Wax On Wax Off and Other Power Plant Janitorial Secrets
Favorites Post #64
Orignally Posted on October 12, 2012:
Two years before the movie Karate Kid came out at the movies in 1984, I had learned the secret of “Wax On, Wax Off”. One that made a significant difference to my Power Plant Janitorial Powers!
The Student Learns from the Master…. “Wax On… Wax Off”
My Janitorial Master was Pat Braden. He is the same age as my father. As I mentioned in an earlier post, Pat Braden reminded me of a rounder version of Red Skelton:
This Picture of Red Skelton reminds me of Pat Braden
Pat was one of the kindest people you would ever meet. He was the head janitor when I became a janitor at the Coal-Fired Power Plant. I had worked with him off and on during the 4 summers when I had worked as a summer help. So I was glad to actually be on his crew as one of the team.
When we had a big waxing job to do, we would schedule a weekend to come in and do it. That way we could wax an entire area without interruption. We could strip off the old wax with the stripping chemicals, then neutralize it, then add the sealer, and finally end up with waxing the floors with the best wax we could buy. As I mentioned in the post “How Many Power Plant Men Can You Put in a 1982 Honda Civic“, we used Johnson Wax’s best wax: Showplace.
The Best Floor Wax money can buy!
We had been “certified” by Johnson and Johnson to wax floors properly. This included the proper buffing techniques once the wax had been applied and had properly dried. A properly waxed and buffed floor is shiny but not a slippery floor.
Floor buffer, used to strip the wax off and buff the wax once it has been applied. The black pad is used with the stripper.
We decided to spend one weekend waxing the Engineering shack. It was a tin building like a Metal Butler Building that the inspectors from Corporate Headquarters would use when they had projects at the plant. In 1982, that was pretty well all of the time, as John Blake and Gene Titus were permanent residents of the Engineers Shack.
A simple metal building sort of like this. Only it was green.
The floor in this building had a regular tile floor like you would see in an office building in the 1960’s. Just the plain square tiles. It looked like it had never been waxed before, and was probably built on the plant grounds long before the power plant existed. The floor had been worn out by the traffic over the years. This was one building that I was expected to keep swept and mopped as part of my daily janitorial responsibilities.
Our Janitor crew consisted of Pat Braden, Doris Voss, James Kanelakos, Ronnie Banks and Curtis Love (and myself of course). We had decided a couple of days before that for lunch we would eat baked onions. “Ok”, I thought. I knew we didn’t get paid much as janitors and we had to be frugal, but I didn’t really think that we were so bad off that we had to resort to eating onions for lunch. But since no one really asked me for my vote (which would have been to bring in some pizza from Ponca City), we were having baked onions for lunch.
We spent the morning removing all the furniture from the building, and then stripping the floor (even though it looked like it had never been waxed before). Then we mopped it a couple of times. By that time it was lunch time, and we headed up to the plant break room where Doris was just finishing up baking our um…. er….. onions. Yeah.. Baked Onions….
It turned out that these were Purple Onions. The ends had been cut off of them and butter and salt and pepper had been put on each end as they were wrapped up in tinfoil like a baked potato, and then baked in the oven just as if they were baked potatoes.
oh yum… a purple onion…
Well. I was never one to complain about food, and I was determined not to show my lack of enthusiasm at the thought of eating an onion for lunch, so I sat down and put on my eager hungry expression as I waited for our (uh) feast. — Well. The joke was on me. As I began to eat the baked onion, I realized right away that it didn’t taste like any onion I had ever eaten. It was kind of sweet and…. well…. it was rather tasty! Power Plant Culture never ceases to amaze me.
Anyway, after I had eaten my share of onions, we were ready to go back to work waxing the engineers shack. We spent the rest of the day doing that (and burping onions) and when we had decided that the wax had dried enough, we carefully brought the furniture back in and put everything back in order.
So, why am I boring you with all this detail about waxing the floor in a metal building that doesn’t even exist today? Well. I have told you now about the “Wax On” part. Now comes the “Wax Off” part. The second part of my training to becoming a Jedi Janitor (hmm… snuck in a Star Wars reference I see).
Here is what happened the next Monday when I wheeled the buffing machine out of the janitor closet in the Engineer’s shack. Gene Titus (who always reminded me of Jerry Reed):
Jerry Reed trying to look like Gene Titus
and John Blake, both were very pleased with their new shiny floor. They looked like they were anxious to show it off to someone… anyone that would come by. I was about to really impress them (I thought) with my fine buffing skills that was “really” going to make their floor shine. So, they watched closely as I attached the red buffing pad on the bottom of the buffer:
The black buffing pad is for stripping the wax. The red one is for normal heavy buffing and the white one is for polishing
I began at the far end of the room from the doors and began buffing…. The first thing I noticed was that the buffer was literally removing the wax from the floor. Yep. It was taking it right off. Wax On…. Wax Off….. I realized that for all our stripping and neutralizing, we hadn’t taken into account the years of dirt and grime that was embedded in the tiles.
Normally John Blake was a likable sensible person. I had carpooled with him for two summers when I was a summer help. But when he saw me removing the wax from the floor he had a very concerned expression, and well, I perceived that a sort of extreme hatred was rising up in his demeanor…. I was glad that John was a quiet mild-mannered sort of person, otherwise, I think he would have walloped me one for ruining the floor that he was so proud of minutes before.
I began thinking to myself what I should do. After all. The floor really did need buffing, and buffing the floor was removing the wax. So as the buffer moved back and forth erasing the shine and bringing back the dull tiles, I thought as hard as I could muster my brain what I should do next….
