Tag Archives: Scientific Method

Doing Dew Point Tests and Lowering Expectations

Originally posted May 9, 2014:

There were times when I was working at the Coal-Fired Power Plant in North Central Oklahoma when I wondered if there was anything that we couldn’t do. Surrounded by True Power Plant Men I found that when we were facing a seemingly impossible task, a Power Plant Man would come up with an extremely creative solution to the problem. One such example was during the “We’ve Got The Power” program. I talked about this program in an early post called “Power Plant We’ve Got the Power Program” so I won’t go into detail here about the program itself. I will just say that we broke out into teams to find creative ways to operate more efficiently, and to cut costs.

I was a team leader of our team, and looking back I must have had two criteria in mind when I picked the team members that would be on my team. The first would have been that they were True Power Plant Men (and woman) with a higher than average intelligence. The second criteria would have been that they were friends of mine. I say this, because everyone on my team fit the bill.

During out team meetings, Terry Blevins would often say some bombastic statement that the average person may be inclined to dismiss immediately as being absurd. I say that because I remember more than once thinking that what Terry had just said wouldn’t amount to much. As it turned out, our biggest money saving ideas were those truly bombastic statements that Terry was making. One such idea had to do with the heaters on the precipitators that kept the hoppers and the insulators on the roof too hot to collect moisture.

The Precipitator is a very large box that takes the ash out of the exhaust before it goes out of the smoke stack (how many times have I made that statement in the last two years?). Anyway, the exhaust from the boiler after the coal has been turned to ash in the fireball in the boiler contains a large amount of moisture. The last thing you want to happen is for the temperature of the flue gas to fall below the dew point. When that happens, moisture collects on the structure in a form of… well… of Acid Rain. Basically eating away the precipitator and the duct work from the inside.

Somewhere along the line, it had been determined that the dewpoint of the flue gas was not higher than 250 degrees. So, as long as the structure was at least 250 degrees, no moisture would be collected. Four heaters were mounted on each of the 84 hoppers (on each of the two precipitators) and heaters were mounted on the roof around each of the insulators that held up the wire racks on both ends.

When Terry walked into the office to attend one of our first “We’ve Got The Power” team meetings, he said, I think we could save a lot of money if we did something about the heaters on the precipitator. — He may remember being greeted with blank stares (at least from me). Um. Ok. Heaters on the precipitator. I knew they were everywhere, but I never gave them much thought.

I think Terry could tell right away that I hadn’t taken his idea seriously. I don’t know. Maybe he was bothered by the sound of my eyeballs rolling around in circles as if someone has conked me on the head. So, he explained his idea further. He pointed out that the roof heaters on just one of the precipitators used about 211 kilowatt-hours and the hopper heaters used about 345 kilowatt-hours. Together it is more than half a Megawatt of power. — This definitely caught our attention. That meant that between both of the Precipitators (since we had two boilers at our plant), we could possibly save over a Megawatt of electricity every hour we could shut down the heaters.

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

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

After discussing all the aspects of the idea, we decided that in order for the idea to have any merit, we had to know if the dew point really was around 250 degrees, or was it possibly a lot lower. 250 degrees seemed high to begin with since the boiling point of water is 212 degrees. If lower, then we could have a workable idea. Originally, I wanted to tackle the task of finding the dew point. So, I went about it in a Science Experiment sort of way.

I figured that if we were able to lower the temperature of the flue gas to a known temperature below the dewpoint, and by knowing the volume of the gas, and the amount of liquid we could condense out of it, we could determine (possibly) the dew point. So, I brought my Graham Condenser to work, and Scott Hubbard and I went up to the 250 foot landing on the smoke stack with the intent of sucking a known amount of exhaust from the smoke stack while the unit was at full load.

Scott Hubbard

Scott Hubbard

We would run it through the condenser while running cool water through it to lower the temperature.

The Exact Graham Condenser used in our experiment Spring 1990

The Exact Graham Condenser used in our experiment Spring 1990 (and that’s my hairy hand in this selfie)

I could measure the output of the vacuum pump by filling up an inverted Erlemeyer flask with water and then letting the flue gas displace the water. — I always loved doing experiments like this in the 9th grade science glass with Mr. Godfrey our Physical Science Teacher (Donna Westhoff, who may sometimes read this blog was in my class and sat right behind me).

An Erlenmeyer Flask (from Google Images, not from my Chemistry Lab)

An Erlenmeyer Flask (from Google Images, not from my Chemistry Lab)

Ok. Side Story, since I mentioned Donna Westhoff from the 9th grade 1974-75 school year.

I knew that Donna’s father was a fire fighter, because one day during a special outing when we were with a group of bicycling Junior High School students and a teacher, we stopped at Donna Westhoff’s house to get a drink of water. On the walls in her house were different types of fire fighting treasures. Donna explained that her father was a fire fighter… That was the Spring of 1975 in Columbia, Missouri

Fast forward 16 years later (1991) at the Power Plant in the middle of nowhere in North Central Oklahoma. Just about a year after the story I’m telling now…. I left the logic room and went to catch the elevator to the Control room. When the doors opened, Tony Mena was in there with a bunch of college age students giving them a tour of the plant. I entered the elevator and turned around to face the door as it closed.

As I was standing there, I suddenly became aware that the person standing next to me was staring right at me. So, I turned to see who it was. Standing next to me was someone that looked very familiar wearing a big grin as if she knew who I was. I recognized her, and while my mind was going through filing cabinets of memories trying to index this particular person, I asked her, “Don’t I know you?” She shook her head and said, “I’m Donna Westhoff!”

A High School picture of Donna Westhoff who is on the Lower Left

A High School picture of Donna Westhoff who is on the Lower Left

As the elevator door opened and we stepped out, Donna and I began talking about what we were both doing there. She was surprised to find that I had become an electrician at a power plant instead of some kind of scientist in a lab somewhere. Donna was going to school in Stillwater where one of the best Fire Fighting Schools in the country is found. Following in her father’s footsteps, I thought. After a while I could tell that Tony was getting a little perturbed that the wisdom he was imparting about the fire protection system on the Turbine Generator wasn’t being absorbed by Donna, so I cut our conversation short. It turned out that a very good friend of hers lived just two houses from where we lived, and her friend’s mother was my landlord. Peggy Pickens.

Ok. End of the side story, and another example of how I occasionally run into friends from my childhood in the most unexpected places (see the post: “Relay Tests and Radio Quizzes with Ben Davis“).

So. Scott Hubbard and I tried using the Graham Condenser and the Erlenmeyer Flask, but we quickly found out that this wasn’t big enough, to capture a large enough quantity. So, we increased the size of the condenser by winding a garden hose around inside of a water bucket and filling it with ice. Then we captured all the water that condensed in the hose.

A 5 gallon water bucket we used as our condenser with a garden hose and ice

A 5 gallon water bucket we used as our condenser with a garden hose and ice

When it finally came down to it. Even though it was fun trying to do this experiment halfway up the 500 foot smoke stack, I never was able to figure out how to calculate the dew point given the data I had collected.

That’s when we decided to look at dew point sensors in the parts catalogs. If we could stick a probe down into the precipitator and measure the dew point directly in the flue gas, that would be best. After looking at a few in the catalog, Terry Blevins said he thought he could make one. So, he went to work.

Terry Blevins

Terry Blevins

The next day he came in with an inch and a half conduit with hoses hanging out the back and a homemade sensor on the other end. I won’t go into detail how the sensor was built because some day Terry may want to patent this thing because, as it turned out, it was so sensitive that it could detect my breathe from about a foot away. If I breathed out of my mouth toward the sensor, it would detect the moisture in my breath. This was perfect!

We went to work on the roof of the precipitator sticking the probe down into different sections of the precipitator. It not only measured the moisture, it also had thermocouples on it that we used to accurately measure the temperature of the sensor as we varied the temperature by blowing cold air through the conduit using the same ice bucket and hose from before.

I could go into a lot of detail about how we performed our experiments, but it would only excite me and bore you. So, let me just say that we came up with two very important results. First of all, at full load when the humidity outside was at 100% the dew point was around 150 degrees! A full 100 degrees below what the plant had originally assumed. This was very important, because a lot of energy was spent trying to keep the flue gas above 250 degrees, and just by lowering it down to 210 degrees, still a safe amount above the dew point, that extra energy could be used to create electricity.

The second thing that we discovered was that the middle sections of the precipitator was a lot cooler inside than the outer fields. We realized that this was caused by the air preheater coils that rotated between the flue gas and the Primary Air intake duct. This took the last amount of heat possible from the exhaust and transferred it to the air going into the boiler so that it was already hot when it was used to burn the coal. Because of the way the air preheater coils rotated, the part of the duct toward the middle of the precipitator was a lot cooler than the air on the outside.

Diagram of a boiler

Diagram of a boiler. See the Air Preheater? Flue Gas on one side and ambient air on the other

Lower temperatures in the precipitator increased the performance, so we decided that if we could mix the air around as it was going into the precipitator so that the outer edges were cooler, then it would increase the overall performance. One suggestion was to put a mobile home in the duct work because in Oklahoma it was a known fact that mobile homes attracted tornadoes and it would probably cause a tornadic reaction that would mix up the flue gases. — We just couldn’t figure out how to convince management to put a mobile home in the duct between the economizer and the precipitator.

Thanks to Terry’s handy dandy Dew Point Sensor, we were able to prove that the hopper and roof heaters could be lowered to where we set the thermostat at 180 degrees. At that setting the heaters that used to always run at 250 degrees would remain off anytime the ambient temperature was above 45 degrees. In Oklahoma, that is most of the year. This turned out to save over $350,000 per year in energy savings at a cost of about 1.5 cents per kilowatt-hour. Not to mention the unknown savings from being able to lower the flue gas temperature by 40 degrees.

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Power Plant Spider Wars and Bugs in the Basement

Originally posted July 27, 2012:

There were two distinct times in my life at the Power Plant Kingdom where I went Head-to-Head (or tête-à-tête as they say in France) with a horde of spiders.  The second time I fought side-by-side with my trusty friend Scott Hubbard, that I knew wouldn’t desert me when things went from bad-to-worse (for some reason I find myself using a lot of hyphens-to-day).  The first battle, however, I had to face alone, armed only with a push broom and a shovel.

It all started a few months after I became a janitor at the power plant (in 1982).  I had received my Psychology degree at the University of Missouri and I was well on my way to becoming a certified “sanitation engineer” (as my Grandmother corrected me after I told her I was a janitor).

It actually came in handy having a Psychology degree.  Power Plant men would sometimes approach me when I was working by myself to stop and have a conversation that usually started like this:  “So, someone told me you are a Psychiatrist.”  I would correct them and tell them that I am a janitor and I only have a bachelor’s degree in Psychology which makes me a properly trained janitor able to sweep the floor in confidence knowing that “I’m OK, and You’re OK.” (which was a joke lost on everyone at the plant except for Jim Kanelakos, who was also a janitor with a Masters in Psychology).

Then they would usually want to talk about problems they were having.  I would lean on my broom and listen.  Nodding my head slightly to show I was listening.  After a while the person would finish and thank me for listening and go on back to work.

The most important thing I learned while obtaining a Bachelors of Arts in Psychology was that Psychology is an art, not a science.  Though certain scientific methods are used in many areas, especially in Behavioral Psychology.  Being an art, means that the person must possess the talent for being a Psychologist.  This is as important as being properly trained.  So I never assumed the role of a real Psychologist, I rather tried my best to just be a friend.  I found that worked well.

As I mentioned, James Kanelakos was also a janitor at the Power Plant.  Which meant that between the 5 janitors and our leader Pat Braden, two of us not only had degrees, but both of them were in Psychology (with James having the Masters degree, and I as his pupil with the Bachelors).

Before I proceed with my battle with the spiders, I should mention a little about the dynamics of our Janitorial crew.

James Kanelakos was obviously Greek.  With a name like Kanelakos, it was rather obvious.  He looked the part also, with a graying moustache that made him look like a Greek sailor.  He never was a “True Power Plant Man” and he would be glad to hear me say that.  Instead he was a person that at the time acted as if he was biding his time at the plant waiting for something else to happen.

This picture reminds me of Jim Kanelakos.  I found it at Mobleyshoots.com

Though he never mentioned it, I know that he was also part Irish, and every now and then I would see the Irish come out.  He was a family man, and in that sense he reminded me of my own father (who was also part Irish).  He was only 35 years old at the time, but he acted as if he had lived longer.  He smoked a pipe like my father did.  As far as I know, he always remained married to his wife Sandy, and together they raised two children, a daughter and a son.  That was where his heart really was.

He made no secret that his family came before anything else.  Not that he would say it straight out to your face, but you could tell it in the way he interacted with others.  Like I said, Jim was there “biding his time”, changing his career at a time when he needed something… else.  Maybe to strengthen his priorities.  He said once that he left the office to go work outside.

Then there was Doris Voss.  She was an unlikely site to see in the Power Plant Palace (especially later when she became an operator).  She was a “Church-going Fundamentalist” who made it clear to me that Catholics, such as myself, were doomed to hell for various reasons.  I always enjoyed our… um… discussions.

I thought it was quite appropriate during Christmas when the janitors drew names from Jim’s Greek Sailor’s hat and I drew Doris’s name to give her a very nice leather-bound Catholic Version of the Family Bible.  I later heard her talking to Curtis Love about it in the kitchen.  He was telling her that she shouldn’t read it and she told him that it looked pretty much the same as hers and she didn’t see anything wrong with it.  Needless-to-say, I was rarely condemned to a regular Catholic’s fate after that.

