas” I was called to his office later that day, but as you will see when I write that much later post, that it turned out it wasn’t because of the remark I had made on the channel I knew he was monitoring (much to my surprise). See the Post Power Plant Trouble With Angels.

 

Comments from the original post:

  1.  

    Bruce Kime June 8, 2013:

    Jimmy Moore always said “Alrighty Then”. Scott Hubbard  “Hubbard Here”. Gerald Ferguson “Hey Laddie”. David Alley “Hand me that Hootis”

  2.  

    Bruce Kime June 8, 2013:

    I J Hale “You scum suckin’ Dog”

  3.  

    Bruce Kime June 8, 2013:

    Jim Cave “Hey Mister”

  4.  

    martianoddity June 9, 2013:

    That was a good read! You often remember people for their phrases. I had this teacher in middle school that answered yes or no questions with “Yes, we have no bananas.”. There’s supposedly an English speaking people, I don’t recall which, who answer negatingly by first saying yes, getting your hopes up, and then saying no, and for them it’s normal.

  5.  

    Tubby June 11, 2013:

    Howard Chumbley (another of the Great Power Plant Men) would say “In twenty years they won’t even remember my name.” That was in 1982. It has been thirty years and some of us still remember and respect Him.

  6.  

    Fred June 13, 2013:

    Here’s a few.

    That sumbuck! Jimmy Moore

    Know what I mean, HUH? (spoken quickly) Jody Morse

    If you think it’s big, IT IS. Bill Moler-

    Going on der, dis n dat. Floyd Coburn.

  7.  

    Jack Curtis June 22, 2013:

    Well, don’t that beat all!

  8.  

    Fred June 22, 2013:

    When you’ve worked a very long day 16-18-20 hours L.D. Hull would say “Sleep fast.” as you left.

  9.  

    PARTNERING WITH EAGLES June 29, 2013:

    About color blindness –
    65% of all males are -to a certain degree- color blind; genetics “F’s” us. We don’t have the corresponding gene to cancel this defect like woman do. I can read the “62″; however, there are dozens of other dot tests like the ones you posted. I found this out when -after Reagan got in- I tried to enlist in the Navy. I failed every one of them.

  10.  

    Monty Hansen August 14, 2013:

    One custom I’ve grown up with in the power business is changing powerplant words to something a little more colorful for our own amusement.

    Circulator = Jerkulator
    inverter = perverter
    cubicle = pubicle

    etc…etc…you get the idea, the low brow humor keeps us grinning thru the day 🙂

Comments from the previous Post:

  •  

    Ron Kilman June 4, 2014:

    Bob Henley (Seminole) “All we lack is finishin’ up.”

    Richard Slaughter (Seminole) “Solid work.”

Moon Walk in a Power Plant Precipitator

The 35th “Rest Of” Power Plant Post

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 Sonny’s 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 Power Plant Man Talk, 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 (See the post “Power Plant Men Learn to Cope with Boring“).

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 HEPA 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” (or “Rotten”), 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….

Resistance in a Coal-Fired Power Plant

The 34th “Rest Of” Power Plant Post

Originally posted April 19, 2013:

Resistance is Futile! You may have heard that before. Especially if you are a Star Trek Fan. If not, then you know that there is always some form of resistance wherever you are.

Captain Picard as Locutus trying to convince you that "Resistance is Futile"

Captain Picard as Locutus trying to convince you that “Resistance is Futile” Like that is ever going to happen

I learned a lot about resistance when I first joined the electric shop at the coal-fired power plant in North Central Oklahoma in 1984. I was assigned to work with Sonny Kendrick and Bill Rivers on the Precipitator during overhauls and when I wasn’t working on the manhole pumps and there wasn’t any other emergencies going on. Actually, from 1984 on, for the next 17 years I continued to work on the precipitator… (if I had only known my fate….).

Not only did I learn a lot about resistance, I also learned about capacitance, reactance, transformers, rectifiers, power supplies, diodes, transistors, op amps, and pots (also known as potentiometers). Bill Rivers was the brains of the outfit. Sonny was the Electric Specialist banished to the Precipitator by Leroy Godfrey (See Singing Along with Sonny Kendrick). Bill thought up the ideas and Sonny went to work to implement them. I just jumped in where I was needed.

The Precipitator is the large box between the boiler and the smokestack (maybe you can see this in the Power plant picture). The purpose of the electrostatic precipitator is to take the smoke (or fly ash) out of the exhaust before it went out of the smokestack.

The plant has a similar electrostatic precipitator, only ours is twice as long

The controls for the Precipitator were all electronic at that time. That meant that there were circuit boards full of resistors, capacitors, transistors, operational amplifiers, diodes and potentiometers. These circuit boards controlled the way the power was distributed throughout the precipitator wires and plates through high powered transformers, and how the rappers and vibrators operated that dropped the collected ash into the hoppers.

Bill had me take an electronics course at the Indian Meridian Vo-tech so I would know the basics. Then he taught me all the shortcuts. I had to be able to look at a resistor and tell right away what the value of resistance it was. Resistors are color-coded and you had to learn what each of the colors represented…

This for instance is a 339 ohm resistor with a 5% tolerance.

This for instance is a 339 ohm resistor with a 5% tolerance.