I figured I would go ahead and buff the entire main room, as if I knew exactly what I was doing, not looking concerned. I don’t know if the confidence that I exhibited while removing the wax relaxed John just enough so that he could leave the building and continue his job, or if he actually stormed out in distress hoping to drown his sorrows in his morning cup of coffee…
When I finished the room with the red pad… I did what I would have done if the wax had buffed up correctly and had actually still existed on the floor…. I put the white pad on the buffer. I thought in my mind that the floor was probably so infiltrated with dust that we hadn’t done a proper job (if it was even possible) to clean the floor before applying the wax on Saturday.
So I thought I would try something that they hadn’t taught us in waxing class… I took a spray bottle and filled it with wax mixed with some water. Then I started in the same corner where I had begun removing the pride and glory of John Blake’s newly waxed dreams. I sprayed some wax and buffed it into the floor. As I guided the buffer back and forth with one hand, I sprayed the floor with the other. To my surprise, not only did it start to leave a shiny polished floor, but it left a polish that was much more clear than before. One that was almost like a mirror.
A plain spray bottle like this
As I buffed the room from one end to the next, the entire room became brighter as the lights from the ceiling reflected from the hard polished wax. I was nearly finished with the room when John walked back in. He was immediately stunned by the brightly polished floor.
I could see his uncharacteristic desire to kill me melt away and his pleasure with his new Shangri-La abode become immediately evident. John Blake from that moment on viewed me with the respect that most Power Plant janitors normally deserve (though I had just stumbled on this accidentally).
I was so impressed with how well the floor looked when I was done, that I went to the Brown and Root building next door and did the same thing there.
I began to wonder what other uses I could make out of this discovery… Spraying wax on the floor and buffing it right in. It finally occurred to me that the floor cleaning machine that I used to clean the Turbine room floor might benefit by adding some wax to the mixture. It had the same type of red buffer pads on it.
We had a Clarke Floor scrubber similar to this one
So, after I had scrubbed the Turbine Generator floor using the regular detergent. I cleaned out the scrubber and put just water in there and about 1/2 gallon of wax. Then I went to try out my experiment. Sure enough…. The bright red Turbine Room floor began to glow. The bright lights overhead were clearly reflected off the floor. This was very successful.
This is a picture of the red turbine room floor, only not with the nice wax job. After I had waxed it, you could see the light bulbs in the floor
So, my next test was to sweep off the turbine-Generators themselves with a red dust mop. Then spray watered down Johnson Wax directly on the dust mop and mop away on the turbine generators:
Like this only with a mop handle
The Turbine Generators took on the same polished shine.
I distinctly remember one Power Plant Operator that gave me a very nice complement one day for keeping the T-G floor so nicely polished. His name was Michael Hurst. He was a True Power Plant Operator.
Michael Hurst is the second Brave Power Plant Operator on the right
As a lowly janitor in a plant of heroes, I found that I was treated with the same respect as everyone else. I would never forget that complement from him because I could see his earnest sincerity.
A few years ago on December 19, 2008 Michael Hurst died in Oklahoma City. What was said about Michael after his death was this: “He had a great sense of humor and a big heart… Many have been blessed with his generosity and his genuine love for people.”
I can include myself in this statement. I know that everyone shown in the picture above from Joe Gallahar (on the left) to Doris Voss (in the middle) to Pat Quiring (on the right) would agree with that testament about Michael.
There was another sentence after this one that stands on it’s own. One that is a sign of a True Power Plant Man. It was also said of Michael Hurst: “Above all else, the most important thing to him was his family.” Though I don’t have a picture of Michael’s immediately family. I believe that I have included a picture above of at least some of his extended family.
I have recently (2020) found a picture with Pat Braden:
Pat Braden (left) with Dick Dale and Mike Gibbs
Comment from previous post:
Comment from previous repost
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My father managed a bowling alley when I was young. I remember large mops, all kinds of pads and rags and a buffing machine. Before he would let me use the machine on the alleys, he had me do the lobby floor. He not only inspected my work, he watched my technique. This brought back some of those memories, thanks.
Psychological Profile of a Power Plant Control Room Operator
Favorites Post #38
Originally posted on July 6, 2012:
I suppose that many parents while raising their children would hear them say, “Dad, can you read that story to us again about the pirates that go to the island to find the treasure but Jim Hawkins fights them single-handed?” Or their children might say to their mother, “Will you tell us the story again about how you met daddy?” In my household, my children would say, “Dad, tell us another story about how you played a joke on Gene Day when you were working at the Coal-Fired Power Plant in Oklahoma? Those are always the best!”
As I pointed out in my third post this year called “Power Plant Humor And Joking With Gene Day” the first time I met Gene Day, I could tell that he was the type of person that would take a joke well, or so I thought…. One of the favorite stories my daughter would like for me to tell her as she was growing up was the one where I had created a Psychological Profile of Gene Day, who at that time was an Auxiliary Operator.
It began one day when I was leaving the electric shop through the Turbine Generator (T-G) building ground floor. A very noisy location as large steam pipes wound around under the Turbines where the steam caused a rumbling or whining sound. It was normal when walking through this area to reach up to the ear plugs that were draped over your shoulders and put them in your ears because the decibels were dangerously high if you were exposed earplug-less too long.
Earplugs on a cord that can be draped over your shoulders when not in use.
I stepped from the landing leading from the electric shop and started toward number 1 boiler when I spied Gene Day making his way around the first floor of the T-G building inspecting equipment and marking his documents indicating that they were operating correctly. As I saw him turn toward my direction I quickly dodged behind the nearest metal pillar (I-Beam). I peaked my head out from behind the pillar and took out the notepad that was in my back pocket, and the pen from my vest pocket pocket protector.