A Bible like this with a Tassel hanging out of the bottom

Curtis Love, as I explained in the post called “Power Plant Safety as Interpreted by Curtis Love“, was very gullible.  It was easy to play a joke on Curtis.  Too easy.  He didn’t take them well, because he would rather believe what you were joking about before believing that you were joking at all.  Because of this, it never occurred to me to play a joke on Curtis.  Some how, though, it is hard to explain, Curtis reminded me of Tweedledee.  Or was it Tweedledum?

I think he reminded me more of the guy on the right… or maybe the left.

Then there was Ronnie Banks.  I talked about Ronnie Banks before in the post where Bob Lillibridge Meets the Boiler Ghost.  He was like a likable young bear standing up on his hind legs.  You could joke around with him and he was fun to be around.  He acted like he enjoyed your company.  Interestingly though, none of the people on our team would ever be classified as “True Power Plant Men”.  We were more like an odd assortment of Misfits.

Pat Braden was our lead Janitor.  He was by far the nicest person one could ever work for.  He constantly had a smile on his face.  He smiled when he talked, he smiled when he walked, and he especially smiled when he stood up from a chair and became dizzy from his blood pressure medicine.  He had a daughter at home that he really loved.  He reminded me of the goodhearted Red Skelton.

This Picture of Red Skelton reminds me of Pat Braden

Now back to the Spider Wars and the bugs in the basement.

When I first became a janitor, I was assigned to clean the Control room and to sweep half of the turbine room floor and the Control room elevator landings and stairs.  I always enjoyed being a janitor.  I first became a janitor when I was 15 years old Sophomore in High School working the night shift (from 11pm to 6am) at a Hilton Inn in Columbia, Missouri.

To me it was a dream job.  Sure, I couldn’t keep my own room cleaned, but put a push broom in my hand and pay me $2.50 an hour and I could clean all night.  When I began as a janitor at the power plant, I was making $5.15 an hour.  Double what I was making at the hotel cleaning the kitchen, the restaurant and the bar in the wee hours of the morning.

Anyway.  I went to work cleaning the control room like there was no tomorrow.  I would shampoo the carpet once each week.  I would clean on the top and the back of the Alarm Panel.  I know I made Ted Holdge (Supervisor of Operations) real nervous once when I laid a vacuum cleaner on the top of the Main Electric Panel (That’s what I call it.  it was the Control panel where you synced up the unit when it was coming online) and I started vacuuming the top of it.  He actually jumped out of his chair in the Shift Supervisor’s office and stood there and watched me closely.  It obviously had never been cleaned before.  I was trying to get rid of a strange odor in the control room that eventually, I found out was years of burned coffee in the coffee maker in the break room.  I even had to scrub the walls in the kitchen to remove the odor from the entire control room.

Anyway.  I was getting to know the Control Room operators, and I was thinking that maybe someday when I had progressed past janitor and labor crew that one day I may become an operator also.

One day Pat Braden came to me and told me that I was going to have to move down to be the janitor of the Electric Shop.  There were many reasons.  The first was that Curtis wanted to be an operator and he thought that if he worked around them that they would get to know him and would want him to join their ranks and he had more seniority than I did, so he had first pick.  The second reason was that for some reason, since Curtis had been the janitor of the Electric Shop he had been bitten twice by a brown recluse spider, which had invaded the janitor closet downstairs.  If he were to be bitten again, he might lose his job for being unsafe.

I didn’t mind.  Cleaning the Electric shop meant that I also was able to clean the Engineers Shack and the Brown and Root Building next to it.  I also decided that the main switchgear which was where the Janitor closet was located needed to be kept clean to cut down on the onslaught of the poisonous brown recluse spiders (which in Oklahoma is a regular house spider).

The Oklahoma house spider — The Brown Recluse.  Otherwise known at the “Fiddleback”

My first day as a Janitor in the Electric Shop as soon as I opened the door to the janitor closet, I could see why Curtis had been bitten by a Brown Recluse (not twice, but three times — the last time he didn’t tell Pat.  He showed me, but just went straight to the doctor for the required shots to counteract the poison.  Not wanting to lose his job).  The janitor closet was full of them.  They were all over the little 4 foot by 6 foot closet.

Thus began the first war on spiders at the coal fired power plant.  The closet was also being used to store Freon and other air conditioning equipment used by Jim Stevenson the Air Conditioning expert in the Electric Shop.  I decided then and there to move all the equipment out of the closet.  The spiders were practicing “Duck and Cover” drills all over this equipment so it had to go.

My main weapon against the spiders were my boots.  When I spied a spider, I stomped on it quickly.  I asked Pat Braden to order a case of insecticide to help me combat the spiders.  The next day he pulled a two-wheeler up to the closet with two cases and said, “Here is your order sir!” (picture Red Skelton saying that).

I had cleaned the shelves, the cabinet and the floor of the janitor closet, and there was no place for spiders to hide in there anymore.  Each morning when I arrived, there was always more spiders there.  3 or 4 at least waiting for me in the closet.  All Brown Recluse.

I surveyed the combat zone and realized that spiders were all over the main switchgear.  So I decided I was going to sweep the switchgear regularly and kill every spider I saw to wipe them out for good.

A picture of a clean switchgear. Picture 6 rows of switchgear like this

So I laid down floor sweep (cedar chips with red oil) to keep the dust down, and began at one corner and worked my way across the switchgear sweeping and killing spiders.  I kept a body count.  I taped a paper in the janitor closet to keep track of my daily kill.  My first day I killed over 200 spiders.

I thought surely in a short time, I will have wiped out the spider population.  After sweeping the switchgear I laid down a blanket of Insecticide (equivalent to Agent Orange in Vietnam).  If I could kill any bugs that are around, the spiders would leave.  The insecticide didn’t kill the spiders.  they would just duck under the switchgear and then come out an hour later to be standing where I left them before.  So I kept stomping them out.

Every day, my body count was around 25 to 30 spiders and this number wasn’t going down.  That was when I discovered the Cable Spreader room…  I had been involved in mere child’s play before I walked down some steps at the tail end of the switchgear and opened one of the two doors at the bottom.

I cannot describe to you exactly what I saw, because nothing I say can put into words what was there.  I guess the best thing I can say is:  Armageddon.

There were two rooms.  One on each side at the bottom of some concrete steps.  They are called Cable Spreader rooms and are directly beneath the switchgear.  One side was unit one, the other was unit 2.  They are large rooms with cable trays lining the walls and across the room at regular intervals.  The floor was damp, and it was black, and it was alive.  There was a small path through the room where the operator would pass through “the gauntlet” once each shift as they muttered prayers that they not be eaten alive by the black oozing mass of bugs spiders and an occasional snake.

The can of bug spray in my hand seemed completely useless.  I knew what I had to do.  These two rooms and the cable tunnels that ran from there underneath the T-G building were the source of my daily trouncing of the meager few spiders that decided to explore the world above to see what was happening in the switchgear.  The real battle was down here in the trenches.  Each room was full of thousands of spiders.

I started with a large box of Plastic Contractor bags, a box of floor sweep, a shovel and a push broom.  I attacked the room the same way I used to clean my own bedroom at home when I was growing up.  I started in one corner and fanned out.  Not letting anything past me.  always keeping a clear supply line back to the steps that led up to freedom and fresh air up above.

At first I just took a large scoop shovel and scooped up the black mass of crawling and dead bugs and dumped them in a bag, until I had enough space to sweep the dust into a pile.  Then I attacked it again.  Occasionally a small snake would appear upset that I had invaded his space, and into the bag it would go.  Everything went in the bags.  The snakes, the bugs, the spiders and the grime.  There was actually a constant battle taking place down there that I was interrupting.  it was bug eat bug, spider eat bug and snake eat bugs and spiders wars.  Everything went in the bags.

I carefully hauled the bags out to the dumpster and out they went.  It took an entire day to clean one room.  Then the next day when I went back I completely cleaned it again.  This time paying more attention to making it livable.  I wanted these two rooms to be so clean that people could go down into these cool damp rooms in the hot summer and have a picnic down there and feel safe.  —  No one ever did though, but such is the life of a cable spreader room.  Years later Tom Gibson setup a sort of a greenhouse down there.

After that, each day I made my rounds of the switchgear, the cable spreader rooms and the cable tunnels killing any spider that showed it’s legs.  After the main battle in the two rooms and tunnels was over of countless spiders and bugs, I recorded about 230 spiders the next day by making my rounds.  The next day that dropped to around 150.  then 80, then 50 and on down.  Finally, when I was down to 3 or 4 spiders each day, I felt like the war was over and a weekly sweeping and daily walk-through would suffice to keep the switchgear safe.  This left the small janitor closet virtually free of spiders from that point.

The interesting twist of the entire battle against the spiders was that the electricians had seen my skills at “Battle Sweeping” and some of them had become impressed.  They told me that I didn’t have to sweep their shop and the main switchgear because they took turns doing it.  I still felt that as the janitor, with my battle hardened push broom, by paying a little more attention to detail would do a slightly better job.

The electricians didn’t really volunteer to clean the shop.  Whoever was the truck driver for that week was supposed to clean the shop at least one time during the week.  At $5.15 an hour, I was more of a volunteer than someone that was hired to do this chore, and I enjoyed it.  So, eventually, Charles Foster (An Electrical Foreman) popped the question to me one day…. He didn’t get down on one knee when he asked me, but either way, he asked me if I would think about becoming an Electrician.

That was something I hadn’t even considered until that moment.  The Electricians to me were the elite squad of Power Plant Maintenance.  Like the Results guys, but with a wider range of skills it seemed.  But that is a story for another time.

Since I originally posted this, I have written the post about the second war with spiders with Scott Hubbard by my side.  So, if this post wasn’t enough for you… read this one:  “Power Plant Spider Wars II The Phantom Menace“.  For a more tame story about spiders try this one:  “Power Plant Spider in the Eye“.

Comments from the previous post:

  1. standninthefire July 28, 2014

    I (a science major in college) always had a running debate with my psychology friends that psychology wasn’t really science. Granted, I only said that to get into an debate about the subject but I think you’re spot on when you say that psychology has an “art” component to it. It’s a combination of both but I think that the better psychologists are the ones who master the art.

  2. mpsharmaauthor July 29, 2014

    I didn’t think I would ever voluntarily read about spiders, but I have been proven wrong. Thank you for reminding me to never say never 🙂

  3. Jonathan Caswell July 29, 2014

    SPIDERS, BUGS AND BASEMENTS…OH MY!!!!

  4. Jim  July 29, 2014

    This has been some of the most enjoyable reading I’ve done for a looooong time 🙂

  5. sacredhandscoven October 21, 2014

    OMGosh, my skin is STILL crawling and I don’t think it will stop for a few decades! Your story reminds me of that scene in the Indiana Jones second movie where the girl had to reach into the bugs and pull the lever to save Indy’s life. If it had been me, he’d a been a goner! If anything has more than 4 legs it needs to stay away from me! I cannot imagine going through that cleaning job.

  6. Willow River January 28, 2015

    Good Lord, this is like reading a horror novel! I swear, if I had been anywhere near that sort of situation, you’d find me huddled up in some corner far away trying not to scream while I cry. This story only strengthens my belief that spiders are, to put it lightly, PURE EVIL!!! You, sir, are a very, very brave soul, and I salute you. From way over here, away from the spiders.

  7. iltorero February 7, 2015

    Curtis was bitten by Brown Recluse twice? They inflict some of the grossest wounds I’ve ever seen. We’ve got them in Maine, but they’re rare.

 

Doing Dew Point Tests and Lowering Expectations

Originally posted May 9, 2014:

There were times when I was working at the Coal-Fired Power Plant in North Central Oklahoma when I wondered if there was anything that we couldn’t do. Surrounded by True Power Plant Men I found that when we were facing a seemingly impossible task, a Power Plant Man would come up with an extremely creative solution to the problem. One such example was during the “We’ve Got The Power” program. I talked about this program in an early post called “Power Plant We’ve Got the Power Program” so I won’t go into detail here about the program itself. I will just say that we broke out into teams to find creative ways to operate more efficiently, and to cut costs.

I was a team leader of our team, and looking back I must have had two criteria in mind when I picked the team members that would be on my team. The first would have been that they were True Power Plant Men (and woman) with a higher than average intelligence. The second criteria would have been that they were friends of mine. I say this, because everyone on my team fit the bill.

During out team meetings, Terry Blevins would often say some bombastic statement that the average person may be inclined to dismiss immediately as being absurd. I say that because I remember more than once thinking that what Terry had just said wouldn’t amount to much. As it turned out, our biggest money saving ideas were those truly bombastic statements that Terry was making. One such idea had to do with the heaters on the precipitators that kept the hoppers and the insulators on the roof too hot to collect moisture.

The Precipitator is a very large box that takes the ash out of the exhaust before it goes out of the smoke stack (how many times have I made that statement in the last two years?). Anyway, the exhaust from the boiler after the coal has been turned to ash in the fireball in the boiler contains a large amount of moisture. The last thing you want to happen is for the temperature of the flue gas to fall below the dew point. When that happens, moisture collects on the structure in a form of… well… of Acid Rain. Basically eating away the precipitator and the duct work from the inside.

Somewhere along the line, it had been determined that the dewpoint of the flue gas was not higher than 250 degrees. So, as long as the structure was at least 250 degrees, no moisture would be collected. Four heaters were mounted on each of the 84 hoppers (on each of the two precipitators) and heaters were mounted on the roof around each of the insulators that held up the wire racks on both ends.