I was expected to know this by sight. Bill would test me. There was a mnemonic device that I was taught to remember what each color represented, but it is not appropriate to repeat it, so I won’t. It is enough to say that the colors go like this: Black, Brown, Red, Orange, Yellow, Green, Blue, Violet, Gray, White (I will never forget this my entire life). These represent the numbers zero through 9. Here is a full explanation of how to read a resistor….. just in case you are curious, or you are such a boring person that you really need some material to bring up when you are at a party and don’t know what to say:

This is how the color codes work

This is how the color codes work for resistors works

I found that having just the correct amount of resistance was very important. Too much or too less, and everything stops working.

Isn’t it that way with management also? If the management is too resistant to change, then things come to a halt. If they have too little resistance, they lose control of the situation. Depending on the circuit (or managerial decision) and what you are trying to do, it helps to have a manager that has a variable resistance to meet the needs of each situation. Resistance to change is always a balancing act.

During the first two years I was an electrician, the main control panels that controlled the operation of the precipitators were electronic. We spent a lot of time in the lab troubleshooting electric circuits looking for blown (or bad) parts that needed to be replaced. Then we would solder new components on the circuit boards and then put them back in operation. I learned how to be an electronics junky. I became addicted to fixing electronic circuit boards. It was like a game to me.

Later, the precipitator controls were changed to digital controls. That is, they were more like little computers controlling the precipitator. Instead of a bunch of circuit boards dumbly, but cleverly, doing their job, (how many commas can I use in one sentence?), little brains were added that made decisions and reacted to conditions in a much more dynamic way.

What was interesting was that one day Bill Rivers was describing how technology was going to be in the future. He said that some day, we will be able to sit in the lab and look on a computer and see what all the controls in the precipitator were doing (this was 1984). If something isn’t working right, we could just reach over, type a few keys on the computer and adjust the controls. Drink our sweet tea (a necessary staple in Oklahoma at the time), and then wait for the next crisis…. Then he would giggle at the look of disbelief on my face and the faces of the other electricians that happen to be within earshot.

When he was telling me this, I was thinking in my head…. Well, that would be nice, but this sounds more like a pipe dream to me than reality. What does an older guy with six kids from a tool and die company in Columbia Missouri (where I grew up, by chance) know about the future of anything….. well…. anything…uh… new age…. If that is what you might call it… I found out you just don’t really know when you are sitting in front of a true “visionary” with tremendous insight.

Bill Rivers had this incredible knack for telling the future. In 1984 he was predicting computer controls in the control room where you ran the entire plant from a computer on a desk instead of using the “Big Board”.

I love this picture!

I love this picture! It makes me feel at home! This was not our plant, but is a Power Plant control room

He said you would be able to call someone on a phone you kept in your pocket or your watch like Dick Tracey.

Dick Tracy in a control room of a power plant sending commands to the hopper nozzle booster pumps

Dick Tracy in a control room of a power plant sending commands to the hopper nozzle booster pumps

I don’t know what journals Bill was reading or if he just dreamed all this stuff up in his head, or maybe he was a Star Trek Fan that believed that if you can dream it up you can do it. I do know that he picked up on subtle queues and made great inferences from them that seemed astronomically unlikely. However, I have to admit that he caught me off guard a number of times with predictions that definitely came true.

I will talk about this more in a future post, but for now I will say that we did upgrade the precipitator to where you could sit in the control room and monitor and adjust the precipitator controls (all 84 on each unit), and even each of the rappers (672 rappers) and vibrators (168 vibrators) on the roof of each precipitator. With one key on the computer I could send a plume of ash out of the smokestack that looked like the unit had just tripped, and a moment later, clean it up again. This meant that I could send smoke signals to the Osage Indian tribe 20 miles north up the Arkansas (pronounced “Are Kansas”) river, telling them that the Pow Wow would begin at sunset.

Today, I understand that the “Big Board” at the plant is just a large junction box and the plant is controlled almost (if not) completely by computers sitting on the desk. Before I left the plant in 2001, this was being transitioned slowly to computer controls. I have another story to tell some day about this, and how an operator named Jim Cave, a Power Plant Genius and true Power Plant Man of the highest integrity, was snubbed by upper management for speeding this technology along. — Another example of Power Plant Resistance….

But for now…. back to my electronic days… before I began re-programming the Eeprom chips in the precipitator controls….

An Eeprom Chip used in the preicpiitator controls

An Eeprom Chip used in the precipitator controls which I had a very “personal” relationship with…

Bill Rivers confided with me one day that when the new Instrument and Controls department had been formed from the “Results” department that his dream had been to become a part of this team. It meant the world to him. It was where he believed he belonged. It was one of his major goals in life.

There used to be two electrical specialists in the Power Plant. Sonny Kendrick was not always the only one. The other specialist was chosen to go to the Instrument and Controls shop. Bill Rivers wanted to move there also. He definitely had the experience and the knowledge to be a superb instrument and controls person. But Bill had this one problem.

He loved to joke around. He loved to pull strings and push buttons. I have mentioned in a previous posts that Bill would play a new joke on Sonny Kendrick every single day. As I have unfortunately found out in my own life… this tends to make them…. well….. it tends to make enemies out of those who have a chip on their shoulder. Those people who naturally feel inadequate in their abilities or their position in life. To go one step further…. anyone who feels “unloved”….. these people definitely do not like being joked with. They seem to never forgive you. My greatest regret in life is joking around with these individuals.