A pocket protector is a must for electricians and computer nerds who need a place to keep their small tools.
Gene saw me and gave me a suspicious look as I began feverishly writing in my notepad while looking from my notepad back to Gene and then back to what I was writing. After I had done this for about 10 seconds or so, I put my pad away, my pen back in the pocket protector and strolled away toward unit 1 to continue my work.
A notepad like this
It happened that this particular week was Gene’s week to monitor the equipment in the T-G building, so throughout the week he would be making his way somewhere around the T-G building with his clipboard in hand. Each time I encountered him I would do the same thing. I would visibly hide behind a beam and write notes in my notepad. I saw Gene rather frequently during the week because the majority of the time, I left the electric shop by going through the T-G room to one of the boilers and then to the precipitators, where I spent most of my time working at this time in my career (but that is another story for a later time).
Each time, Gene would watch me suspiciously knowing that I was just messing with him, but not exactly sure what I was “up to”. At the time, I wasn’t sure either. So I just wrote down what I saw Gene doing, that way, if he ran over and grabbed my notepad from me, it wouldn’t say anything other than what I saw.
It had happened at the plant a few years earlier when I was a janitor that the company had hired an efficiency expert to monitor the employees at the plant. He would walk around the plant with a stopwatch observing the employees. When he saw them he would write notes on his clipboard. It became very unnerving because you would walk around the corner and there he would be standing writing something down about you.
I went to the Assistant Plant Manager Bill Moler and told him that this creepy guy keeps showing up in the main switchgear by the janitors closet. And every time he sees me, he writes something down. I told Bill that it really bothered me. He explained that he is an efficiency expert and he has a certain path that he takes throughout the day and takes a snapshot of what the workers are doing at that moment and writes it down. By doing that he calculates how efficient we are. It seemed pretty silly to me, because most mechanics when they saw him coming put their tools down and did nothing while he walked by until he was out of sight again.
When I was on the labor crew a few weeks later, and I was blowing coal dust off of all the I-Beams above the bowl mills with a high pressure air hose, I looked down, and through my fogged up goggles I could see this guy standing directly under me. I was about 50 feet above him crawling across an I-Beam with the air hose blowing black dust everywhere. He had crossed my barrier tape to go into the bowl mill area to see how efficient I was being.
This is the type of barrier tape I was using. It is made of woven plastic fibers.
I was so mad I turned off my air hose, climbed down the wall Spiderman-like (no. not head first) and went straight into the A-Foreman’s office and told Marlin McDaniel that the Efficiency Expert had crossed my barrier tape and was standing directly under me as I was blowing down the beams with air.
It turned out that the Efficiency Expert had gone upstairs to complain that some guy in the bowl mill had dumped a bunch of coal dust on him while he was monitoring him from below. Evidently, he wasn’t expert enough to know you weren’t supposed to cross someone’s barrier tape without permission, as was indicated on the caution tags that were tied to the barrier tape. From that point on, the efficiency expert (now in lowercase) had to be accompanied by someone from the plant to make sure he wasn’t breaking any safety rules and putting himself at harm.
To make a long side story short, we turned out to be so efficient, people came from all over the world to study us. Somebody downtown hired the efficiency expert full time, but later he was laid off during the first downsizing.
He reminds me of a person on an episode of Star Trek The Next Generation where this guy Lieutenant Commander Remmick comes aboard the Enterprise and he walks around inspecting everything and asking everyone questions that make them uncomfortable and at the end asks Picard if he could come work on the Enterprise. He looked so much like him, that I thought maybe our efficiency expert went to Hollywood to become an actor.
Lieutenant Commander Remmick
Back to Gene Day. I suppose the thought of the efficiency expert may have been going through my mind as I was taking notes about Gene Day at work. Like I said, at the time, I didn’t know what I was going to do with it.
Oh. Let me include a picture of Gene Day:
Gene Day is the one standing on the right with the Orange shirt.
It finally came to me on Thursday morning. This was the last day that Gene was going to be on the day shift, so I figured I might as well do something about it. So when I entered the shop that morning, I sat down at the desk of my foreman Andy Tubbs and began to write. The title at the top of the page was: “The Psychological Profile of Gene Day”.
Using the notes I had taken during the week, I wrote things like the following: “Gene Day walks around the Turbine Generator building with a clipboard in his hand trying desperately to look like he’s doing something important. He constantly hopes that someone is watching him because he dislikes doing so much work to act busy for no reason.
At times Gene Day gets paranoid and believes that he sees people spying on him from behind every corner (especially I-Beams). Sometimes Gene Day stands in the middle of the T-G floor staring up into space as if he forgot what he was supposed to be doing.” I wrote more similar observations, but I don’t remember everything… but I do remember the last two sentences. I will save that for a couple of paragraphs from now.
I took my Psychological Profile of Gene Day and went up to the Control Room. I noticed out of the corner of my eye that Gene had just walked over toward the break room behind the Auxiliary Control Panel so I walked over by the Shift Supervisor’s office and I leaned against the top of the large Blue Monitor and placed the Psychological Profile on the top of the monitor in front of me.
Less than a minute later Gene came walking around behind me and seeing the paper on the top of the monitor came up behind me and looked over my shoulder and began to read….. He wasn’t trying to hide the fact that he was reading the paper, and I obviously knew he was there, and the title in large bold letters did say, “The Psychological Profile of Gene Day”. So, he read on.
I heard a few chuckles as he read through my interpretation of what he had done during the week. Then he came to the “Second from the Last Sentence”, as I could hear him reading quietly in my ear… The sentence read, “Gene Day sneaks up behind people and reads their private material over their shoulder!” — Bingo! I had him!