When Terry walked into the office to attend one of our first “We’ve Got The Power” team meetings, he said, I think we could save a lot of money if we did something about the heaters on the precipitator. — He may remember being greeted with blank stares (at least from me). Um. Ok. Heaters on the precipitator. I knew they were everywhere, but I never gave them much thought.

I think Terry could tell right away that I hadn’t taken his idea seriously. I don’t know. Maybe he was bothered by the sound of my eyeballs rolling around in circles as if someone has conked me on the head. So, he explained his idea further. He pointed out that the roof heaters on just one of the precipitators used about 211 kilowatt-hours and the hopper heaters used about 345 kilowatt-hours. Together it more than half a Megawatt of power. — This definitely caught our attention. That meant that between both of the Precipitators (since we had two boilers at our plant), we could possibly save over a Megawatt of electricity every hour we could shut down the heaters.

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

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

After discussing all the aspects of the idea, we decided that in order for the idea to have any merit, we had to know if the dew point really was around 250 degrees, or was it possibly a lot lower. 250 degrees seemed high to begin with since the boiling point of water is 212 degrees. If lower, then we could have a workable idea. Originally, I wanted to tackle the task of finding the dew point. So, I went about it in a Science Experiment sort of way.

I figured that if we were able to lower the temperature of the flue gas to a known temperature below the dewpoint, and by knowing the volume of the gas, and the amount of liquid we could condense out of it, we could determine (possibly) the dew point. So, I brought my Graham Condenser to work, and Scott Hubbard and I went up to the 250 foot landing on the smoke stack with the intent of sucking a known amount of exhaust from the smoke stack while the unit was at full load.

Scott Hubbard

Scott Hubbard

We would run it through the condenser while running cool water through it to lower the temperature.

The Exact Graham Condenser used in our experiment Spring 1990

The Exact Graham Condenser used in our experiment Spring 1990 (and that’s my hairy hand in this selfie)

I could measure the output of the vacuum pump by filling up an inverted Erlemeyer flask with water and then letting the flue gas displace the water. — I always loved doing experiments like this in the 9th grade science glass with Mr. Godfrey our Physical Science Teacher (Donna Westhoff, who may sometimes read this blog was in my class and sat right behind me).

An Erlenmeyer Flask (from Google Images, not from my Chemistry Lab)

An Erlenmeyer Flask (from Google Images, not from my Chemistry Lab)

Ok. Side Story, since I mentioned Donna Westhoff from the 9th grade 1974-75 school year.

I knew that Donna’s father was a fire fighter, because one day during a special outing when we were with a group of bicycling Junior High School students and a teacher, we stopped at Donna Westhoff’s house to get a drink of water. On the walls in her house were different types of fire fighting treasures. Donna explained that her father was a fire fighter… That was the Spring of 1975 in Columbia, Missouri

Fast forward 16 years later (1991) at the Power Plant in the middle of nowhere in North Central Oklahoma. Just about a year after the story I’m telling now…. I left the logic room and went to catch the elevator to the Control room. When the doors opened, Tony Mena was in there with a bunch of college age students giving them a tour of the plant. I entered the elevator and turned around to face the door as it closed.

As I was standing there, I suddenly became aware that the person standing next to me was staring right at me. So, I turned to see who it was. Standing next to me was someone that looked very familiar wearing a big grin as if she knew who I was. I recognized her, and while my mind was going through filing cabinets of memories trying to index this particular person, I asked her, “Don’t I know you?” She shook her head and said, “I’m Donna Westhoff!”

A High School picture of Donna Westhoff  who is on the Lower Left

A High School picture of Donna Westhoff who is on the Lower Left

As the elevator door opened and we stepped out, Donna and I began talking about what we were both doing there. She was surprised to find that I had become an electrician at a power plant instead of some kind of scientist in a lab somewhere. Donna was going to school in Stillwater where one of the best Fire Fighting Schools in the country is found. Following in her father’s footsteps, I thought. After a while I could tell that Tony was getting a little perturbed that the wisdom he was imparting about the fire protection system on the Turbine Generator wasn’t being absorbed by Donna, so I cut our conversation short. It turned out that a very good friend of hers lived just two houses from where we lived, and her friend’s mother was my landlord. Peggy Pickens.

Ok. End of the side story, and another example of how I occasionally run into friends from my childhood in the most unexpected places (see the post: “Relay Tests and Radio Quizzes with Ben Davis“).

So. Scott Hubbard and I tried using the Graham Condenser and the Erlenmeyer Flask, but we quickly found out that this wasn’t big enough, to capture a large enough quantity. So, we increased the size of the condenser by winding a garden hose around inside of a water bucket and filling it with ice. Then we captured all the water that condensed in the hose.

A 5 gallon water bucket we used as our condenser with a garden hose and ice

A 5 gallon water bucket we used as our condenser with a garden hose and ice

When it finally came down to it. Even though it was fun trying to do this experiment halfway up the 500 foot smoke stack, I never was able to figure out how to calculate the dew point given the data I had collected.

That’s when we decided to look at dew point sensors in the parts catalogs. If we could stick a probe down into the precipitator and measure the dew point directly in the flue gas, that would be best. After looking at a few in the catalog, Terry Blevins said he thought he could make one. So, he went to work.

Terry Blevins

Terry Blevins

The next day he came in with an inch and a half conduit with hoses hanging out the back and a homemade sensor on the other end. I won’t go into detail how the sensor was built because some day Terry may want to patent this thing because, as it turned out, it was so sensitive that it could detect my breathe from about a foot away. If I breathed out of my mouth toward the sensor, it would detect the moisture in my breath. This was perfect!

We went to work on the roof of the precipitator sticking the probe down into different sections of the precipitator. It not only measured the moisture, it also had thermocouples on it that we used to accurately measure the temperature of the sensor as we varied the temperature by blowing cold air through the conduit using the same ice bucket and hose from before.

I could go into a lot of detail about how we performed our experiments, but it would only excite me and bore you. So, let me just say that we came up with two very important results. First of all, at full load when the humidity outside was at 100% the dew point was around 150 degrees! A full 100 degrees below what the plant had originally assumed. This was very important, because a lot of energy was spent trying to keep the flue gas above 250 degrees, and just by lowering it down to 210 degrees, still a safe amount above the dew point, that extra energy could be used to create electricity.

The second thing that we discovered was that the middle sections of the precipitator was a lot cooler inside than the outer fields. We realized that this was caused by the air preheater coils that rotated between the flue gas and the Primary Air intake duct. This took the last amount of heat safely possible from the exhaust and transferred it to the air going into the boiler so that it was already hot when it was used to burn the coal. Because of the way the air preheater coils rotated, the part of the duct toward the middle of the precipitator was a lot cooler than the air on the outside.

Diagram of a boiler

Diagram of a boiler. See the Air Preheater? Flue Gas on one side and ambient air on the other

Lower temperatures in the precipitator increased the performance, so we decided that if we could mix the air around as it was going into the precipitator so that the outer edges were cooler, then it would increase the overall performance. One suggestion was to put a mobile home in the duct work because in Oklahoma it was a known fact that mobile homes attracted tornadoes and it would probably cause a tornadic reaction that would mix up the flue gases. — We just couldn’t figure out how to convince management to put a mobile home in the duct between the economizer and the precipitator.

Thanks to Terry’s handy dandy Dew Point Sensor, we were able to prove that the hopper and roof heaters could be lowered to where we set the thermostat at 180 degrees. At that setting the heaters that used to always run at 250 degrees would remain off anytime the ambient temperature was above 45 degrees. In Oklahoma, that is most of the year. This turned out to save over $350,000 per year in energy savings at a cost of about 1.5 cents per kilowatt-hour. Not to mention the unknown savings from being able to lower the flue gas temperature by 40 degrees.

Power Plant Spider Wars and Bugs in the Basement

Originally posted July 27, 2012:

There were two distinct times in my life at the Power Plant Kingdom where I went Head-to-Head (or tête-à-tête as they say in France) with a horde of spiders.  The second time I fought side-by-side with my trusty friend Scott Hubbard, that I knew wouldn’t desert me when things went from bad-to-worse (for some reason I find myself using a lot of hyphens-to-day).  The first battle, however, I had to face alone, armed only with a push broom and a shovel.

It all started a few months after I became a janitor at the power plant (in 1982).  I had received my Psychology degree at the University of Missouri and I was well on my way to becoming a certified “sanitation engineer” (as my Grandmother corrected me after I told her I was a janitor).

It actually came in handy having a Psychology degree.  Power Plant men would sometimes approach me when I was working by myself to stop and have a conversation that usually started like this:  “So, someone told me you are a Psychiatrist.”  I would correct them and tell them that I am a janitor and I only have a bachelor’s degree in Psychology which makes me a properly trained janitor able to sweep the floor in confidence that “I’m OK, and You’re OK.” (which was a joke lost on everyone at the plant except for Jim Kanelakos, who was also a janitor with a Masters in Psychology).

Then they would usually want to talk about problems they were having.  I would lean on my broom and listen.  Nodding my head slightly to show I was listening.  After a while the person would finish and thank me for listening and go on back to work.

The most important thing I learned while obtaining a Bachelors of Arts in Psychology was that Psychology is an art, not a science.  Though certain scientific methods are used in many areas, especially in Behavioral Psychology.  Being an art, means that the person must possess the talent for being a Psychologist.  This is as important as being properly trained.  So I never assumed the role of a real Psychologist, I rather tried my best to just be a friend.  I found that worked well.

As I mentioned, James Kanelakos was also a janitor at the Power Plant.  Which meant that between the 5 janitors and our leader Pat Braden, two of us not only had degrees, but both of them were in Psychology (with James having the Masters degree, and I as his pupil with the Bachelors).

Before I proceed with my battle with the spiders, I should mention a little about the dynamics of our Janitorial crew.

James Kanelakos was obviously Greek.  With a name like Kanelakos, it was rather obvious.  He looked the part also, with a graying moustache that made him look like a Greek sailor.  He never was a “True Power Plant Man” and he would be glad to hear me say that.  Instead he was a person that at the time acted as if he was biding his time at the plant waiting for something else to happen.

This picture reminds me of Jim Kanelakos.  I found it at Mobleyshoots.com

Though he never mentioned it, I know that he was also part Irish, and every now and then I would see the Irish come out.  He was a family man, and in that sense he reminded me of my own father (who was also part Irish).  He was only 35 years old at the time, but he acted as if he had lived longer.  He smoked a pipe like my father did.  As far as I know, he always remained married to his wife Sandy, and together they raised two children, a daughter and a son.  That was where his heart really was.

He made no secret that his family came before anything else.  Not that he would say it straight out to your face, but you could tell it in the way he interacted with others.  Like I said, Jim was there “biding his time”, changing his career at a time when he needed something… else.  Maybe to strengthen his priorities.  He said once that he left the office to go work outside.

Then there was Doris Voss.  She was an unlikely site to see in the Power Plant Palace (especially later when she became an operator).  She was a “Church-going Fundamentalist” who made it clear to me that Catholics, such as myself, were doomed to hell for various reasons.  I always enjoyed our… um… discussions.

I thought it was quite appropriate during Christmas when the janitors drew names from Jim’s Greek Sailor’s hat and I drew Doris’s name to give her a very nice leather-bound Catholic Version of the Family Bible.  I later heard her talking to Curtis Love about it in the kitchen.  He was telling her that she shouldn’t read it and she told him that it looked pretty much the same as hers and she didn’t see anything wrong with it.  Needless-to-say, I was rarely condemned to a regular Catholic’s fate after that.

A Bible like this with a Tassel hanging out of the bottom

Curtis Love, as I explained in the post called “Power Plant Safety as Interpreted by Curtis Love“, was very gullible.  It was easy to play a joke on Curtis.  Too easy.  He didn’t take them well, because he would rather believe what you were joking about before believing that you were joking at all.  Because of this, it never occurred to me to play a joke on Curtis.  Some how, though, it is hard to explain, Curtis reminded me of Tweedledee.  Or was it Tweedledum?

I think he reminded me more of the guy on the right… or maybe the left.

Then there was Ronnie Banks.  I talked about Ronnie Banks before in the post where Bob Lillibridge Meets the Boiler Ghost.  He was like a likable young bear standing up on his hind legs.  You could joke around with him and he was fun to be around.  He acted like he enjoyed your company.  Interestingly though, none of the people on our team would ever be classified as “True Power Plant Men”.  We were more like an odd assortment of Misfits.

Pat Braden was our lead Janitor.  He was by far the nicest person one could ever work for.  He constantly had a smile on his face.  He smiled when he talked, he smiled when he walked, and he especially smiled when he stood up from a chair and became dizzy from his blood pressure medicine.  He had a daughter at home that he really loved.  He reminded me of the goodhearted Red Skelton.

This Picture of Red Skelton reminds me of Pat Braden

Now back to the Spider Wars and the bugs in the basement.

When I first became a janitor, I was assigned to clean the Control room and to sweep half of the turbine room floor and the Control room elevator landings and stairs.  I always enjoyed being a janitor.  I first became a janitor when I was 15 years old Sophomore in High School working the night shift (from 11pm to 6am) at a Hilton Inn in Columbia, Missouri.

To me it was a dream job.  Sure, I couldn’t keep my own room cleaned, but put a push broom in my hand and pay me $2.50 an hour and I could clean all night.  When I began as a janitor at the power plant, I was making $5.15 an hour.  Double what I was making at the hotel cleaning the kitchen, the restaurant and the bar in the wee hours of the morning.