So, when it came time to choose who would be a part of the new Instrument and Controls shop, Bill Rivers was turned down. It was explained to him that the reason he was not given the job was because he cut off the leads of a transistor when he replaced them. — I’m not kidding. Bill Rivers had the habit of cutting off the leads of each resistor, transistor, diode or capacitor that he replaced…. this is why Monty Adams turned down his request for joining the “elite” Instrument and Controls shop (as he told Bill to his face).

Someone had told the Instrument and Controls Supervisor Monty Adams that Bill Rivers cut the leads off of transistors and resistors when he replaced them so that you couldn’t test them to see if they were all right. Implying that he didn’t want you to know whether he had replaced the transistor or resistor by mistake.

Bill Rivers took several transistors, cut the leads off of each of them and handed them to me and asked me to test them to see if they were still good or if they were bad. I took out my voltmeter, set it to ohms, and proceeded to test them as Bill Rivers had taught me. I told him…. this transistor is good….. this one is bad….

You see…. there is no way to cut the leads off of a transistor in such a way to make it impossible to tell if a transistor is good or bad…. In reality…. you cut the leads off of a bad transistor so that the person working on the circuit board knows that this is a bad transistor and doesn’t use it again by accident. This was electronics 101.

When Bill told me this story, he literally had tears in his eyes. This was because being part of the Instrument and Controls team was part of his dream. The future of his family and the entire rest of his life was decided the day he was told that he was not going to be a part of a team that he believed was his true lot in life.

I remember his exact words as he sat there in the lab alone and told me this story. He said, “… and Monty didn’t know… He didn’t know that you cut the leads…. that is standard procedure….” In Bill’s giggly way, he was crying out loud as he told me this.

From that point on….I knew that the decisions Bill made in his life were driven by that one decision to exclude him from this team. Unlike many of us that could say to ourselves…. “That is their loss”…. Bill kept this pain in his heart each day…. Every decision from that day further was effected by this event.

I calculated it out one day that I spent 414 hours driving back and forth from Stillwater, Oklahoma to the plant and back each day with Bill Rivers (along with Yvonne Taylor and Rich Litzer and occasionally others that needed a ride), and over that time, I became very close to Bill, even to the point of tutoring his son in Algebra (see post: How Many Power Plant Men Can You Put in a 1982 Honda Civic?).

I say this because I know about the pain that inflicted Bill River by a rash decision based on the hearsay of someone that held a grudge. I know how his entire life was changed and how it ended for Bill Rivers as a power plant employee. I know that every decision by Bill after this date was made in response to this one decision. Anyone who experienced Bill after 1983 knows what I am talking about.

I realized that today my own decisions in life help spell out my future. How some little remark may be misinterpreted, or even properly so. I realize as I write this post that how I accept or reject these events in my life, determines the future of my family. After seeing how every event in Bill’s life after that day at the power company was determined by his experience was to his detriment, I am determined not to let the same thing happened to me…..

That is why I have taken on the philosophy in my life that no matter how my actions are misinterpreted, I am determined to remain true to myself. I know what I mean, and I mean what I say, and I say what I mean, and an Elephant is Faithful 100 %.

From Horton Hatches an Egg

From Horton Hatches an Egg by Dr. Seuss

Comment from the Original Post:

  1. Ron Kilman April 21, 2013

    It’s amazing how many decisions are made based on incorrect / incomplete information (at all levels).

Something Is In The Water at the Muskogee Power Plant

The 33rd “Rest Of” Power Plant Post

Originally posted: April 15, 2013:

“Something is in the water in Muskogee.” That is what I used to say. Something that makes people feel invulnerable. That was what I attributed to David Stewart’s belief that he could jump up in a falling elevator just before it crashed into the ground and he would be saved (see After Effects of Power Plant Drop Tests).

There was another story at the Muskogee Coal-fired Power Plant where this one mechanic believed that he could stick his finger in the path of the blade of a running lawnmower and pull it out so fast that it wouldn’t cut his finger off. Of course, True Power Plant Men tried to reason with him to convince him that it was impossible…. Then there were others who said… “Ok. Prove it.”

Think about it. A lawnmower spins at the same rate that a Turbine Generator spins when it makes electricity. 3,600 time a minute. Or 60 times each second. Since the blade in a lawnmower extends in both directions, a blade would fly by your finger 120 times each second. Twice as fast as the electric current in your house cycles positive and negative.

Typical Power Plant Lawnmower

Typical Power Plant Lawnmower

This means that the person will have to stick their finger in the path of the lawnmower blade and pull it out within 8/1000th of a second…. IF they were able to time it so that they put their finger in the path at the precise moment that the blade passed by. Meaning that on average, the person only has 4/1000th of a second (or 0.004 seconds) to perform this feat (on average… could be a little more, could be less).

Unfortunately for this person, he was not convinced by the logicians that it was impossible, and therefore proceeded to prove his case. If you walked over and met this person in the maintenance shop at Muskogee, you would find that he was missing not only one finger, but two. Why? Because after failing the first time and having his finger chopped off, he was still so stubborn to think that he could have been wrong, so later he tried it again. Hence the reason why two of his fingers were missing.