When he read that he grabbed me by the throat and started to Throttle me! Shaking me back and forth. This would have been a humdinger of a joke at that point, but I had one more sentence up my sleeve… ur… I mean on the paper….
As I was wavering (is that a word?) back and forth between life and death I managed to eke out something like: “Wait! There’s More!”…. Gene Day let up on me a little and looked down at the page and read the last sentence…… It read….. “Gene Day tries to strangle people who are only trying to help him by creating his Psychological Profile.”
That was all it took. Another perfect joke played on Gene Day, and I was able to live to tell about it. When Gene read that he was stunned into dismay. Giggling as hard as he could he retreated shaking his head in defeat.
Now, I know that Gene reads these posts, and he may remember this story a little differently, and I’ll give him that because Gene is older than dirt and his memory isn’t that good. But I was the one that was being strangled, and I still have a vivid image of those few moments. Not only do I, but so do my children, who will one day tell their children, who will say, “Mommy, will you tell us that story again about how Grandpa was strangled by Gene Day that time in the Control Room at the Coal-Fired Power Plant in Oklahoma?”
Psychological Profile of a Power Plant Control Room Operator
Originally posted on July 6, 2012:
I suppose that many parents while raising their children would hear them say, “Dad, can you read that story to us again about the pirates that go to the island to find the treasure but Jim Hawkins fights them single-handed?” Or their children might say to their mother, “Will you tell us the story again about how you met daddy?” In my household, my children would say, “Dad, tell us another story about how you played a joke on Gene Day when you were working at the Coal-Fired Power Plant in Oklahoma? Those are always the best!”
As I pointed out in my third post this year called “Power Plant Humor And Joking With Gene Day” the first time I met Gene Day, I could tell that he was the type of person that would take a joke well, or so I thought…. One of the favorite stories my daughter would like for me to tell her as she was growing up was the one where I had created a Psychological Profile of Gene Day, who at that time was an Auxiliary Operator.
It began one day when I was leaving the electric shop through the Turbine Generator (T-G) building ground floor. A very noisy location as large steam pipes wound around under the Turbines where the steam caused a rumbling or whining sound. It was normal when walking through this area to reach up to the ear plugs that were draped over your shoulders and put them in your ears because the decibels were dangerously high if you were exposed earplugless too long.
Earplugs on a cord that can be draped over your shoulders when not in use.
I stepped from the landing leading from the electric shop and started toward number 1 boiler when I spied Gene Day making his way around the first floor of the T-G building inspecting equipment and marking his documents indicating that they were operating correctly. As I saw him turn toward my direction I quickly dodged behind the nearest metal pillar (I-Beam). I peaked my head out from behind the pillar and took out the notepad that was in my back pocket, and the pen from my vest pocket pocket protector.
A pocket protector is a must for electricians and computer nerds who need a place to keep their small tools.
Gene saw me and gave me a suspicious look as I began feverishly writing in my notepad while looking from my notepad back to Gene and then back to what I was writing. After I had done this for about 10 seconds or so, I put my pad away, my pen back in the pocket protector and strolled away toward unit 1 to continue my work.
A notepad like this
It happened that this particular week was Gene’s week to monitor the equipment in the T-G building, so throughout the week he would be making his way somewhere around the T-G building with his clipboard in hand. Each time I encountered him I would do the same thing. I would visibly hide behind a beam and write notes in my notepad. I saw Gene rather frequently during the week because the majority of the time, I left the electric shop by going through the T-G room to one of the boilers and then to the precipitators, where I spent most of my time working at this time in my career (but that is another story for a later time).
Each time, Gene would watch me suspiciously knowing that I was just messing with him, but not exactly sure what I was “up to”. At the time, I wasn’t sure either. So I just wrote down what I saw Gene doing, that way, if he ran over and grabbed my notepad from me, it wouldn’t say anything other than what I saw.
It had happened at the plant a few years earlier when I was a janitor that the company had hired an efficiency expert to monitor the employees at the plant. He would walk around the plant with a stopwatch observing the employees. When he saw them he would write notes on his clipboard. It became very unnerving because you would walk around the corner and there he would be standing writing something down about you.
I went to the Assistant Plant Manager Bill Moler and told him that this creepy guy keeps showing up in the main switchgear by the janitors closet. And every time he sees me, he writes something down. I told Bill that it really bothered me. He explained that he is an efficiency expert and he has a certain path that he takes throughout the day and takes a snapshot of what the workers are doing at that moment and writes it down. By doing that he calculates how efficient we are. It seemed pretty silly to me, because most mechanics when they saw him coming put their tools down and did nothing while he walked by until he was out of sight again.
When I was on the labor crew a few weeks later, and I was blowing coal dust off of all the I-Beams above the bowl mills with a high pressure air hose, I looked down, and through my fogged up goggles I could see this guy standing directly under me. I was about 50 feet above him crawling across an I-Beam with the air hose blowing black dust everywhere. He had crossed my barrier tape to go into the bowl mill area to see how efficient I was being.
This is the type of barrier tape I was using. It is made of woven plastic fibers.
I was so mad I turned off my air hose, climbed down the wall Spiderman-like (no. not head first) and went straight into the A-Foreman’s office and told Marlin McDaniel that the Efficiency Expert had crossed my barrier tape and was standing directly under me as I was blowing down the beams with air.