Anyway.  I went to work cleaning the control room like there was no tomorrow.  I would shampoo the carpet once each week.  I would clean on the top and the back of the Alarm Panel.  I know I made Ted Holdge (Supervisor of Operations) real nervous once when I laid a vacuum cleaner on the top of the Main Electric Panel (That’s what I call it.  it was the Control panel where you synced up the unit when it was coming online) and I started vacuuming the top of it.  He actually jumped out of his chair in the Shift Supervisor’s office and stood there and watched me closely.  It obviously had never been cleaned before.  I was trying to get rid of a strange odor in the control room that eventually, I found out was years of burned coffee in the coffee maker in the break room.  I even had to scrub the walls in the kitchen to remove the odor from the entire control room.

Anyway.  I was getting to know the Control Room operators, and I was thinking that maybe someday when I had progressed past janitor and labor crew that one day I may become an operator also.

One day Pat Braden came to me and told me that I was going to have to move down to be the janitor of the Electric Shop.  There were many reasons.  The first was that Curtis wanted to be an operator and he thought that if he worked around them that they would get to know him and would want him to join their ranks.  The second reason was that for some reason, since Curtis had been the janitor of the Electric Shop he had been bitten twice by a brown recluse spider, which had invaded the janitor closet downstairs.  If he were to be bitten again, he might lose his job for being unsafe.

I didn’t mind.  Cleaning the Electric shop meant that I also was able to clean the Engineers Shack and the Brown and Root Building next to it.  I also decided that the main switchgear which was where the Janitor closet was located needed to be kept clean to cut down on the onslaught of the poisonous brown recluse spiders (which in Oklahoma is a regular house spider).

The Oklahoma house spider — The Brown Recluse.  Otherwise known at the “Fiddleback”

My first day as a Janitor in the Electric Shop as soon as I opened the door to the janitor closet, I could see why Curtis had been bitten by a Brown Recluse (not twice, but three times — the last time he didn’t tell Pat.  He showed me, but just went straight to the doctor for the required shots to counteract the poison.  Not wanting to lose his job).  The janitor closet was full of them.  They were all over the little 4 foot by 5 foot closet.

Thus began the first war on spiders at the coal fired power plant.  The closet was also being used to store Freon and other air conditioning equipment used by Jim Stevenson the Air Conditioning expert in the Electric Shop.  I decided then and there to move all the equipment out of the closet.  The spiders were practicing “Duck and Cover” drills all over this equipment so it had to go.

My main weapon against the spiders were my boots.  When I spied a spider, I stomped on it quickly.  I asked Pat Braden to order a case of insecticide to help me combat the spiders.  The next day he pulled a two-wheeler up to the closet with two cases and said, “Here is your order sir!” (picture Red Skelton saying that).

I had cleaned the shelves, the cabinet and the floor of the janitor closet, and there was no place for spiders to hide in there anymore.  Each morning when I arrived, there was always more spiders there.  3 or 4 at least waiting for me in the closet.  All Brown Recluse.

I surveyed the combat zone and realized that spiders were all over the main switchgear.  So I decided I was going to sweep the switchgear regularly and kill every spider I saw to wipe them out for good.

A picture of a clean switchgear. Picture 6 rows of switchgear like this

So I laid down floor sweep (cedar chips with red oil) to keep the dust down, and began at one corner and worked my way across the switchgear sweeping and killing spiders.  I kept a body count.  I taped a paper in the janitor closet to keep track of my daily kill.

I thought surely in a short time, I will have wiped out the spider population.  After sweeping the switchgear I laid down a blanket of Insecticide (equivalent to Agent Orange in Vietnam).  If I could kill any bugs that are around, the spiders would leave.  The insecticide didn’t kill the spiders.  they would just duck under the switchgear and then come out an hour later to be standing where I left them before.  So I kept stomping them out.

Every day, my body count was around 25 to 30 spiders and this number wasn’t going down.  That was when I discovered the Cable Spreader room…  I had been involved in mere child’s play before I walked down some steps at the tail end of the switchgear and opened one of the two doors at the bottom.

I cannot describe to you exactly what I saw, because nothing I say can put into words what was there.  I guess the best thing I can say is:  Armageddon.

There were two rooms.  One on each side at the bottom of some concrete steps.  They are called Cable Spreader rooms and are directly beneath the switchgear.  One side was unit one, the other was unit 2.  They are large rooms with cable trays lining the walls and across the room at regular intervals.  The floor was damp, and it was black, and it was alive.  There was a small path through the room where the operator would pass through “the gauntlet” once each shift as they muttered prayers that they not be eaten alive by the black oozing mass of bugs spiders and an occasional snake.

The can of bug spray in my hand seemed completely useless.  I knew what I had to do.  These two rooms and the cable tunnels that ran from there underneath the T-G building were the source of my daily trouncing of the meager few spiders that decided to explore the world above to see what was happening in the switchgear.  The real battle was down here in the trenches.  Each room was full of thousands of spiders.

I started with a large box of Plastic Contractor bags, a box of floor sweep, a shovel and a push broom.  I attacked the room the same way I used to clean my own bedroom at home when I was growing up.  I started in one corner and fanned out.  Not letting anything past me.  always keeping a clear supply line back to the steps that led up to freedom and fresh air up above.

At first I just took a large scoop shovel and scooped up the black mass of crawling and dead bugs and dumped them in a bag, until I had enough space to sweep the dust into a pile.  Then I attacked it again.  Occasionally a small snake would appear upset that I had invaded his space, and into the bag it would go.  Everything went in the bags.  The snakes, the bugs, the spiders and the grime.  There was actually a constant battle taking place down there that I was interrupting.  it was bug eat bug, spider eat bug and snake eat bugs and spiders wars.  Everything went in the bags.

I carefully hauled the bags out to the dumpster and out they went.  It took an entire day to clean one room.  Then the next day when I went back I completely cleaned it again.  This time paying more attention to making it livable.  I wanted these two rooms to be so clean that people could go down into these cool damp rooms in the hot summer and have a picnic down there and feel safe.  —  No one ever did though, but such is the life of a cable spreader room.

After that, each day I made my rounds of the switchgear, the cable spreader rooms and the cable tunnels killing any spider that showed it’s legs.  After the main battle in the two rooms and tunnels was over of countless spiders and bugs, I recorded about 230 spiders the next day by making my rounds.  The next day that dropped to around 150.  then 80, then 50 and on down.  Finally, when I was down to 3 or 4 spiders each day, I felt like the war was over and a weekly sweeping and daily walk-through would suffice to keep the switchgear safe.  This left the small janitor closet virtually free of spiders from that point.

The interesting twist of the entire battle against the spiders was that the electricians had seen my skills at “Battle Sweeping” and some of them had become impressed.  They told me that I didn’t have to sweep their shop and the main switchgear because they took turns doing it.  I still felt that as the janitor, with my battle hardened push broom, by paying a little more attention to detail would do a slightly better job.

The electricians didn’t really volunteer to clean the shop.  Whoever was the truck driver for that week was supposed to clean the shop at least one time during the week.  At $5.15 an hour, I was more of a volunteer than someone that was hired to do this chore, and I enjoyed it.  So, eventually, Charles Foster (An Electrical Foreman) popped the question to me one day…. He didn’t get down on one knee when he asked me, but either way, he asked me if I would think about becoming an Electrician.

That was something I hadn’t even considered until that moment.  The Electricians to me were the elite squad of Power Plant Maintenance.  Like the Results guys, but with a wider range of skills it seemed.  But that is a story for another time.

Since I originally posted this, I have written the post about the second war with spiders with Scott Hubbard by my side.  So, if this post wasn’t enough for you… read this one:  “Power Plant Spider Wars II The Phantom Menace“.  For a more tame story about spiders try this one:  “Power Plant Spider in the Eye“.

Comments from the previous post:

  1. standninthefire July 28, 2014

    I (a science major in college) always had a running debate with my psychology friends that psychology wasn’t really science. Granted, I only said that to get into an debate about the subject but I think you’re spot on when you say that psychology has an “art” component to it. It’s a combination of both but I think that the better psychologists are the ones who master the art.

  2. mpsharmaauthor July 29, 2014

    I didn’t think I would ever voluntarily read about spiders, but I have been proven wrong. Thank you for reminding me to never say never 🙂

  3. Jonathan Caswell July 29, 2014

    SPIDERS, BUGS AND BASEMENTS…OH MY!!!!

  4. Jim  July 29, 2014

    This has been some of the most enjoyable reading I’ve done for a looooong time 🙂

  5. sacredhandscoven October 21, 2014

    OMGosh, my skin is STILL crawling and I don’t think it will stop for a few decades! Your story reminds me of that scene in the Indiana Jones second movie where the girl had to reach into the bugs and pull the lever to save Indy’s life. If it had been me, he’d a been a goner! If anything has more than 4 legs it needs to stay away from me! I cannot imagine going through that cleaning job.

  6. Willow River January 28, 2015

    Good Lord, this is like reading a horror novel! I swear, if I had been anywhere near that sort of situation, you’d find me huddled up in some corner far away trying not to scream while I cry. This story only strengthens my belief that spiders are, to put it lightly, PURE EVIL!!! You, sir, are a very, very brave soul, and I salute you. From way over here, away from the spiders.

  7. iltorero February 7, 2015

    Curtis was bitten by Brown Recluse twice? They inflict some of the grossest wounds I’ve ever seen. We’ve got them in Maine, but they’re rare.

 

Doing Dew Point Tests and Lowering Expectations

Originally posted May 9, 2014:

There were times when I was working at the Coal-Fired Power Plant in North Central Oklahoma when I wondered if there was anything that we couldn’t do. Surrounded by True Power Plant Men I found that when we were facing a seemingly impossible task, a Power Plant Man would come up with an extremely creative solution to the problem. One such example was during the “We’ve Got The Power” program. I talked about this program in an early post called “Power Plant We’ve Got the Power Program” so I won’t go into detail here about the program itself. I will just say that we broke out into teams to find creative ways to operate more efficiently, and to cut costs.

I was a team leader of our team, and looking back I must have had two criteria in mind when I picked the team members that would be on my team. The first would have been that they were True Power Plant Men (and woman) with a higher than average intelligence. The second criteria would have been that they were friends of mine. I say this, because everyone on my team fit the bill.

During out team meetings, Terry Blevins would often say some bombastic statement that the average person may be inclined to dismiss immediately as being absurd. I say that because I remember more than once thinking that what Terry had just said wouldn’t amount to much. As it turned out, our biggest money saving ideas were those truly bombastic statements that Terry was making. One such idea had to do with the heaters on the precipitators that kept the hoppers and the insulators on the roof too hot to collect moisture.

The Precipitator is a very large box that takes the ash out of the exhaust before it goes out of the smoke stack (how many times have I made that statement in the last two years?). Anyway, the exhaust from the boiler after the coal has been turned to ash in the fireball in the boiler contains a large amount of moisture. The last thing you want to happen is for the temperature of the flue gas to fall below the dew point. When that happens, moisture collects on the structure in a form of… well… of Acid Rain. Basically eating away the precipitator and the duct work from the inside.

Somewhere along the line, it had been determined that the dewpoint of the flue gas was not higher than 250 degrees. So, as long as the structure was at least 250 degrees, no moisture would be collected. Four heaters were mounted on each of the 84 hoppers (on each of the two precipitators) and heaters were mounted on the roof around each of the insulators that held up the wire racks on both ends.

When Terry walked into the office to attend one of our first “We’ve Got The Power” team meetings, he said, I think we could save a lot of money if we did something about the heaters on the precipitator. — He may remember being greeted with blank stares (at least from me). Um. Ok. Heaters on the precipitator. I knew they were everywhere, but I never gave them much thought.

I think Terry could tell right away that I hadn’t taken his idea seriously. I don’t know. Maybe he was bothered by the sound of my eyeballs rolling around in circles as if someone has conked me on the head. So, he explained his idea further. He pointed out that the roof heaters on just one of the precipitators used about 211 kilowatt-hours and the hopper heaters used about 345 kilowatt-hours. Together it more than half a Megawatt of power. — This definitely caught our attention. That meant that between both of the Precipitators (since we had two boilers at our plant), we could possibly save over a Megawatt of electricity every hour we could shut down the heaters.

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

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

After discussing all the aspects of the idea, we decided that in order for the idea to have any merit, we had to know if the dew point really was around 250 degrees, or was it possibly a lot lower. 250 degrees seemed high to begin with since the boiling point of water is 212 degrees. If lower, then we could have a workable idea. Originally, I wanted to tackle the task of finding the dew point. So, I went about it in a Science Experiment sort of way.

I figured that if we were able to lower the temperature of the flue gas to a known temperature below the dewpoint, and by knowing the volume of the gas, and the amount of liquid we could condense out of it, we could determine (possibly) the dew point. So, I brought my Graham Condenser to work, and Scott Hubbard and I went up to the 250 foot landing on the smoke stack with the intent of sucking a known amount of exhaust from the smoke stack while the unit was at full load.

Scott Hubbard

Scott Hubbard

We would run it through the condenser while running cool water through it to lower the temperature.

The Exact Graham Condenser used in our experiment Spring 1990

The Exact Graham Condenser used in our experiment Spring 1990 (and that’s my hairy hand in this selfie)

I could measure the output of the vacuum pump by filling up an inverted Erlemeyer flask with water and then letting the flue gas displace the water. — I always loved doing experiments like this in the 9th grade science glass with Mr. Godfrey our Physical Science Teacher (Donna Westhoff, who may sometimes read this blog was in my class and sat right behind me).

An Erlenmeyer Flask (from Google Images, not from my Chemistry Lab)

An Erlenmeyer Flask (from Google Images, not from my Chemistry Lab)

Ok. Side Story, since I mentioned Donna Westhoff from the 9th grade 1974-75 school year.