Upon hearing this story, I came to the conclusion that there must be something in the water at Muskogee. I drank soft drinks as much as possible while I was there on overhaul during the fall of 1984.

As I mentioned in the post Power Plant Rags to Riches, in 1984 I was on overhaul at Muskogee with Ben Davis. An overhaul is when a unit is taken offline for a number of weeks so that maintenance can be performed on equipment that is only possible when the unit is offline. During this particular overhaul, Unit 6 at Muskogee was offline.

Ben and I were working out of the Unit 6 Electric shop. Ben was staying with his friend Don Burnett, a machinist that used to work at our plant when I was a summer help. Before Don worked for the electric company, he worked in a Zinc Smelting plant by Tonkawa, Oklahoma. Not only was Don an expert machinist, he was also one of the kindest people you would run across. Especially at Muskogee.

I was staying in a “trailer down by the river” by the old plant. Units one, two and three. They were older gas-fired units. I think at the time, only Unit 3 was still operational. The first 2 weeks of the overhaul, I stayed in a rectory with the Catholic priests in town. Then David Stewart offered to let me stay in his trailer down by the river for only $50 a week.

After the first couple of weeks it was decided that the 4 week overhaul had turned into a 9 week overhaul because of some complications that they found when inspecting something on the turbine. So, I ended up staying another month.

When they found out that they were going to be down for an extra 5 weeks, they called in for reinforcements, and that is when I met my new “roomie”, Steven Trammell from the plant in Midwest City. He shared the trailer for the last 4 weeks of the overhaul. From that time on, Steven and I were good friends. To this day (and I know Steven reads this blog) we refer to each other as “roomie”, even though it has been 29 years (now 36 years) since we bunked together in a trailer…..down by the river.

I have one main story that I would like to tell with this post that I am saving until the end. It was what happened to me the day I think I accidentally drank some of the water…. (sounds like Mexico doesn’t it?). Before I tell that story, I want to introduce you to a couple of other True Power Plant Men that lived next door to “roomie” and me in another trailer down by the river (this was the Arkansas River by the way…. Yeah… The Arkansas river that flowed from Kansas into Oklahoma… — go figure. The same river that we used at our plant to fill our lake. See the post Power Plant Men taking the Temperature Down By The River).

Joe Flannery was from Seminole Plant and I believe that Chet Turner was from Horseshoe Plant, though I could be mistaken about Chet. I know he was living in south Oklahoma City at the time, so he could have been working at Seminole as well. These were two electricians that were very great guys. Joe Flannery had a nickname. I don’t remember exactly what it was, but I think it was “Bam Bam”.

Yeah. This Bam Bam. From the Flintstones

Yeah. This Bam Bam. From the Flintstones

Joe was very strong, like Bam Bam. He also reminded me of Goober on the Andy Griffith Show, though Gary Lyons at our plant even resembled Goober more:

Goober from the Andy Griffith Show (played by George Lindsey)

Goober from the Andy Griffith Show (played by George Lindsey)

Chet was older than Joe by quite a lot, but I could tell that my Roomie and Joe held him in high esteem… So much so, that I might just wait on the story I was going to tell you about the time that I drank the water in Muskogee to focus more on Chet Turner… otherwise known as Chester A Turner (The story about when I drank the water can be found here:  Lap o’ Luxury at the Muskogee Power Plant).

I first met Chet when my roomie asked me if I wanted to go out and eat with him and our two trailer neighbors. On the way to dinner, we had to stop by a used car lot to look at what was available because Chet loved looking at cars. He had gray hair and was 60 years old at the time.

During the next 5 weeks, we went out to eat almost every night during the week with Chet and Joe. We explored Muskogee as best we could. That means that we visited about every car lot in the town. We also ate at a really good BBQ place where you sat at a picnic table and ate the BBQ on a piece of wax paper.

One night we were invited by another electrician (I think his name was Kevin Davis) to meet him at a Wal-Mart (or some other similar store) parking lot where his son was trying to win a car by being the last person to keep his hand on the car. He had already been doing it for about 4 days, and was exhausted. It would have reminded me of the times I had spent adjusting the precipitator controls after a fouled start-up, only, only I hadn’t done that yet.

I was usually hungry when we were on our way to dinner, and I was slightly annoyed by the many visits to car lots when my stomach was set on “growl” mode. I never said anything about it, because I could tell that Chet was having a lot of fun looking at cars.

If only I had known Chet’s story when I met him, I would have treated him with the respect that he deserved. If I had known his history, I would have paid for his meals. It was only much later that I learned the true nature of Chet, a humble small gray-haired man that seemed happy all the time, and just went with the flow.

You know… It is sometimes amazing to me that I can work next to someone for a long time only to find out that they are one of our nation’s greatest heroes. I never actually worked with Chet, but I did sit next to him while we ate our supper only to return to the trailers down by the river exhausted from the long work days.

Let me start by saying that Chet’s father was a carpenter. Like another friend of mine, and Jesus Christ himself, Chester had a father that made furniture by hand. During World War II, Chester’s mother helped assemble aircraft for the United States Air Force.

While Chet’s mother was working building planes for the Air Force, Chet had joined the Navy and learned to be an electrician. He went to work on a ship in the Pacific called the USS Salt Lake City. It was in need of repairs, so he was assigned to work on the repairs.