It turned out that the Efficiency Expert had gone upstairs to complain that some guy in the bowl mill had dumped a bunch of coal dust on him while he was monitoring him from below. Evidently, he wasn’t expert enough to know you weren’t supposed to cross someone’s barrier tape without permission, as was indicated on the caution tags that were tied to the barrier tape. From that point on, the efficiency expert (now in lowercase) had to be accompanied by someone from the plant to make sure he wasn’t breaking any safety rules and putting himself at harm.
To make a long side story short, we turned out to be so efficient, people came from all over the world to study us. Somebody downtown hired the efficiency expert full time, but later he was laid off during the first downsizing.
He reminds me of a person on an episode of Star Trek The Next Generation where this guy Lieutenant Commander Remmick comes aboard the Enterprise and he walks around inspecting everything and asking everyone questions that make them uncomfortable and at the end asks Picard if he could come work on the Enterprise. He looked so much like him, that I thought maybe our efficiency expert went to Hollywood to become an actor.
Lieutenant Commander Remmick
Back to Gene Day. I suppose the thought of the efficiency expert may have been going through my mind as I was taking notes about Gene Day at work. Like I said, at the time, I didn’t know what I was going to do with it.
It finally came to me on Thursday morning. This was the last day that Gene was going to be on the day shift, so I figured I might as well do something about it. So when I entered the shop that morning, I sat down at the desk of my foreman Andy Tubbs and began to write. The title at the top of the page was: “The Psychological Profile of Gene Day”.
Using the notes I had taken during the week, I wrote things like the following: “Gene Day walks around the Turbine Generator building with a clipboard in his hand trying desperately to look like he’s doing something important. He constantly hopes that someone is watching him because he dislikes doing so much work to act busy for no reason.
At times Gene Day gets paranoid and believes that he sees people spying on him from behind every corner (especially I-Beams). Sometimes Gene Day stands in the middle of the T-G floor staring up into space as if he forgot what he was supposed to be doing.” I’m sure I wrote more, but I don’t remember everything… but I do remember the second from the last sentence. I will save that for a couple of paragraphs from now.
I took my Psychological Profile of Gene Day and went up to the Control Room. I noticed out of the corner of my eye that Gene had just walked over toward the break room behind the Auxiliary Control Panel so I walked over by the Shift Supervisor’s office and I leaned against the top of the large Blue Monitor and placed the Psychological Profile on the top of the monitor in front of me.
Less than a minute later Gene came walking around behind me and seeing the paper on the top of the monitor came up behind me and looked over my shoulder and began to read….. He wasn’t trying to hide the fact that he was reading the paper, and I obviously knew he was there, and the title in large bold letters did say, “The Psychological Profile of Gene Day”. So, he read on.
I heard a few chuckles as he read through my interpretation of what he had done during the week. Then he came to the “Second from the Last Sentence”, as I could hear him reading quietly in my ear… The sentence read, “Gene Day sneaks up behind people and reads their private material over their shoulder!” — Bingo! I had him!
When he read that he grabbed me by the throat and started to Throttle me! Shaking me back and forth. This would have been a humdinger of a joke at that point, but I had one more sentence up my sleeve… ur… I mean on the paper….
As I was wavering (is that a word?) back and forth between life and death I managed to eke out something like: “Wait! There’s More!”…. Gene Day let up on me a little and looked down at the page and read the last sentence…… It read….. “Gene Day tries to strangle people who are only trying to help him by creating his Psychological Profile.”
That was all it took. Another perfect joke played on Gene Day, and I was able to live to tell about it. When Gene read that he was stunned into dismay. Giggling as hard as he could he retreated shaking his head in defeat.
Now, I know that Gene reads these posts, and he may remember this story a little differently, and I’ll give him that because Gene is older than dirt and his memory isn’t that good. But I was the one that was being strangled, and I still have a vivid image of those few moments. Not only do I, but so do my children, who will one day tell their children, who will say, “Mommy, will you tell us that story again about how Grandpa was strangled by Gene Day that time in the Control Room at the Coal-Fired Power Plant in Oklahoma?”
Wax On Wax Off and Other Power Plant Janitorial Secrets
Orignally Posted on October 12, 2012:
Two years before the movie Karate Kid came out at the movies in 1984, I had learned the secret of “Wax On, Wax Off”. One that made a significant difference to my Power Plant Janitorial Powers!
The Student Learns from the Master…. “Wax On… Wax Off”
My Janitorial Master was Pat Braden. He is the same age as my father. As I mentioned in an earlier post, Pat Braden reminded me of a rounder version of Red Skelton:
This Picture of Red Skelton reminds me of Pat Braden
Pat was one of the kindest people you would ever meet. He was the head janitor when I became a janitor at the Coal-Fired Power Plant. I had worked with him off and on during the 4 summers when I had worked as a summer help. So I was glad to actually be on his crew as one of the team.
When we had a big waxing job to do, we would schedule a weekend to come in and do it. That way we could wax an entire area without interruption. We could strip off the old wax with the stripping chemicals, then neutralize it, then add the sealer, and finally end up with waxing the floors with the best wax we could buy. As I mentioned in the post “How Many Power Plant Men Can You Put in a 1982 Honda Civic“, we used Johnson Wax’s best wax: Showplace.
The Best Floor Wax money can buy!
We had been “certified” by Johnson and Johnson to wax floors properly. This included the proper buffing techniques once the wax had been applied and had properly dried. A properly waxed and buffed floor is shiny but not a slippery floor.
Floor buffer, used to strip the wax off and buff the wax once it has been applied. The black pad is used with the stripper.
We decided to spend one weekend waxing the Engineering shack. It was a tin building like a Metal Butler Building that the inspectors from Corporate Headquarters would use when they had projects at the plant. In 1982, that was pretty well all of the time, as John Blake and Gene Titus were permanent residents of the Engineers Shack.