I knew that Donna’s father was a fire fighter, because one day during a special outing when we were with a group of bicycling Junior High School students and a teacher, we stopped at Donna Westhoff’s house to get a drink of water. On the walls in her house were different types of fire fighting treasures. Donna explained that her father was a fire fighter… That was the Spring of 1975 in Columbia, Missouri

Fast forward 16 years later (1991) at the Power Plant in the middle of nowhere in North Central Oklahoma. Just about a year after the story I’m telling now…. I left the logic room and went to catch the elevator to the Control room. When the doors opened, Tony Mena was in there with a bunch of college age students giving them a tour of the plant. I entered the elevator and turned around to face the door as it closed.

As I was standing there, I suddenly became aware that the person standing next to me was staring right at me. So, I turned to see who it was. Standing next to me was someone that looked very familiar wearing a big grin as if she knew who I was. I recognized her, and while my mind was going through filing cabinets of memories trying to index this particular person, I asked her, “Don’t I know you?” She shook her head and said, “I’m Donna Westhoff!”

A High School picture of Donna Westhoff  who is on the Lower Left

A High School picture of Donna Westhoff who is on the Lower Left

As the elevator door opened and we stepped out, Donna and I began talking about what we were both doing there. She was surprised to find that I had become an electrician at a power plant instead of some kind of scientist in a lab somewhere. Donna was going to school in Stillwater where one of the best Fire Fighting Schools in the country is found. Following in her father’s footsteps, I thought. After a while I could tell that Tony was getting a little perturbed that the wisdom he was imparting about the fire protection system on the Turbine Generator wasn’t being absorbed by Donna, so I cut our conversation short. It turned out that a very good friend of hers lived just two houses from where we lived, and her friend’s mother was my landlord. Peggy Pickens.

Ok. End of the side story, and another example of how I occasionally run into friends from my childhood in the most unexpected places (see the post: “Relay Tests and Radio Quizzes with Ben Davis“).

So. Scott Hubbard and I tried using the Graham Condenser and the Erlenmeyer Flask, but we quickly found out that this wasn’t big enough, to capture a large enough quantity. So, we increased the size of the condenser by winding a garden hose around inside of a water bucket and filling it with ice. Then we captured all the water that condensed in the hose.

A 5 gallon water bucket we used as our condenser with a garden hose and ice

A 5 gallon water bucket we used as our condenser with a garden hose and ice

When it finally came down to it. Even though it was fun trying to do this experiment halfway up the 500 foot smoke stack, I never was able to figure out how to calculate the dew point given the data I had collected.

That’s when we decided to look at dew point sensors in the parts catalogs. If we could stick a probe down into the precipitator and measure the dew point directly in the flue gas, that would be best. After looking at a few in the catalog, Terry Blevins said he thought he could make one. So, he went to work.

Terry Blevins

Terry Blevins

The next day he came in with an inch and a half conduit with hoses hanging out the back and a homemade sensor on the other end. I won’t go into detail how the sensor was built because some day Terry may want to patent this thing because, as it turned out, it was so sensitive that it could detect my breathe from about a foot away. If I breathed out of my mouth toward the sensor, it would detect the moisture in my breath. This was perfect!

We went to work on the roof of the precipitator sticking the probe down into different sections of the precipitator. It not only measured the moisture, it also had thermocouples on it that we used to accurately measure the temperature of the sensor as we varied the temperature by blowing cold air through the conduit using the same ice bucket and hose from before.

I could go into a lot of detail about how we performed our experiments, but it would only excite me and bore you. So, let me just say that we came up with two very important results. First of all, at full load when the humidity outside was at 100% the dew point was around 150 degrees! A full 100 degrees below what the plant had originally assumed. This was very important, because a lot of energy was spent trying to keep the flue gas above 250 degrees, and just by lowering it down to 210 degrees, still a safe amount above the dew point, that extra energy could be used to create electricity.

The second thing that we discovered was that the middle sections of the precipitator was a lot cooler inside than the outer fields. We realized that this was caused by the air preheater coils that rotated between the flue gas and the Primary Air intake duct. This took the last amount of heat safely possible from the exhaust and transferred it to the air going into the boiler so that it was already hot when it was used to burn the coal. Because of the way the air preheater coils rotated, the part of the duct toward the middle of the precipitator was a lot cooler than the air on the outside.

Diagram of a boiler

Diagram of a boiler. See the Air Preheater? Flue Gas on one side and ambient air on the other

Lower temperatures in the precipitator increased the performance, so we decided that if we could mix the air around as it was going into the precipitator so that the outer edges were cooler, then it would increase the overall performance. One suggestion was to put a mobile home in the duct work because in Oklahoma it was a known fact that mobile homes attracted tornadoes and it would probably cause a tornadic reaction that would mix up the flue gases. — We just couldn’t figure out how to convince management to put a mobile home in the duct between the economizer and the precipitator.

Thanks to Terry’s handy dandy Dew Point Sensor, we were able to prove that the hopper and roof heaters could be lowered to where we set the thermostat at 180 degrees. At that setting the heaters that used to always run at 250 degrees would remain off anytime the ambient temperature was above 45 degrees. In Oklahoma, that is most of the year. This turned out to save over $350,000 per year in energy savings at a cost of about 1.5 cents per kilowatt-hour. Not to mention the unknown savings from being able to lower the flue gas temperature by 40 degrees.

Power Plant Spider Wars and Bugs in the Basement — Repost

There were two distinct times in my life at the Power Plant Kingdom where I went Head-to-Head (or tête-à-tête as they say in France) with a horde of spiders.  The second time I fought side-by-side with my trusty friend Scott Hubbard, that I knew wouldn’t desert me when things went from bad-to-worse (for some reason I find myself using a lot of hyphens-to-day).  The first battle, however, I had to face alone, armed only with a push broom and a shovel.

It all started a few months after I became a janitor at the power plant (in 1982).  I had received my Psychology degree at the University of Missouri and I was well on my way to becoming a certified “sanitation engineer” (as my Grandmother corrected me after I told her I was a janitor).

It actually came in handy having a Psychology degree.  Power Plant men would sometimes approach me when I was working by myself to stop and have a conversation that usually started like this:  “So, someone told me you are a Psychiatrist.”  I would correct them and tell them that I am a janitor and I only have a bachelor’s degree in Psychology which makes me a properly trained janitor able to sweep the floor in confidence that “I’m OK, and You’re OK.” (which was a joke lost on everyone at the plant except for Jim Kanelakos, who was also a janitor with a Masters in Psychology).  Then they would usually want to talk about problems they were having.  I would lean on my broom and listen.  Nodding my head slightly to show I was listening.  After a while the person would be done and thank me for listening and go on back to work.

The most important thing I learned while obtaining a Bachelors of Arts in Psychology was that Psychology is an art, not a science.  Though certain scientific methods are used in many areas, especially in Behavioral Psychology.  Being an art, means that the person must possess the talent for being a Psychologist.  This is as important as being properly trained.  So I never assumed the role of a real Psychologist, I rather tried my best to just be a friend.  I found that worked well.

As I mentioned, James Kanelakos was also a janitor at the Power Plant.  Which meant that between the 5 of us janitors and our leader Pat Braden, two of us not only had degrees, but both of them were in Psychology (with James having the Masters degree, and I as his pupil with the Bachelors).

Before I proceed with my battle with the spiders, I should mention a little about the dynamics of our Janitorial crew.

James Kanelakos was obviously Greek.  With a name like Kanelakos, it was rather obvious.  He looked the part also, with a graying moustache that made him look like a Greek sailor.  He never was a “True Power Plant Man” and he would be glad to hear me say that.  Instead he was a person that at the time acted as if he was buying his time at the plant waiting for something else to happen.

This picture reminds me of Jim Kanelakos.  I found it at Mobleyshoots.com

Though he never mentioned it, I know that he was also part Irish, and every now and then I would see the Irish come out.  He was a family man, and in that sense he reminded me of my own father (who was also part Irish).  He was only 35 years old at the time, but he acted as if he had lived longer.  He smoked a pipe like my father did.  As far as I know, he always remained married to his wife Sandy, and together they raised two children, a daughter and a son.  That was where his heart really was.

He made no secret that his family came before anything else.  Not that he would say it straight out to your face, but you could tell it in the way he interacted with others.  Like I said, Jim was there “buying his time”, changing his career at a time when he needed something… else.  Maybe to strengthen his priorities.  He said once that he left the office to go work outside.

Then there was Doris Voss.  She was an unlikely site to see in the Power Plant Palace (especially later when she became an operator).  She was a “Church-going Fundamentalist” who made it clear to me that Catholics, such as myself, were doomed to hell for various reasons.  I always enjoyed our… um… discussions.

I thought it was quite appropriate during Christmas when the janitors drew names from Jim’s Greek Sailor’s hat and I drew Doris’s name to give her a very nice leather-bound Catholic Version of the Family Bible.  I later heard her talking to Curtis Love about it in the kitchen.  He was telling her that she shouldn’t read it and she told him that it looked pretty much the same as hers and she didn’t see anything wrong with it.  Needless-to-say, I was rarely condemned to a regular Catholic’s fate after that.

A Bible like this with a Tassel hanging out of the bottom

Curtis Love, as I explained in the post called “Power Plant Safety as Interpreted by Curtis Love“, was very gullible.  It was easy to play a joke on Curtis.  Too easy.  He didn’t take them well, because he would rather believe what you were joking about before believing that you were joking at all.  Because of this, it never occurred to me to play a joke on Curtis.  Some how, though, it is hard to explain, Curtis reminded me of Tweedledee.  Or was it Tweedledum?

I think he reminded me more of the guy on the right… or maybe the left.

Then there was Ronnie Banks.  I talked about Ronnie Banks before in the post where Bob Lillibridge Meets the Boiler Ghost.  He was like a likable young bear standing up on his hind legs.  You could joke around with him and he was fun to be around.  He acted like he enjoyed your company.  Interestingly though, none of the people on our team would ever be classified as “True Power Plant Men”.  We were more like an odd assortment of Misfits.

Pat Braden was our lead Janitor.  He was by far the nicest person one could ever work for.  He constantly had a smile on his face.  He smiled when he talked, he smiled when he walked, and he especially smiled when he stood up from a chair and became dizzy from his blood pressure medicine.  He had a daughter at home that he really loved.  He reminded me of the goodhearted Red Skelton.

This Picture of Red Skelton reminds me of Pat Braden

Now back to the Spider Wars and the bugs in the basement.

When I first became a janitor, I was assigned to clean the Control room and to sweep half of the turbine room floor and the Control room elevator landings and stairs.  I always enjoyed being a janitor.  I first became a janitor when I was 15 years old Sophomore in High School working the night shift (from 11pm to 6am) at a Hilton Inn in Columbia, Missouri.

To me it was a dream job.  Sure, I couldn’t keep my own room cleaned, but put a push broom in my hand and pay me $2.50 an hour and I could clean all night.  When I began as a janitor at the power plant, I was making $5.15 an hour.  Double what I was making at the hotel cleaning the kitchen, the restaurant and the bar in the wee hours of the morning.

Anyway.  I went to work cleaning the control room like there was no tomorrow.  I would shampoo the carpet once each week.  I would clean on the top and the back of the Alarm Panel.  I know I made Ted Holdge real nervous once when I laid a vacuum cleaner on the top of the Main Electric Panel (That’s what I call it.  it was the Control panel where you synced up the unit when it was coming online) and I started vacuuming the top of it.  He actually jumped out of his chair in the Shift Supervisor’s office and stood there and watched me closely.  It obviously had never been cleaned before.  I was trying to get rid of a strange odor in the control room that eventually, I found out was years of burned coffee in the coffee maker in the break room.  I even had to scrub the walls in the kitchen to remove the odor from the entire control room.

Anyway.  I was getting to know the Control Room operators, and I was thinking that maybe someday when I had progressed past janitor and labor crew that one day I may become an operator also.

One day Pat Braden came to me and told me that I was going to have to move down to be the janitor of the Electric Shop.  There were many reasons.  The first was that Curtis wanted to be an operator and he thought that if he worked around them that they would get to know him and would want him to join their ranks.  The second reason was that for some reason, since Curtis had been the janitor of the Electric Shop he had been bitten twice by a brown recluse spider, which had invaded the janitor closet downstairs.  If he were to be bitten again, he might lose his job for being unsafe.

I didn’t mind.  Cleaning the Electric shop meant that I also was able to clean the Engineers Shack and the Brown and Root Building next to it.  I also decided that the main switchgear which was where the Janitor closet was located needed to be kept clean to cut down on the onslaught of the poisonous brown recluse spiders (which in Oklahoma is a regular house spider).

The Oklahoma house spider — The Brown Recluse.  Otherwise known at the “Fiddleback”

My first day as a Janitor in the Electric Shop as soon as I opened the door to the janitor closet, I could see why Curtis had been bitten by a Brown Recluse (not twice, but three times — the last time he didn’t tell Pat.  He showed me, but just went straight to the doctor for the required shots to counteract the poison.  Not wanting to lose his job).  The janitor closet was full of them.  They were all over the little 4 foot by 5 foot closet.

Thus began the first war on spiders at the coal fired power plant.  The closet was also being used to store Freon and other air conditioning equipment used by Jim Stevenson the Air Conditioning expert in the Electric Shop.  I decided then and there to move all the equipment out of the closet.  The spiders were practicing “Duck and Cover” drills all over this equipment so it had to go.