While working on the ship, it was called to service, and Chet, since he happened to be on the ship, went to war. After a couple of battles where the ship was damaged from Japanese shelling it went to Hawaii to be repaired. After that, it was sent to the battle at Iwo Jima. That’s right. The Iwo Jima that we all know about. Chet was actually there to see the flag being raised by the Marines on Mount Suribachi:

The Iwo Jima Monument

The Iwo Jima Monument

Chet fought valiantly in the battle at Iwo Jima and was able to recall stories of specific attacks against targets that would make your hair stand on end to listen to. After it was all said and done, Chet was awarded the Victory Medal,

The Victory Medal

The Victory Medal

Asiatic-Pacific Campaign Medal,

asiatic_pacific_campaign_medal

and the Philippine Liberation Campaign Ribbon.

Philippine Liberation Ribbon

Philippine Liberation Ribbon

As well as others….

At the time that I knew Chet, I didn’t know any of this about him. Isn’t that the case so many times in our lives. Think twice about that Wal-Mart Greeter when you go to the store (well, I heard that Wal-Mart is no longer going to have greeters, so my long term retirement plan has taken a turn). When you see an elderly old man or woman struggling with her cart to put her groceries in her car…. You may be looking at a hero.

I was looking at Chet thinking, “boy. This guy sure enjoys looking at cars…. I’m hungry.” This past week I was thinking about writing tonight about an event that took place while Ben and I were on overhaul at Muskogee. I thought it would be a funny story that you would enjoy. So, I asked my roomie, “What was the name of the guy that was staying with Joe Flannery in the trailer? The one with the gray hair?”

He reminded me that his name was Chet Turner. Steven told me that Chet had died a while back (on January 12, 2012, less than two weeks after I started writing about Power Plant Men) and that he was a good friend. So much so, that Steven found it hard to think about him being gone without bringing tears to his eyes. This got me thinking…. I knew Chet for a brief time. I wondered what was his story. I knew from my own experience that most True Power Plant Men are Heroes of some kind, so I looked him up.

Now you know what I found. What I have told you is only a small portion of the wonderful life of a great man. I encourage everyone to go and read about Chet Turner. The Story of Chester A. Turner

Notice the humble beginning of this man who’s father was a carpenter. Who’s mother worked in the same effort that her son did during the war to fight against tyranny. How he became an electrician at a young age, not to rule the world, but to serve mankind.

Looking at cars has taken on an entirely new meaning to me. I am honored today to have Chet forever in my memory.

Comment from Original Post:

Roomy April 15, 2013:

Hey Roomy, been on vacation for a while. Just got around to the story. All I can say is thanks. My eyes are a little blurry at the moment. I will write you later when I can see better.

 Comment from Previous post:

 

  1. Roomies daughter April 10, 2014:

    I enjoy reading your blog very much and am so happy you take the time to share these memories. Chet was a wonderful man and I am very blessed to have been raised in the presence of these true heroes.
    Looking forward to reading more!

Personal Power Plant Hero — Charles Foster

The 32nd “Rest Of” Power Plant Post

Originally posted March 30, 2013:

When you think about it, you probably spend more time with your best friend than you ever did talking to your own father. That is, unless your father is your best friend. Charles Foster was my “Foster Father”. Though I was grateful for his effort to bring me into the Electric Shop at the Coal-Fired Plant, when I had little to no electrical experience, that wasn’t the reason why we became such good friends.

When I moved into the electric shop from the labor crew, Charles Foster was my B Foreman. He was my foreman for only the first year of the 18 years I spent as an electrician. He was my friend from the first day I met him until… well… until the end of eternity.

I found that most of the electricians were more intelligent than others it seemed. The shop had people that were Heroes in their own right. Andy Tubbs, Craig Jones, Terry Blevins, Diana Lucas and Ben Davis were what I thought of as “Delta Force” Electricians. They were sent to tackle the toughest of jobs because everyone knew that they would pour all they had into their work until the job was done.

Sonny Kendrick and Bill Rivers were the electronics buffs. They would work on calibrating, programming and monitoring different plant systems. These are the people that you went to when a piece of electronic equipment was on the fritz, and they would analyze, test and repair it with their endless drawers of all types of electronic parts.

There were some other electricians, such as Art Hammond, Bill Ennis, Jim Stevenson and Mike Rose that had their own special knowledge that made each of them unique (to be sure). The other two foremen were Howard Chumbley and O.D. McGaha (prounounced: Oh Dee Muh Gay Hay).

Charles Foster didn’t fall in the same category as the others. He wasn’t the type of person to wire up a Boiler Water Circulating Pump, or run conduit up the side of the boiler. Though he would do these tasks when the A-Team wasn’t around to do it. He liked to work alone, or at least alongside one other person. I felt lucky that Charles enjoyed working with me.

When I first joined the electric shop Charles made two things clear to me; don’t call him Charlie and don’t make fun of his spelling. He was sensitive about those two things. I agreed, and I never did…. call him Charlie or make fun of his spelling.

Charles knew he had a problem with spelling, and there didn’t seem to be anything he could do about it. So, I often checked over his work before he sent something. — This was before Personal Computers were available in the office with spell checkers.

During my first electrical year (1984), Charles and I would sit in the Electric Shop Office during lunch and talk about movies we had seen. We took turns relaying entire movies to each other. We would start out by saying, “Have you seen “Karate Kid”? Well you see, there was this boy who was moving to California with his mom from someplace in the east and….”