A simple metal building sort of like this. Only it was green.
The floor in this building had a regular tile floor like you would see in an office building in the 1960’s. Just the plain square tiles. It looked like it had never been waxed before, and was probably built on the plant grounds long before the power plant existed. The floor had been worn out by the traffic over the years. This was one building that I was expected to keep swept and mopped as part of my daily janitorial responsibilities.
Our Janitor crew consisted of Pat Braden, Doris Voss, James Kanelakos, Ronnie Banks and Curtis Love (and myself of course). We had decided a couple of days before that for lunch we would eat baked onions. “Ok”, I thought. I knew we didn’t get paid much as janitors and we had to be frugal, but I didn’t really think that we were so bad off that we had to resort to eating onions for lunch. But since no one really asked me for my vote (which would have been to bring in some pizza from Ponca City), we were having baked onions for lunch.
We spent the morning removing all the furniture from the building, and then stripping the floor (even though it looked like it had never been waxed before). Then we mopped it a couple of times. By that time it was lunch time, and we headed up to the plant break room where Doris was just finishing up baking our um…. er….. onions. Yeah.. Baked Onions….
It turned out that these were Purple Onions. The ends had been cut off of them and butter and salt and pepper had been put on each end as they were wrapped up in tinfoil like a baked potato, and then baked in the oven just as if they were baked potatoes.
oh yum… a purple onion…
Well. I was never one to complain about food, and I was determined not to show my lack of enthusiasm at the thought of eating an onion for lunch, so I sat down and put on my eager hungry expression as I waited for our (uh) feast. — Well. The joke was on me. As I began to eat the baked onion, I realized right away that it didn’t taste like any onion I had ever eaten. It was kind of sweet and…. well…. it was rather tasty! Power Plant Culture never ceases to amaze me.
Anyway, after I had eaten my share of onions, we were ready to go back to work waxing the engineers shack. We spent the rest of the day doing that (and burping onions) and when we had decided that the wax had dried enough, we carefully brought the furniture back in and put everything back in order.
So, why am I boring you with all this detail about waxing the floor in a metal building that doesn’t even exist today? Well. I have told you now about the “Wax On” part. Now comes the “Wax Off” part. The second part of my training to becoming a Jedi Janitor (hmm… snuck in a Star Wars reference I see).
Here is what happened the next Monday when I wheeled the buffing machine out of the janitor closet in the Engineer’s shack. Gene Titus (who always reminded me of Jerry Reed):
Jerry Reed trying to look like Gene Titus
and John Blake, both were very pleased with their new shiny floor. They looked like they were anxious to show it off to someone… anyone that would come by. I was about to really impress them (I thought) with my fine buffing skills that was “really” going to make their floor shine. So, they watched closely as I attached the red buffing pad on the bottom of the buffer:
The black buffing pad is for stripping the wax. The red one is for normal heavy buffing and the white one is for polishing
I began at the far end of the room from the doors and began buffing…. The first thing I noticed was that the buffer was literally removing the wax from the floor. Yep. It was taking it right off. Wax On…. Wax Off….. I realized that for all our stripping and neutralizing, we hadn’t taken into account the years of dirt and grime that was embedded in the tiles.
Normally John Blake was a likable sensible person. I had carpooled with him for two summers when I was a summer help. But when he saw me removing the wax from the floor he had a very concerned expression, and well, I perceived that a sort of extreme hatred was rising up in his demeanor…. I was glad that John was a quiet mild-mannered sort of person, otherwise, I think he would have walloped me one for ruining the floor that he was so proud of minutes before.
I began thinking to myself what I should do. After all. The floor really did need buffing, and buffing the floor was removing the wax. So as the buffer moved back and forth erasing the shine and bringing back the dull tiles, I thought as hard as I could muster my brain what I should do next….
I figured I would go ahead and buff the entire main room, as if I knew exactly what I was doing, not looking concerned. I don’t know if the confidence that I exhibited while removing the wax relaxed John just enough so that he could leave the building and continue his job, or if he actually stormed out in distress hoping to drown his sorrows in his morning cup of coffee…
When I finished the room with the red pad… I did what I would have done if the wax had buffed up correctly and had actually still existed on the floor…. I put the white pad on the buffer. I thought in my mind that the floor was probably so infiltrated with dust that we hadn’t done a proper job (if it was even possible) to clean the floor before applying the wax on Saturday.
So I thought I would try something that they hadn’t taught us in waxing class… I took a spray bottle and filled it with wax mixed with some water. Then I started in the same corner where I had begun removing the pride and glory of John Blake’s newly waxed dreams. I sprayed some wax and buffed it into the floor. As I guided the buffer back and forth with one hand, I sprayed the floor with the other. To my surprise, not only did it start to leave a shiny polished floor, but it left a polish that was much more clear than before. One that was almost like a mirror.
A plain spray bottle like this
As I buffed the room from one end to the next, the entire room became brighter as the lights from the ceiling reflected from the hard polished wax. I was nearly finished with the room when John walked back in. He was immediately stunned by the brightly polished floor.
I could see his uncharacteristic desire to kill me melt away and his pleasure with his new Shangri-La abode become immediately evident. John Blake from that moment on viewed me with the respect that most Power Plant janitors normally deserve.
I was so impressed with how well the floor looked when I was done, that I went to the Brown and Root building next door and did the same thing there.
I began to wonder what other uses I could make out of this discovery… Spraying wax on the floor and buffing it right in. It finally occurred to me that the floor cleaning machine that I used to clean the Turbine room floor might benefit by adding some wax to the mixture. It had the same type of red buffer pads on it.