My main weapon against the spiders were my boots.  When I spied a spider, I stomped on it quickly.  I asked Pat Braden to order a case of insecticide to help me combat the spiders.  The next day he pulled a two-wheeler up to the closet with two cases and said, “Here is your order sir!” (picture Red Skelton saying that).

I had cleaned the shelves, the cabinet and the floor of the janitor closet, and there was no place for spiders to hide in there anymore.  Each morning when I arrived, there was always more spiders there.  3 or 4 at least waiting for me in the closet.  All Brown Recluse.

I surveyed the combat zone and realized that spiders were all over the main switchgear.  So I decided I was going to sweep the switchgear regularly and kill every spider I saw to wipe them out for good.

A picture of a clean switchgear. Picture 6 rows of switchgear like this

So I laid down floor sweep (cedar chips with red oil) to keep the dust down, and began at one corner and worked my way across the switchgear sweeping and killing spiders.  I kept a body count.  I taped a paper in the janitor closet to keep track of my daily kill.

I thought surely in a short time, I will have wiped out the spider population.  After sweeping the switchgear I laid down a blanket of Insecticide (equivalent to Agent Orange in Vietnam).  If I could kill any bugs that are around, the spiders would leave.  The insecticide didn’t kill the spiders.  they would just duck under the switchgear and then come out an hour later to be standing where I left them before.  So I kept stomping them out.

Every day, my body count was around 25 to 30 spiders and this number wasn’t going down.  That was when I discovered the Cable Spreader room…  I had been involved in mere child’s play before I walked down some steps at the tail end of the switchgear and opened one of the two doors at the bottom.

I cannot describe to you exactly what I saw, because nothing I say can put into words what was there.  I guess the best thing I can say is:  Armageddon.

There were two rooms.  One on each side at the bottom of some concrete steps.  They are called Cable Spreader rooms and are directly beneath the switchgear.  One side was unit one, the other was unit 2.  They are large rooms with cable trays lining the walls and across the room at regular intervals.  The floor was damp, and it was black, and it was alive.  There was a small path through the room where the operator would pass through “the gauntlet” once each shift as they muttered prayers that they not be eaten alive by the black oozing mass of bugs spiders and an occasional snake.

I knew what I had to do.  These two rooms and the cable tunnels that ran from there underneath the T-G building were the source of my daily trouncing of the meager few spiders that decided to explore the world above to see what was happening in the switchgear.  The real battle was down here in the trenches.

I started with a large box of Plastic Contractor bags, a box of floor sweep, a shovel and a push broom.  I attacked the room the same way I used to clean my own bedroom at home when I was growing up.  I started in one corner and fanned out.  Not letting anything past me.  always keeping a clear supply line back to the steps that led up to freedom and air up above.

At first I just took a large scoop shovel and scooped up the black mass of crawling and dead bugs and dumped them in a bag, until I had enough space to sweep the dust into a pile.  Then I attacked it again.  Occasionally a small snake would appear upset that I had invaded his space, and into the bag it would go.  Everything went in the bags.  The snakes, the bugs, the spiders and the grime.  There was actually a constant battle taking place down there that I was interrupting.  it was bug eat bug, spider eat bug and snake eat bugs and spiders wars.  Everything went in the bags.

I carefully hauled the bags out to the dumpster and out they went.  It took an entire day to clean one room.  Then the next day when I went back I completely cleaned it again.  This time paying more attention to making it livable.  I wanted these two rooms to be so clean that people could go down into these cool damp rooms in the hot summer and have a picnic down there and feel safe.  —  No one ever did though, but such is the life of a cable spreader room.

After that, each day I made my rounds of the switchgear, the cable spreader rooms and the cable tunnels killing any spider that showed it’s legs.  After the main battle in the two rooms and tunnels was over of countless spiders and bugs, I recorded about 230 spiders the next day by making my rounds.  The next day that dropped to around 150.  then 80, then 50 and on down.  Finally, when I was down to 3 or 4 spiders each day, I felt like the war was over and a weekly sweeping and daily walk-through would suffice to keep the switchgear safe.  This left the small janitor closet virtually free of spiders from that point.

The interesting twist of the entire battle against the spiders was that the electricians had seen my skills at Battle sweeping and some of them had become impressed.  They told me that I didn’t have to sweep their shop and the main switchgear because they took turns doing it.  I still felt that as the janitor, with my battle hardened push broom, by paying a little more attention to detail would do a slightly better job.

The electricians didn’t really volunteer to clean the shop.  Whoever was the truck driver for that week was supposed to clean the shop at least one time during the week.  At $5.15 an hour, I was more of a volunteer than someone that was hired to do this chore, and I enjoyed it.  So, eventually, Charles Foster (An Electrical Foreman) popped the question to me one day…. He asked me if I would think about becoming an Electrician.

That was something I hadn’t even considered until that moment.  The Electricians to me were the elite squad of Power Plant Maintenance.  Like the Results guys, but with a wider range of skills it seemed.  But that is a story for another time.

Doing Dew Point Tests and Lowering Expectations

There were times when I was working at the Coal-Fired Power Plant in North Central Oklahoma when I wondered if there was anything that we couldn’t do.  Surrounded by True Power Plant Men I found that when we were facing a seemingly impossible task, a Power Plant Man would come up with an extremely creative solution to the problem.  One such example was during the “We’ve Got The Power” program.  I talked about this program in an early post called “Power Plant We’ve Got the Power Program” so I won’t go into detail here about the program itself.  I will just say that we broke out into teams to find creative ways to operate more efficiently, and to cut costs.

I was a team leader of our team, and looking back I must have had two criteria in mind when I picked the team members that would be on my team.  The first would have been that they were True Power Plant Men (and woman) with a higher than average intelligence.  The second criteria would have been that they were friends of mine.  I say this, because everyone on my team fit the bill.

During out team meetings, Terry Blevins would often say some bombastic statement that the average person may be inclined to dismiss immediately as being absurd.  I say that because I remember more than once thinking that what Terry had just said wouldn’t amount to much.  As it turned out, our biggest money saving ideas were those truly bombastic statements that Terry was making.  One such idea had to do with the heaters on the precipitators that kept the hoppers and the insulators on the roof too hot to collect moisture.

The Precipitator is a very large box that takes the ash out of the exhaust before it goes out of the smoke stack (how many times have I made that statement in the last two years?).  Anyway, the exhaust from the boiler after the coal has been turned to ash in the fireball in the boiler contains a large amount of moisture.   The last thing you want to happen is for the temperature of the flue gas to fall below the dew point.  When that happens, moisture collects on the structure in a form of… well…  of Acid Rain.  Basically eating away the precipitator and the duct work from the inside.

Somewhere along the line, it had been determined that the dewpoint of the flue gas was not higher than 250 degrees.  So, as long as the structure was at least 250 degrees, no moisture would be collected.    Four heaters were mounted on each of the 84 hoppers (on each of the two precipitators) and heaters were mounted on the roof around each of the insulators that held up the wire racks on both ends.

When Terry walked into the office to attend one of our first “We’ve Got The Power” team meetings, he said, I think we could save a lot of money if we did something about the heaters on the precipitator. —  He may remember being greeted with blank stares (at least from me).  Um.  Ok.  Heaters on the precipitator.  I knew they were everywhere, but I never gave them much thought.

I think Terry could tell right away that I hadn’t taken his idea seriously.  I don’t know.  Maybe he was bothered by the sound of my eyeballs rolling around in circles as if someone has conked me on the head.  So, he explained his idea further.  He pointed out that the roof heaters on just one of the precipitators used about 211 kilowatt-hours and the hopper heaters used about 345 kilowatt-hours.  Together it more than half a Megawatt of power.  — This definitely caught our attention.  That meant that between both of the Precipitators (since we had two boilers at our plant), we could possibly save over a Megawatt of electricity every hour we could shut down the heaters.

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

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

After discussing all the aspects of the idea, we decided that in order for the idea to have any merit, we had to know if the dew point really was around 250 degrees, or was it possibly a lot lower.  250 degrees seemed high to begin with since the boiling point of water is 212 degrees.  If lower, then we could have a workable idea.  Originally, I wanted to tackle the task of finding the dew point.  So, I went about it in a Science Experiment sort of way.

I figured that if we were able to lower the temperature of the flue gas to a known temperature below the dewpoint, and by knowing the volume of the gas, and the amount of liquid we could condense out of it, we could determine (possibly) the dew point.  So, I brought my Graham Condenser to work, and Scott Hubbard and I went up to the 250 foot landing on the smoke stack with the intent of sucking a known amount of exhaust from the smoke stack while the unit was at full load.

Scott Hubbard

Scott Hubbard

We would run it through the condenser while running cool water through it to lower the temperature.

The Exact Graham Condenser used in our experiment Spring 1990

The Exact Graham Condenser used in our experiment Spring 1990 (and that’s my hairy hand in this selfie)

I could measure the output of the vacuum pump by filling up an inverted Erlemeyer flask with water and then letting the flue gas displace the water.  — I always loved doing experiments like this in the 9th grade science glass with Mr. Godfrey our Physical Science Teacher (Donna Westhoff, who may sometimes read this blog was in my class and sat right behind me).

An Erlenmeyer Flask (from Google Images, not from my Chemistry Lab)

An Erlenmeyer Flask (from Google Images, not from my Chemistry Lab)

Ok.  Side Story, since I mentioned Donna Westhoff from the 9th grade 1974-75 school year.

I knew that Donna’s father was a fire fighter, because one day during a special outing when we were with a group of bicycling Junior High School students and a teacher, we stopped at Donna Westoff’s house to get a drink of water.  On the walls in her house were different types of fire fighting treasures.  Donna explained that her father was a fire fighter…  That was the Spring of 1975 in Columbia, Missouri

Fast forward 16 years later (1991) at the Power Plant in the middle of nowhere in North Central Oklahoma.  Just about a year after the story I’m telling now…. I left the logic room and went to catch the elevator to the Control room.  When the doors opened, Tony Mena was in there with a bunch of college age students giving them a tour of the plant.  I entered the elevator and turned around to face the door as it closed.

As I was standing there, I suddenly became aware that the person standing next to me was staring right at me.  So, I turned to see who it was.  Standing next to me was someone that looked very familiar wearing a big grin as if she knew who I was.  I recognized her, and while my mind was going through filing cabinets of memories trying to index this particular person, I asked her, “Don’t I know you?”  She shook her head and said, “I’m Donna Westhoff!”

A High School picture of Donna Westhoff  who is on the Lower Left

A High School picture of Donna Westhoff who is on the Lower Left

As the elevator door opened and we stepped out, Donna and I began talking about what we were both doing there.  She was surprised to find that I had become an electrician at a power plant instead of some kind of scientist in a lab somewhere.  Donna was going to school in Stillwater where one of the best Fire Fighting Schools in the country is found.  Following in her father’s footsteps, I thought.  After a while I could tell that Tony was getting a little perturbed that the wisdom he was imparting about the fire protection system on the Turbine Generator wasn’t being absorbed by Donna, so I cut our conversation short.  It turned out that a very good friend of hers lived just two houses from where we lived, and her friend’s mother was my landlord.  Peggy Pickens.

Ok.  End of the side story, and another example of how I occasionally run into friends from my childhood in the most unexpected places (see the post:  “Relay Tests and Radio Quizzes with Ben Davis“).

So.  Scott Hubbard and I tried using the Graham Condenser and the Erlenmeyer Flask, but we quickly found out that this wasn’t big enough, to capture a large enough quantity.  So, we increased the size of the condenser by winding a garden hose around inside of a water bucket and filling it with ice.  Then we captured all the water that condensed in the hose.

A 5 gallon water bucket we used as our condenser with a garden hose and ice

A 5 gallon water bucket we used as our condenser with a garden hose and ice

When it finally came down to it.  Even though it was fun trying to do this experiment halfway up the 500 foot smoke stack, I never was able to figure out how to calculate the dew point given the data I had collected.

That’s when we decided to look at dew point sensors in the parts catalogs.  If we could stick a probe down into the precipitator and measure the dew point directly in the flue gas, that would be best.  After looking at a few in the catalog, Terry Blevins said he thought he could make one.  So, he went to work.

Terry Blevins

Terry Blevins

The next day he came in with an inch and a half conduit with hoses hanging out the back and a homemade sensor on the other end.  I won’t go into detail how the sensor was built because some day Terry may want to patent this thing because, as it turned out, it was so sensitive that it could detect my breathe from about a foot away.  If I breathed out of my mouth toward the sensor, it would detect the moisture in my breath.  This was perfect!

We went to work on the roof of the precipitator sticking the probe down into different sections of the precipitator.  It not only measured the moisture, it also had thermocouples on it that we used to accurately measure the temperature of the sensor as we varied the temperature by blowing cold air through the conduit using the same ice bucket and hose from before.

I could go into a lot of detail about how we performed our experiments, but it would only excite me and bore you.  So, let me just say that we came up with two very important results.  First of all, at full load when the humidity outside was at 100% the dew point was around 150 degrees!  A full 100 degrees below what the plant had originally assumed.  This was very important, because a lot of energy was spent trying to keep the flue gas above 250 degrees, and just by lowering it down to 210 degrees, still a safe amount above the dew point, that extra energy could be used to create electricity.

The second thing that we discovered was that the middle sections of the precipitator was a lot cooler inside than the outer fields.  We realized that this was caused by the air preheater coils that rotated between the flue gas and the Primary Air intake duct.  This took the last amount of heat safely possible from the exhaust and transferred it to the air going into the boiler so that it was already hot when it was used to burn the coal.  Because of the way the air preheater coils rotated, the part of the duct toward the middle of the precipitator was a lot cooler than the air on the outside.