The Karate Kid

The Karate Kid

We quickly learned that we liked the same kind of movies and shows, and even more, we liked telling each other about them. It seems that we spent years during lunch talking about one movie (or TV show) after the other. I looked forward to just sitting with Charles and talking during lunch.

I noticed in the years that I worked at the Power Plant that, in general, Power Plant Men have the knack of thinking outside of the box. Charles Foster was very good at doing this, and we would have discussions about all sorts of subjects. From God and the Universe to time travel and gardening. The more we talked, the more I came to realize that this man was brilliant.

Not “Newton” brilliant, but “Einstein” brilliant…. If you know what I mean…. Newton had a great mathematical mind and used that ability to become the father of Physics. Einstein on the other hand used his ability to take an observation and mix it with his idea of reality to come up with something that seemed totally unrelated, but made sense nonetheless. This was Charles.

So, what great plans did Charles come up with? What plot to take over the world (as my current manager at Dell, Clay Worley accuses me of weekly)? He became a good father to his son and daughter and a good husband to his wife Margaret. All the things that are really important for the survival of mankind.

One day while Andy Tubbs and I were driving to the River Pump station to check the transformers during substation checks, we stopped along the roadside and I picked a stalk from a Cattail that was about ready to bloom.

A Power Plant Cattail

A Power Plant Cattail

The plan was to put it in Charles’ top right hand desk drawer. The reason is that when handled just right, this brown furry “flower” (if you want to call it that) will literally explode into tens of thousands of tiny floating bits of fur. Sort of like a dandelion does when it turns white, only more furry and much more numerous. A thousand times more numerous.

When we arrived back in the shop, I walked into the office and told Charles that I had a present for him. Holding the stalk in my hand I opened his drawer. As Charles leaped out of his chair to stop me, I dropped the cattail into his drawer full of tools and odds and end parts, and it exploded into a huge ball of fur. Cattail fur went flying around the room.

Charles was genuinely upset. You see… It wasn’t bad enough that our clothes and hair and nose were being speckled with fur… Charles had allergies and this fur wasn’t helping. So Charles hurried into the shop and wheeled the Shop Vac over to the door and unraveled the hose and plugged it in to vacuum out his drawer.

A Shop-Vac like this

A Shop-Vac like this

Charles was trying to vacuum up the mess in his drawer before the office became flooded with the fur. He turned the vacuum on and turned around to put the end of the hose in the drawer. As he turned, Andy quickly disconnected the hose from the intake and attached it to the outtake. Notice the two holes on the front of the Shop-Vac. The bottom one is to vacuum while the top hose connect actually blows out the air.

By the time Charles plunged the end of the hose into the drawer, it was blasting air from the hose which caused just the opposite effect that Charles was hoping for. The entire room became so full of flying fur that any attempt to clean it up became impossible. I couldn’t help it, I was over in the corner laughing at the situation that Charles found himself in….. Of course… I was standing in the middle of what looked like a heavy snowstorm.

After about 5 minutes some of the flying fur had settled on the floor and the entire floor in the office was covered with what seemed like about 2 inches of fur. — Ok. So, I felt guilty about this. I hadn’t thought about Charles’ allergies. For the next 2 months (at least), each morning Charles would remind me that I was still supposed to feel bad about it by opening his drawer when he first came in, and blowing down into the drawer causing fur to stir up and fly around the room. Yeah, it was remarkable that it lasted so long.

During a Major Overhaul, the electricians do alarm checks. During this time, you go down the list of every alarm in the plant and test it to make sure it is still working as designed. There are hundreds of alarms. You take blueprints with you to go to every conceivable alarm on the unit that is down for overhaul. Then while someone is sitting in the control room watching the alarm printout and the alarm monitors, the electrician will place a jumper across the apparatus that brings in the alarm and wait until the person in the control room acknowledges the alarm.

To do this job, you need to read the wire numbers on the print and match them with the wires on the terminal blocks. Then you call the Control room on the radio and ask them if alarm so and so came in. We found out quickly that we didn’t want Charles doing either of these two jobs. Charles had the habit of reading the numbers out of order. Instead of wire number 25496, he might read 24956.

I know that some of you recognize the signs that I have described about Charles. I know that Charles felt a great frustration with his problem spelling and transposing numbers. One night in 1992, I watched a movie on TV called “The Secret” with Kirk Douglas.

The SecretI wouldn’t normally have sat and watched a movie like this because it dragged on for a while and didn’t seem to have much of a plot. What kept me glued to the TV was that the man in the movie played by Kirk Douglas was just like Charles except that he couldn’t read at all. He was very smart and was trying to hide the fact that he just couldn’t read.

When his grandson began having the same problem, he realized he had to do something about it. That was when he found out that he had Dyslexia. There are different forms or degrees of Dyslexia, but I recognized right away that this was a story about Charles Foster. I knew that his son Tim who was in High School at the time was having the same difficulty with spelling.

The next morning when I arrived in the Electric Shop Office I had to tell Charles right away (I couldn’t wait until our normal lunch time movie review) that I knew why he had so much trouble spelling and why he always jumbled his numbers around. It was because he had Dyslexia. I explained the movie to him. As I was telling this to Charles I could see that he was beginning to understand…. everything fit.