We had a Clarke Floor scrubber similar to this one
So, after I had scrubbed the Turbine Generator floor using the regular detergent. I cleaned out the scrubber and put just water in there and about 1/2 gallon of wax. Then I went to try out my experiment. Sure enough…. The bright red Turbine Room floor began to glow. The bright lights overhead were clearly reflected off the floor. This was very successful.
This is a picture of the red turbine room floor, only not with the nice wax job. After I had waxed it, you could see the light bulbs in the floor
So, my next test was to sweep off the turbine-Generators themselves with a red dust mop. Then spray watered down Johnson Wax directly on the dust mop and mop away on the turbine generators:
Like this only with a mop handle
The Turbine Generators took on the same polished shine.
I distinctly remember one Power Plant Operator that gave me a very nice complement one day for keeping the T-G floor so nicely polished. His name was Michael Hurst. He was a True Power Plant Operator.
Michael Hurst is the second Brave Power Plant Operator on the right
As a lowly janitor in a plant of heroes, I found that I was treated with the same respect as everyone else. I would never forget that complement from him because I could see his earnest sincerity.
A few years ago on December 19, 2008 Michael Hurst died in Oklahoma City. What was said about Michael after his death was this: “He had a great sense of humor and a big heart… Many have been blessed with his generosity and his genuine love for people.”
I can include myself in this statement. I know that everyone shown in the picture above from Joe Gallahar (on the left) to Doris Voss (in the middle) to Pat Quiring (on the right) would agree with that testament about Michael.
There was another sentence after this one that stands on it’s own. One that is a sign of a True Power Plant Man. It was also said of Michael Hurst: “Above all else, the most important thing to him was his family.” Though I don’t have a picture of Michael’s immediately family. I believe that I have included a picture above of at least some of his extended family.
Comment from previous post:
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Thanks, Kevin.
Did you know that (years ago) John Blake’s dad was Manager of Power Production (Generation Dept. in those days)? I remember Martin Louthan and other “old” Power Plant Men speak of “Mr. Blake” with respect.-
I didn’t know that. I do know that everyone seemed to treat John with respect. Which he deserved in his own right. We carpooled together my second summer as a summer help with Stanley Elmore.
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Comment from previous repost
My father managed a bowling alley when I was young. I remember large mops, all kinds of pads and rags and a buffing machine. Before he would let me use the machine on the alleys, he had me do the lobby floor. He not only inspected my work, he watched my technique. This brought back some of those memories, thanks.
In Pursuit of the Power Plant Gai-tronics Gray Phone Ghost
Originally Posted June 14, 2013:
When I first watched the movie “The Goonies”, I recognized right away that the script was inspired from another Pirate treasure movie I had watched when I was a child. I have never seen the movie again, and it was probably a made for TV movie or something that has been lost in the archives years ago. I’m sure that Steven Spielberg when he was growing up must have been inspired by this movie when he wrote the script to Goonies, because this was a movie that had inspired us when we were young.
The Goonies looking at the treasure map
You see… In the movie I had watched as a kid, some children that were trying to save their family or an old house or something similar to the Goonies story, found a clue to where a Pirate treasure was buried. The clue had something to do with a “crow’s nest”. It turned out that the model of a ship that had been sitting on the mantle piece in the old house had another clue in the pole holding the crow’s nest. This clue had holes in the paper, and when held up to a certain page in a certain book, it gave them another clue to where there was a hidden passageway. Which led them one step closer to the treasure.
Anyway. As a child, this inspired us (and I’m sure a million other kids) to play a game called “Treasure Hunt”. It was where you placed clues all around the house, or the yard, or the neighborhood (depending on how ambitious of a treasure hunt you were after), with each clue leading to the other clue, and eventually some prize at the end.
Why am I telling you this story about this movie that I watched when I was a child? Well, because I felt this same way all over again when I became an electrician at a coal-fired power plant out in the country in north central Oklahoma. Here is why.
I used to carpool to work from Stillwater, Oklahoma to the power plant 25 miles north of town with another electrician named Bill Rivers. He had kept urging me to become an electrician along with Charles Foster, who had suggested that I take some electric courses to prepare for the job. Once I became an electrician, Charles Foster, my foreman, would often send me with Bill Rivers to repair anything that had to do with electronics. Bill Rivers was good at troubleshooting electronic equipment, and well, he was generally a good troubleshooter when he wasn’t getting himself into trouble.
I remember the morning when Charles told me to go with Bill to go fix the incessant humming that was coming over the PA system…. “What?” I asked him. “I can’t hear you over the loud hum coming over the PA system.” — No not really… We called the Gai-tronics PA system the “Gray Phone” because the phones all over the plant where you could page people and talk on 5 different lines was gray.
Gaitronics Gray Phone
I walked into the electric lab where Bill Rivers was usually hanging out causing Sonny Kendrick grief. I hadn’t been in the electric shop very long at this point. I think it was before the time when I went to work on the Manhole pumps (see the post Power Plant Manhole Mania). In the lab there was an electric cord going from a plug-in on the counter up into the cabinet above as if something inside the cabinet was plugged in…. which was true. I asked Bill what was plugged in the cabinet and he explained that it was the coffee maker.
An old Coffee pot like this
You see, our industrious plant manager had decided that all coffee at the plant had to come from the authorized coffee machines where a dime had to be inserted before dispensing the cup of coffee. This way the “Canteen committee” could raise enough money to…. uh…. pay for the coffee. So, all rogue coffee machines had to go. There was to be no free coffee at the plant.