Diagram of a boiler

Diagram of a boiler.  See the Air Preheater?  Flue Gas on one side and ambient air on the other

Lower temperatures in the precipitator increased the performance, so we decided that if we could mix the air around as it was going into the precipitator so that the outer edges were cooler, then it would increase the overall performance.  One suggestion was to put a mobile home in the duct work because in Oklahoma it was a known fact that mobile homes attracted tornadoes and it would probably cause a tornadic reaction that would mix up the flue gases.  — We just couldn’t figure out how to convince management to put a mobile home in the duct between the economizer and the precipitator.

Thanks to Terry’s handy dandy Dew Point Sensor, we were able to prove that the hopper and roof heaters could be lowered to where we set the thermostat at 180 degrees.  At that setting the heaters that used to always run at 250 degrees would remain off anytime the ambient temperature was above 45 degrees.  In Oklahoma, that is  most of the year.  This turned out to save over $350,000 per year in energy savings at a cost of about 1.5 cents per kilowatt-hour.  Not to mention the unknown savings from being able to lower the flue gas temperature by 40 degrees.

Power Plant Spider Wars and Bugs in the Basement — Repost

There were two distinct times in my life at the Power Plant Kingdom where I went Head-to-Head (or tête-à-tête as they say in France) with a horde of spiders.  The second time I fought side-by-side with my trusty friend Scott Hubbard, that I knew wouldn’t desert me when things went from bad-to-worse (for some reason I find myself using a lot of hyphens-to-day).  The first battle, however, I had to face alone, armed only with a push broom and a shovel.

It all started a few months after I became a janitor at the power plant (in 1982).  I had received my Psychology degree at the University of Missouri and I was well on my way to becoming a certified “sanitation engineer” (as my Grandmother corrected me after I told her I was a janitor).

It actually came in handy having a Psychology degree.  Power Plant men would sometimes approach me when I was working by myself to stop and have a conversation that usually started like this:  “So, someone told me you are a Psychiatrist.”  I would correct them and tell them that I am a janitor and I only have a bachelor’s degree in Psychology which makes me a properly trained janitor able to sweep the floor in confidence that “I’m OK, and You’re OK.” (which was a joke lost on everyone at the plant except for Jim Kanelakos, who was also a janitor with a Masters in Psychology).  Then they would usually want to talk about problems they were having.  I would lean on my broom and listen.  Nodding my head slightly to show I was listening.  After a while the person would be done and thank me for listening and go on back to work.

The most important thing I learned while obtaining a Bachelors of Arts in Psychology was that Psychology is an art, not a science.  Though certain scientific methods are used in many areas, especially in Behavioral Psychology.  Being an art, means that the person must possess the talent for being a Psychologist.  This is as important as being properly trained.  So I never assumed the role of a real Psychologist, I rather tried my best to just be a friend.  I found that worked well.

As I mentioned, James Kanelakos was also a janitor at the Power Plant.  Which meant that between the 5 of us janitors and our leader Pat Braden, two of us not only had degrees, but both of them were in Psychology (with James having the Masters degree, and I as his pupil with the Bachelors).

Before I proceed with my battle with the spiders, I should mention a little about the dynamics of our Janitorial crew.

James Kanelakos was obviously Greek.  With a name like Kanelakos, it was rather obvious.  He looked the part also, with a graying moustache that made him look like a Greek sailor.  He never was a “True Power Plant Man” and he would be glad to hear me say that.  Instead he was a person that at the time acted as if he was buying his time at the plant waiting for something else to happen.

This picture reminds me of Jim Kanelakos.  I found it at Mobleyshoots.com

Though he never mentioned it, I know that he was also part Irish, and every now and then I would see the Irish come out.  He was a family man, and in that sense he reminded me of my own father (who was also part Irish).  He was only 35 years old at the time, but he acted as if he had lived longer.  He smoked a pipe like my father did.  As far as I know, he always remained married to his wife Sandy, and together they raised two children, a daughter and a son.  That was where his heart really was.

He made no secret that his family came before anything else.  Not that he would say it straight out to your face, but you could tell it in the way he interacted with others.  Like I said, Jim was there “buying his time”, changing his career at a time when he needed something… else.  Maybe to strengthen his priorities.  He said once that he left the office to go work outside.

Then there was Doris Voss.  She was an unlikely site to see in the Power Plant Palace (especially later when she became an operator).  She was a “Church-going Fundamentalist” who made it clear to me that Catholics, such as myself, were doomed to hell for various reasons.  I always enjoyed our… um… discussions.

I thought it was quite appropriate during Christmas when the janitors drew names from Jim’s Greek Sailor’s hat and I drew Doris’s name to give her a very nice leather-bound Catholic Version of the Family Bible.  I later heard her talking to Curtis Love about it in the kitchen.  He was telling her that she shouldn’t read it and she told him that it looked pretty much the same as hers and she didn’t see anything wrong with it.  Needless-to-say, I was rarely condemned to a regular Catholic’s fate after that.

A Bible like this with a Tassel hanging out of the bottom

Curtis Love, as I explained in the post called “Power Plant Safety as Interpreted by Curtis Love“, was very gullible.  It was easy to play a joke on Curtis.  Too easy.  He didn’t take them well, because he would rather believe what you were joking about before believing that you were joking at all.  Because of this, it never occurred to me to play a joke on Curtis.  Some how, though, it is hard to explain, Curtis reminded me of Tweedledee.  Or was it Tweedledum?

I think he reminded me more of the guy on the right… or maybe the left.

Then there was Ronnie Banks.  I talked about Ronnie Banks before in the post where Bob Lillibridge Meets the Boiler Ghost.  He was like a likable young bear standing up on his hind legs.  You could joke around with him and he was fun to be around.  He acted like he enjoyed your company.  Interestingly though, none of the people on our team would ever be classified as “True Power Plant Men”.  We were more like an odd assortment of Misfits.

Pat Braden was our lead Janitor.  He was by far the nicest person one could ever work for.  He constantly had a smile on his face.  He smiled when he talked, he smiled when he walked, and he especially smiled when he stood up from a chair and became dizzy from his blood pressure medicine.  He had a daughter at home that he really loved.  He reminded me of the goodhearted Red Skelton.

This Picture of Red Skelton reminds me of Pat Braden

Now back to the Spider Wars and the bugs in the basement.

When I first became a janitor, I was assigned to clean the Control room and to sweep half of the turbine room floor and the Control room elevator landings and stairs.  I always enjoyed being a janitor.  I first became a janitor when I was 15 years old Sophomore in High School working the night shift (from 11pm to 6am) at a Hilton Inn in Columbia, Missouri.

To me it was a dream job.  Sure, I couldn’t keep my own room cleaned, but put a push broom in my hand and pay me $2.50 an hour and I could clean all night.  When I began as a janitor at the power plant, I was making $5.15 an hour.  Double what I was making at the hotel cleaning the kitchen, the restaurant and the bar in the wee hours of the morning.

Anyway.  I went to work cleaning the control room like there was no tomorrow.  I would shampoo the carpet once each week.  I would clean on the top and the back of the Alarm Panel.  I know I made Ted Holdge real nervous once when I laid a vacuum cleaner on the top of the Main Electric Panel (That’s what I call it.  it was the Control panel where you synced up the unit when it was coming online) and I started vacuuming the top of it.  He actually jumped out of his chair in the Shift Supervisor’s office and stood there and watched me closely.  It obviously had never been cleaned before.  I was trying to get rid of a strange odor in the control room that eventually, I found out was years of burned coffee in the coffee maker in the break room.  I even had to scrub the walls in the kitchen to remove the odor from the entire control room.

Anyway.  I was getting to know the Control Room operators, and I was thinking that maybe someday when I had progressed past janitor and labor crew that one day I may become an operator also.

One day Pat Braden came to me and told me that I was going to have to move down to be the janitor of the Electric Shop.  There were many reasons.  The first was that Curtis wanted to be an operator and he thought that if he worked around them that they would get to know him and would want him to join their ranks.  The second reason was that for some reason, since Curtis had been the janitor of the Electric Shop he had been bitten twice by a brown recluse spider, which had invaded the janitor closet downstairs.  If he were to be bitten again, he might lose his job for being unsafe.

I didn’t mind.  Cleaning the Electric shop meant that I also was able to clean the Engineers Shack and the Brown and Root Building next to it.  I also decided that the main switchgear which was where the Janitor closet was located needed to be kept clean to cut down on the onslaught of the poisonous brown recluse spiders (which in Oklahoma is a regular house spider).

The Oklahoma house spider — The Brown Recluse.  Otherwise known at the “Fiddleback”

My first day as a Janitor in the Electric Shop as soon as I opened the door to the janitor closet, I could see why Curtis had been bitten by a Brown Recluse (not twice, but three times — the last time he didn’t tell Pat.  He showed me, but just went straight to the doctor for the required shots to counteract the poison.  Not wanting to lose his job).  The janitor closet was full of them.  They were all over the little 4 foot by 5 foot closet.

Thus began the first war on spiders at the coal fired power plant.  The closet was also being used to store Freon and other air conditioning equipment used by Jim Stevenson the Air Conditioning expert in the Electric Shop.  I decided then and there to move all the equipment out of the closet.  The spiders were practicing “Duck and Cover” drills all over this equipment so it had to go.

My main weapon against the spiders were my boots.  When I spied a spider, I stomped on it quickly.  I asked Pat Braden to order a case of insecticide to help me combat the spiders.  The next day he pulled a two-wheeler up to the closet with two cases and said, “Here is your order sir!” (picture Red Skelton saying that).

I had cleaned the shelves, the cabinet and the floor of the janitor closet, and there was no place for spiders to hide in there anymore.  Each morning when I arrived, there was always more spiders there.  3 or 4 at least waiting for me in the closet.  All Brown Recluse.

I surveyed the combat zone and realized that spiders were all over the main switchgear.  So I decided I was going to sweep the switchgear regularly and kill every spider I saw to wipe them out for good.

A picture of a clean switchgear. Picture 6 rows of switchgear like this

So I laid down floor sweep (cedar chips with red oil) to keep the dust down, and began at one corner and worked my way across the switchgear sweeping and killing spiders.  I kept a body count.  I taped a paper in the janitor closet to keep track of my daily kill.

I thought surely in a short time, I will have wiped out the spider population.  After sweeping the switchgear I laid down a blanket of Insecticide (equivalent to Agent Orange in Vietnam).  If I could kill any bugs that are around, the spiders would leave.  The insecticide didn’t kill the spiders.  they would just duck under the switchgear and then come out an hour later to be standing where I left them before.  So I kept stomping them out.

Every day, my body count was around 25 to 30 spiders and this number wasn’t going down.  That was when I discovered the Cable Spreader room…  I had been involved in mere child’s play before I walked down some steps at the tail end of the switchgear and opened one of the two doors at the bottom.

I cannot describe to you exactly what I saw, because nothing I say can put into words what was there.  I guess the best thing I can say is:  Armageddon.

There were two rooms.  One on each side at the bottom of some concrete steps.  They are called Cable Spreader rooms and are directly beneath the switchgear.  One side was unit one, the other was unit 2.  They are large rooms with cable trays lining the walls and across the room at regular intervals.  The floor was damp, and it was black, and it was alive.  There was a small path through the room where the operator would pass through “the gauntlet” once each shift as they muttered prayers that they not be eaten alive by the black oozing mass of bugs spiders and an occasional snake.

I knew what I had to do.  These two rooms and the cable tunnels that ran from there underneath the T-G building were the source of my daily trouncing of the meager few spiders that decided to explore the world above to see what was happening in the switchgear.  The real battle was down here in the trenches.

I started with a large box of Plastic Contractor bags, a box of floor sweep, a shovel and a push broom.  I attacked the room the same way I used to clean my own bedroom at home when I was growing up.  I started in one corner and fanned out.  Not letting anything past me.  always keeping a clear supply line back to the steps that led up to freedom and air up above.

At first I just took a large scoop shovel and scooped up the black mass of crawling and dead bugs and dumped them in a bag, until I had enough space to sweep the dust into a pile.  Then I attacked it again.  Occasionally a small snake would appear upset that I had invaded his space, and into the bag it would go.  Everything went in the bags.  The snakes, the bugs, the spiders and the grime.  There was actually a constant battle taking place down there that I was interrupting.  it was bug eat bug, spider eat bug and snake eat bugs and spiders wars.  Everything went in the bags.

I carefully hauled the bags out to the dumpster and out they went.  It took an entire day to clean one room.  Then the next day when I went back I completely cleaned it again.  This time paying more attention to making it livable.  I wanted these two rooms to be so clean that people could go down into these cool damp rooms in the hot summer and have a picnic down there and feel safe.  —  No one ever did though, but such is the life of a cable spreader room.

After that, each day I made my rounds of the switchgear, the cable spreader rooms and the cable tunnels killing any spider that showed it’s legs.  After the main battle in the two rooms and tunnels was over of countless spiders and bugs, I recorded about 230 spiders the next day by making my rounds.  The next day that dropped to around 150.  then 80, then 50 and on down.  Finally, when I was down to 3 or 4 spiders each day, I felt like the war was over and a weekly sweeping and daily walk-through would suffice to keep the switchgear safe.  This left the small janitor closet virtually free of spiders from that point.

The interesting twist of the entire battle against the spiders was that the electricians had seen my skills at Battle sweeping and some of them had become impressed.  They told me that I didn’t have to sweep their shop and the main switchgear because they took turns doing it.  I still felt that as the janitor, with my battle hardened push broom, by paying a little more attention to detail would do a slightly better job.