I watched as Charles soaked in what I had just told him. A lifetime of feeling like he had failed at the most simple of tasks were drying up before his eyes. He had a condition that was not only common, but was also treatable in the sense that you could learn to improve using the correct techniques. Just knowing why was good enough for Charles. He had spent years coping and working around. Now he knew why. I will never forget that moment when I was sitting in the office smiling at Charles smiling back at me.

Charles Foster - A True Power Plant Hero!

Charles Foster – A True Power Plant Hero!

I mentioned above that Charles reminded me of Albert Einstein. It is an interesting coincidence (or is it?) that the movie “The Secret” earned the Einstein Award from the National Dyslexia Research Foundation in 1992. It seems that Einstein, Charles Foster and Dyslexia go together.

God Bless you Charles and your wonderful family!

Comment from Previous Post:

  1.  

    This was an awesome piece of writing! I liked that you described your ordinary man turned into a hero in your life. I like that using his last name Foster, you made him into your Foster father or friend. It is a great tribute to YOU, though, that this quiet solitary man took you under his wing. Thanks for all the ‘likes’ you push on my posts. I am belated at getting back. Have you ever seen in my comments, that I work at a warehouse so get only about an hour a day at the library and then, scurry on the weekend, visiting grandkids, reading blogs at the library and trying to be able to stay connected? Not an ‘excuse’ more of an “I’m Sorry to you!” Take care, robin

From Power Plant Rags To Riches

The 31st “Rest Of” Power Plant Post

Originally posted on March 9, 2013:

There is one item that all Oklahoma power plant men carry with them almost every day. Whether they are electricians working on a motor, a mechanic pulling a pump, or an operator making his rounds. All of them carry and use this one item. It is so important that, without it, it would be difficult for the maintenance shop to function properly.

This item of course is a rag from the Chief Wiping Cloth Rag Box:

Every Power Plant Man uses Chief Wiping Cloths on a daily basis

Every Power Plant Man uses Chief Wiping Cloths on a daily basis

As an electrician, I used rags all the time. Whether I was working on a breaker, doing battery inspection, elevator maintenance or just looking for a clean place to sit my back side, I had to have a rag from the box of Chief Wiping Cloths. Chief Wiping Cloths come from the Oklahoma Waste & Wiping Rag Company in Oklahoma City.

When I was on the labor crew, I was dirty all the time. I was doing coal clean-up, digging ditches, pouring concrete, shoveling bottom ash and wading through fly ash. I had little reason to stay clean or to clean things. My life was full of dirt and grime. I was always dirty, so much so that when I went into the electric shop in 1983 and Bill Bennett was talking to Charles Foster about who should repair the Manhole pump motors, Bill told Charles, “Let Kevin do it. He enjoys getting dirty.”

I didn’t argue with Bill, because, well…. what was the point. But as an electrician, I not only had desired to have a cleaner job, but I also wished to fulfill Jerry Mitchell’s prophesy that “When I become as good as him, I will be able to remain clean even in the face of “Coal Dust and Fly Ash” (See the post A Power Plant Man Becomes an Unlikely Saint). The boxes of rags were my opportunity.

So, when I left to go on a job, I would always grab at least a couple of rags from the box and put them in my tool bucket and at least one hanging out of my back pocket. That way, if I needed to plop down on the ground to unwire a motor too low to sit on my bucket, I could sit on a rag on the coal dust covered ground instead. This helped my goal of remaining as clean as possible.

It’s funny that years later I should miss the boxes of rags that I used to use to do my job. There was more to it than just the rags I used to wipe my hands, battery posts, greasy bearings, breaker parts and my nose. You see, these rags were made from recycled clothes. Yes. They were sterilized for our use, but these were from recycled clothes.

Actually, the Oklahoma Waste and Wiping Rag Company, founded in 1940, was one of the largest purchasers of donated clothing in the country. That meant that many of the rags we used in the rag box were actually worn by someone. Sure, a lot of the rags came from defective clothing from factories, but some of the rags had been clothes actually worn by a person.

As odd as it may sound, while I was grabbing rags from the rag box, I was thinking (at times… it wasn’t like it was an obsession with me), that these rags may have been worn by someone for years before ending up covered with bearing grease by my hand and tossed into a proper Fire protection trash can.

Trash cans like this were used because they prevented oily rags from burning down the shop when they would spontaneously combust

Trash cans like this were used because they prevented oily rags from burning down the shop when they would spontaneously “combust”

So, anyway….. Thinking about how these rags were possibly once worn by people throughout the United States, I felt that some of the rags had a specific connection to some unknown person somewhere. So, I would actually go through the rag box looking for pieces of rags that I felt had been worn by someone before. You know (or maybe you don’t), rags that had an aura around them like someone had once had a “personal relationship” with them.

I would take these rags and I would “pseudo-dress up” in them. So, if it was a rag made out of a pair of pants, I would tuck it in my belt and I would carry it that way until I needed it. In a weird way (and I know… you are thinking a “really weird” way), I would feel connected to the person that had worn this piece of clothing in the past. I felt as if I was honoring their piece of cloth just one last time before I stained it with coal dust, fly ash, or snot, just one last time.

And in my even weirder way, I would sort of pray for that person, whoever they may be. I would even, kind of, thank them for the use of their old clothes (I know, I stretched the English Language in those last two sentences to meet my unusual need).