The electricians didn’t really volunteer to clean the shop.  Whoever was the truck driver for that week was supposed to clean the shop at least one time during the week.  At $5.15 an hour, I was more of a volunteer than someone that was hired to do this chore, and I enjoyed it.  So, eventually, Charles Foster (An Electrical Foreman) popped the question to me one day…. He asked me if I would think about becoming an Electrician.

That was something I hadn’t even considered until that moment.  The Electricians to me were the elite squad of Power Plant Maintenance.  Like the Results guys, but with a wider range of skills it seemed.  But that is a story for another time.

Power Plant Spider Wars and Bugs in the Basement

There were two distinct times in my life at the Power Plant Kingdom where I went Head-to-Head (or tête-à-tête as they say in France) with a horde of spiders.  The second time I fought side-by-side with my trusty friend Scott Hubbard, that I knew wouldn’t desert me when things went from bad-to-worse (for some reason I find myself using a lot of hyphens-to-day).  The first battle, however, I had to face alone, armed only with a push broom and a shovel.

It all started a few months after I became a janitor at the power plant (in 1982).  I had received my Psychology degree at the University of Missouri and I was well on my way to becoming a certified “sanitation engineer” (as my Grandmother corrected me after I told her I was a janitor).

It actually came in handy having a Psychology degree.  Power Plant men would sometimes approach me when I was working by myself to stop and have a conversation that usually started like this:  “So, someone told me you are a Psychiatrist.”  I would correct them and tell them that I am a janitor and I only have a bachelor’s degree in Psychology which makes me a properly trained janitor able to sweep the floor in confidence that “I’m OK, and You’re OK.” (which was a joke lost on everyone at the plant except for Jim Kanelakos, who was also a janitor with a Masters in Psychology).  Then they would usually want to talk about problems they were having.  I would lean on my broom and listen.  Nodding my head slightly to show I was listening.  After a while the person would be done and thank me for listening and go on back to work.

The most important thing I learned while obtaining a Bachelors of Arts in Psychology was that Psychology is an art, not a science.  Though certain scientific methods are used in many areas, especially in Behavioral Psychology.  Being an art, means that the person must possess the talent for being a Psychologist.  This is as important as being properly trained.  So I never assumed the role of a real Psychologist, I rather tried my best to just be a friend.  I found that worked well.

As I mentioned, James Kanelakos was also a janitor at the Power Plant.  Which meant that between the 5 of us janitors and our leader Pat Braden, two of us not only had degrees, but both of them were in Psychology (with James having the Masters degree, and I as his pupil with the Bachelors).

Before I proceed with my battle with the spiders, I should mention a little about the dynamics of our Janitorial crew.

James Kanelakos was obviously Greek.  With a name like Kanelakos, it was rather obvious.  He looked the part also, with a graying moustache that made him look like a Greek sailor.  He never was a “True Power Plant Man” and he would be glad to hear me say that.  Instead he was a person that at the time acted as if he was buying his time at the plant waiting for something else to happen.

This picture reminds me of Jim Kanelakos.  I found it at Mobleyshoots.com

Though he never mentioned it, I know that he was also part Irish, and every now and then I would see the Irish come out.  He was a family man, and in that sense he reminded me of my own father (who was also part Irish).  He was only 35 years old at the time, but he acted as if he had lived longer.  He smoked a pipe like my father did.  As far as I know, he always remained married to his wife Sandy, and together they raised two children, a daughter and a son.  That was where his heart really was.

He made no secret that his family came before anything else.  Not that he would say it straight out to your face, but you could tell it in the way he interacted with others.  Like I said, Jim was there “buying his time”, changing his career at a time when he needed something… else.  Maybe to strengthen his priorities.  He said once that he left the office to go work outside.

Then there was Doris Voss.  She was an unlikely site to see in the Power Plant Palace (especially later when she became an operator).  She was a “Church-going Fundamentalist” who made it clear to me that Catholics, such as myself, were doomed to hell for various reasons.  I always enjoyed our… um… discussions.

I thought it was quite appropriate during Christmas when the janitors drew names from Jim’s Greek Sailor’s hat and I drew Doris’s name to give her a very nice leather-bound Catholic Version of the Family Bible.  I later heard her talking to Curtis Love about it in the kitchen.  He was telling her that she shouldn’t read it and she told him that it looked pretty much the same as hers and she didn’t see anything wrong with it.  Needless-to-say, I was rarely condemned to a regular Catholic’s fate after that.

A Bible like this with a Tassel hanging out of the bottom

Curtis Love, as I explained in the post called “Power Plant Safety as Interpreted by Curtis Love”, was very gullible.  It was easy to play a joke on Curtis.  Too easy.  He didn’t take them well, because he would rather believe what you were joking about before believing that you were joking at all.  Because of this, it never occurred to me to play a joke on Curtis.  Some how, though, it is hard to explain, Curtis reminded me of Tweedledee.  Or was it Tweedledum?

I think he reminded me more of the guy on the right… or maybe the left.

Then there was Ronnie Banks.  I talked about Ronnie Banks before in the post where Bob Lillibridge Meets the Boiler Ghost.  He was like a likable young bear standing up on his hind legs.  You could joke around with him and he was fun to be around.  He acted like he enjoyed your company.  Interestingly though, none of the people on our team would ever be classified as “True Power Plant Men”.  We were more like an odd assortment of Misfits.

Pat Braden was our lead Janitor.  He was by far the nicest person one could ever work for.  He constantly had a smile on his face.  He smiled when he talked, he smiled when he walked, and he especially smiled when he stood up from a chair and became dizzy from his blood pressure medicine.  He had a daughter at home that he really loved.  He reminded me of the goodhearted Red Skelton.

This Picture of Red Skelton reminds me of Pat Braden

Now back to the Spider Wars and the bugs in the basement.

When I first became a janitor, I was assigned to clean the Control room and to sweep half of the turbine room floor and the Control room elevator landings and stairs.  I always enjoyed being a janitor.  I first became a janitor when I was 15 years old working the night shift (from 11pm to 6am) at a Hilton Inn in Columbia, Missouri.

To me it was a dream job.  Sure, I couldn’t keep my own room cleaned, but put a push broom in my hand and pay me $2.50 an hour and I could clean all night.  When I began as a janitor at the power plant, I was making $5.15 an hour.  Double what I was making at the hotel cleaning the kitchen, the restaurant and the bar in the wee hours of the morning.

Anyway.  I went to work cleaning the control room like there was no tomorrow.  I would shampoo the carpet once each week.  I would clean on the top and the back of the Alarm Panel.  I know I made Ted Holdge real nervous once when I laid a vacuum cleaner on the top of the Auxiliary Control Panel (That’s what I call it.  it was the Control panel where you synced up the unit when it was coming online) and I started vacuuming the top of it.  He actually jumped out of his chair in the Shift Supervisor’s office and stood there and watched me closely.  It obviously had never been cleaned before.  I was trying to get rid of a strange odor in the control room that eventually, I found out was years of burned coffee in the coffee maker.  I even had to scrub the walls in the kitchen to remove the odor from the entire control room.

Anyway.  I was getting to know the Control Room operators, and I was thinking that maybe someday when I had progressed past janitor and labor crew that one day I may become an operator also.

One day Pat Braden came to me and told me that I was going to have to move down to be the janitor of the Electric Shop.  There were many reasons.  The first was that Curtis wanted to be an operator and he thought that if he worked around them that they would get to know him and would want him to join their ranks.  The second reason was that for some reason, since Curtis had been the janitor of the Electric Shop he had been bitten twice by a brown recluse spider, which had invaded the janitor closet downstairs.  If he were to be bitten again, he might lose his job for being unsafe.

I didn’t mind.  Cleaning the Electric shop meant that I also was able to clean the Engineers Shack and the Brown and Root Building next to it.  I also decided that the main switchgear which was where the Janitor closet was located needed to be kept clean to cut down on the onslaught of the poisonous brown recluse spiders (which in Oklahoma is a regular house spider).

The Oklahoma house spider — The Brown Recluse.  Otherwise known at the “Fiddleback”

My first day as a Janitor in the Electric Shop as soon as I opened the door to the janitor closet, I could see why Curtis had been bitten by a Brown Recluse (not twice, but three times — the last time he didn’t tell Pat.  He showed me, but just went straight to the doctor for the required shots to counteract the poison.  Not wanting to lose his job).  The janitor closet was full of them.  They were all over the little 4 foot by 5 foot closet.

Thus began the first war on spiders at the coal fired power plant.  The closet was also being used to store Freon and other air conditioning equipment used by Jim Stevenson the Air Conditioning expert in the Electric Shop.  I decided then and there to move all the equipment out of the closet.  The spiders were practicing “Duck and Cover” drills all over this equipment so it had to go.

My main weapon against the spiders were my boots.  When I spied a spider, I stomped on it quickly.  I asked Pat Braden to order a case of insecticide to help me combat the spiders.  The next day he pulled a two-wheeler up to the closet with two cases and said, “Here is your order sir!” (picture Red Skelton saying that).

I had cleaned the shelves, the cabinet and the floor of the janitor closet, and there was no place for spiders to hide in there anymore.  Each morning when I arrived, there was always more spiders there.  3 or 4 at least waiting for me in the closet.  All Brown Recluse.

I surveyed the combat zone and realized that spiders were all over the main switchgear.  So I decided I was going to sweep the switchgear regularly and kill every spider I saw to wipe them out for good.

A picture of a clean switchgear. Picture 6 rows of switchgear like this

So I laid down floor sweep (cedar chips with red oil) to keep the dust down, and began at one corner and worked my way across the switchgear sweeping and killing spiders.  I kept a body count.  I taped a paper in the janitor closet to keep track of my daily kill.

I thought surely in a short time, I will have wiped out the spider population.  After sweeping the switchgear I laid down a blanket of Insecticide (equivalent to Agent Orange in Vietnam).  If I could kill any bugs that are around, the spiders would leave.  The insecticide didn’t kill the spiders.  they would just duck under the switchgear and then come out an hour later to be standing where I left them before.  So I kept stomping them out.

Every day, my body count was around 25 to 30 spiders and this number wasn’t going down.  That was when I discovered the Cable Spreader room…  I had been involved in mere child’s play before I walked down some steps at the tail end of the switchgear and opened one of the two doors at the bottom.

I cannot describe to you exactly what I saw, because nothing I say can put into words what was there.  I guess the best thing I can say is:  Armageddon.

There were two rooms.  One on each side at the bottom of some concrete steps.  They are called Cable Spreader rooms and are directly beneath the switchgear.  One side was unit one, the other was unit 2.  They are large rooms with cable trays lining the walls and across the room at regular intervals.  The floor was damp, and it was black, and it was alive.  There was a small path through the room where the operator would pass through “the gauntlet” once each shift as they muttered prayers that they not be eaten alive by the black oozing mass of bugs spiders and an occasional snake.

I knew what I had to do.  These two rooms and the cable tunnels that ran from there underneath the T-G building were the source of my daily trouncing of the meager few spiders that decided to explore the world above to see what was happening in the switchgear.  The real battle was down here in the trenches.

I started with a large box of Plastic Contractor bags, a box of floor sweep, a shovel and a push broom.  I attacked the room the same way I used to clean my own bedroom at home when I was growing up.  I started in one corner and fanned out.  Not letting anything past me.  always keeping a clear supply line back to the steps that led up to freedom and air up above.

At first I just took a large scoop shovel and scooped up the black mass of crawling and dead bugs and dumped them in a bag, until I had enough space to sweep the dust into a pile.  Then I attacked it again.  Occasionally a small snake would appear upset that I had invaded his space, and into the bag it would go.  Everything went in the bags.  The snakes, the bugs, the spiders and the grime.  There was actually a constant battle taking place down there that I was interrupting.  it was bug eat bug, spider eat bug and snake eat bugs and spiders wars.  Everything went in the bags.

I carefully hauled the bags out to the dumpster and out they went.  It took an entire day to clean one room.  Then the next day when I went back I completely cleaned it again.  This time paying more attention to making it livable.  I wanted these two rooms to be so clean that people could go down into these cool damp rooms in the hot summer and have a picnic down there and feel safe.  —  No one ever did though, but such is the life of a cable spreader room.

After that, each day I made my rounds of the switchgear, the cable spreader rooms and the cable tunnels killing any spider that showed it’s legs.  After the main battle in the two rooms and tunnels was over of countless spiders and bugs, I recorded about 230 spiders the next day by making my rounds.  The next day that dropped to around 150.  then 80, then 50 and on down.  Finally, when I was down to 3 or 4 spiders each day, I felt like the war was over and a weekly sweeping and daily walk-through would suffice to keep the switchgear safe.  This left the small janitor closet virtually free of spiders from that point.

The interesting twist of the entire battle against the spiders was that the electricians had seen my skills at Battle sweeping and some of them had become impressed.  They told me that I didn’t have to sweep their shop and the main switchgear because they took turns doing it.  I still felt that as the janitor, with my battle hardened push broom, by paying a little more attention to detail would do a slightly better job.

The electricians didn’t really volunteer to do it.  Whoever was the truck driver for that week was supposed to clean the shop at least one time during the week.  At $5.15 an hour, I was more of a volunteer than someone that was hired to do this chore, and I enjoyed it.  So, eventually, Charles Foster (An Electrical Foreman) popped the question to me one day…. He asked me if I would think about becoming an Electrician.

That was something I hadn’t even considered until that moment.  The Electricians to me were the elite squad of Power Plant Maintenance.  Like the Results guys, but with a wider range of skills it seemed.  But that is a story for another time.