I have a picture in my mind of myself standing on the platform of the 6A Forced Draft Fan at Muskogee in the fall of 1984 (one year after becoming an electrician), dressing myself up in pieces of clothing from the rag box, all giddy because I had found enough pieces to make an entire outfit made of half male and half female clothing.

Ben Davis, who was on overhaul at Muskogee with me from our plant is shaking his head in disbelief that he had to work with such a goof. Not exactly sure who he has been assigned to work with… — I actually felt sorry for Ben. I knew I was a normal person. The trouble was… I was the only person that knew it (For an explanation about where that phrase originated, see the post “Bobbin’ Along with Bob Kennedy“).

Ben Davis

Ben Davis

Levity is healthy. And at times when stress is at its greatest, levity is a way back to sanity. Just today I was invited to a conference call to discuss something that I was working on, and when I was done, I stayed on the line even though I was no longer needed. As I listened, one person on the other end was remarking about how he enjoyed his team so much because they were able to crack up and reduce the stress by being humorous.

A friend of mine, and fellow teammate Don McClure who had invited me to the call was coming up with one “one-liner” after the other. They were “spot-on” and very funny (as he usually is — ok. He’s going to correct me on the “usually” part). But he said one thing that hit home with me. He said that he had been in the Hot-seat so long that he had to put on a pair of Asbestos underwear.

This, of course, made me immediately think of the asbestos gloves we used to wear in the electric shop before Asbestos had been formerly outlawed. We had an old pair of asbestos gloves from Osage Plant ( to find out more about the Osage Plant read about it in the post Pioneers Of Power Plant Fame Finally Find Peace).

Asbestos Gloves worn when putting hot bearings on a motor shaft (for instance)

Asbestos Gloves worn when putting hot bearings on a motor shaft (for instance)

Along with the rags in the rag box, when I used to put on the asbestos gloves I used to think of Howard Chumbley (who died on August 4, 1998 at the age of 70), at the age of 24 working at the Osage Plant, before his hair turned to gray and then to white, wearing these same gloves while he pulled a bearing off of a heater and slapped it onto a motor shaft.

Here Lies Howard Chumbley

Here Lies Howard Chumbley

It gave a special meaning to motor repair. Even though Howard retired from plant life in 1985, for years I could put on his old pair of asbestos gloves and feel like I was stepping into his young shoes. I would think… If only I could be a true “Power Plant Man” like Howard…. I love Howard with all my heart, and today, I have never met a better human being than him.

Note that in the picture of Howard’s gravestone it says that he was an EM3 in the Navy. This is an “Electrician’s Mate 3rd Class”. There is no way I was ever going to measure up to Howard. He was a hero to his country and a man of great integrity and humility. If I had saved up all the nice things I had done in my life and done them all on one day, I may have slightly resembled Howard on a regular day. Just like Jim Waller that I had discussed in my last post… Only Men of the greatest integrity measure up to be “True Power Plant Men”.

This made changing the bearings on a motor almost a sacred event to me. I don’t know if the other electricians felt what I felt, but there was something about placing those gloves on my hands that seemed to transform me for a moment into someone noble. I never mentioned it to them (which was odd, because I was usually in the habit of telling them every little crazy thought that entered my head).

I remember at break time one day Margie Belongia (who was a plant janitor at the time) telling me in 1981 when I was a summer help, that she wanted to go to hell because that was where all of her friends would be. I asked her at the time how she was so certain that being in hell guaranteed that she would be able to be with her friends, and she was taken aback by my question. “What do you mean? Why wouldn’t I be with my friend?” — I responded, “Suppose in hell you are alone. With no one but yourself.” I think I unnerved her by my response. She said that she had never considered that. She had counted on being with her friends. They had all decided that was the way it was going to be.

At any rate. I kept her thought in my mind. I hope every day that someday I will be able to walk up behind Howard Chumbley (not in hell of course, the other place) and just stand there and listen to him tell stories about when he worked at the old Osage Plant, and how he used to be up to his elbows in oil that contained PCBs and never thought twice about it. Or how he played a harmless joke on someone dear to him, and he would laugh….

Howard was my foreman for only about 5 months before he retired. I remember sitting in the electric shop office for a year and a half during lunch listening to him tell his stories. He would grin like Andy Griffith and laugh in such a genuine way that you knew that his heart was as pure as his manners.

Andy Griffith in this picture reminds me of Howard Chumbley

Andy Griffith in this picture reminds me of Howard Chumbley

To this day I know that I have never been richer than I was when I was able to sit in the shop and listen to Howard Chumbley pass on his life experience to us. Even years later when I was able to slip on the pair of Asbestos Gloves worn by him years earlier I could feel that I was following in his footsteps. Just the thought of that would make me proud to be an Electrician in a Power Plant.

I used to imagine that the Chief on the Chief rag boxes knew the history of all the pieces of rags in the box. When I moved to Texas in 2001, I used some sturdy Chief rag boxes when I was packing to leave. They are sturdy boxes. Just this past year, we threw away the last Chief rag box that contained Christmas decorations in exchange for plastic tubs. Even though it seems like a little thing. I miss seeing the Chief on those boxes of rags.

The chief on the Chief Rag Boxes

The chief on the Chief Rag Boxes