So, of course, the most logical result of this mandate was to hide the coffee maker in the cabinet in case a wandering plant manager or one of his undercover coffee monitor minions were to enter the lab unexpectedly. Maintaining the free flow of coffee to those electricians that just had to silently protest the strong arm tactics of the Power Plant Coffee Tax by having a sort of… “Tea Party” or was it a “Coffee Party”.
I told Bill Rivers that Charles wanted me to help him fix the hum on the gray phones. Bill Rivers said, “Great! Then let us play a game. let’s call it, ‘Treasure Hunt’.”
Bill reached up in one of the cabinets and pulled out a blue telephone test set. I’m sure you must have seen a telephone repairman with one of these hanging from his hip. ” Oh boy.” I thought. “A new toy!”
Power Plant Telephone Test Set
I grabbed my tool bucket from the shop and followed Bill Rivers out into the T-G basement. This is a loud area where the steam pipes carry the steam to the Turbine to spin the Generator. It is called T-G for Turbine Generator. Bill walked over to a junction box mounted near the north exit going to unit 1. He explained that except for the gray phones in the Control-room section of the plant, all the other gray phones go through this one junction box.
Bill said that the game was to find the Gray Phone ghost. Where is the hum coming from? He showed me how the different cables coming into this one box led to Unit 1, Unit 2, the office area and the coal yard. I just had to figure out which way the hum came from. So, I went to work lifting wires off of the terminal blocks. We could hear the hum over the gray phone speakers near us, so if I were to lift the right wires, we should know right away that I had isolated the problem.
Power Plant Gray Phone Speaker
We determined that the noise was coming from Unit 1. So we took the elevator halfway up the boiler to another junction box, and then another where we traced the problem to a gray phone under the surge bin tower. It took 4 screws to remove the phone from the box. When I did, I could clearly see the problem. The box was full of water. Water had run down the conduit and into the phone box.
Bill Rivers told me that now that we found the problem, we wanted to make sure it didn’t happen again, so we drilled a small weep hole in the bottom of the box, and we took plumbers putty and stuffed it into the top of the conduit where it opened into a cable tray.
A tub of Power Plant Plumbers Putty
The box would fill with water when the labor crew would do coal cleanup. On labor crew we would spray the entire surge bin tower down with high powered water hoses to wash off all the coal dust. Each time, some water would end up going down the conduit into the gray phone until it grounded the circuit enough to cause a hum.
Bill and I continued searching throughout the plant for phones that were causing a hum. Most were caused by water in the box. Some were caused by circuits that had gone bad (most likely because they had water in them at some point). Those we took to the electric shop lab where we played a different kind of treasure hunt. — Let’s call it…. Finding the bad component. It reminded me of an old video game I had bought for my brother for Christmas in 1983 that winter when I gave him an Intellivision (so I could play with it). It was the latest greatest video game console at the time.
An Intellivision Game Console
I had given my brother a game called “Bomb Squad”. Where you had a certain amount of time to diffuse a bomb by going through a circuit board cutting out components with some snippers. If you cut the wrong connection, you had to hurry up and solder it back on before the bomb blew up.
Bomb Squad. It even talked to you and a siren went off if you were going to blow yourself up.
That’s what we were doing with the Gray Phones. We were testing the different components until we found one that wasn’t working correctly. Then we would replace that transistor, or capacitor, or resistor, or diode, and then test the phone by plugging it in the switchgear gray phone box and calling each other.
I have a story later about someone using this technique while fixing gray phones, only he would call himself on the gray phone where I would call Bill and Bill would call me. Someone misinterpreted this and thought the person was trying to make everyone think he was more important because he was always being paged, when he was only paging himself. He was removed from fixing gray phones for this reason, even though he was only person at the plant in Mustang Oklahoma that knew a transistor from a capacitor.
So, why am I going on about a seemingly boring story about fixing a hum on a PA system? I think it’s because to me it was like a game. It was like playing a treasure hunt. From the day I started as an electrician, we would receive trouble tickets where we needed to go figure something out. We had to track down a problem and then find a solution on how to fix it. As I said in previous posts, it was like solving a puzzle.
Each time we would fix something, someone was grateful. Either the operator or a mechanic, or the Shift Supervisor, or the person at home vacuuming their carpet, because the electricity was still flowing through their house. How many people in the world can say that they work on something that impacts so many people?
Well… I used to feel like I was in a unique position. I was able to play in a labyrinth of mechanical and electrical equipment finding hidden treasures in the form of some malfunction. As I grew older, I came to realize that the uniqueness was limited only to the novelty of my situation. If you took all the power plant men in the country, they could probably all fit in one large football stadium. But the impact on others was another thing altogether.
The point I am trying to make is that it was obvious to me that I was impacting a large portion of people in the state of Oklahoma by helping to keep the plant running smoothly by chasing down the boiler ghosts and exorcising the Coalyard demons from the coal handling equipment. Even though it isn’t so obvious to others, like the janitor, or the laborer or the person that fills the vending machine. Everyone in some way helps to support everyone else.
A cook in a restaurant is able to cook the food because the electricity and the natural gas is pumped into the restaurant by others. Then the cook feeds the mailman, who delivers that mail, that brings the check to the person waiting to go to the grocery store so they can buy food that was grown by some farmer who plowed his field on a tractor made in a huge tractor factory by a machinist after driving there in a car made by a manufacturer in Detroit who learned how to use a lathe in a Vocational school taught by a teacher who had a degree from a university where each day this person would walk to class during the winter snow wearing boots that came from a clothes store where the student had bought them from a store clerk that greeted people by saying “Good Morning! How are you today?” Cheering up all the people that they met.
I could have walked into the lab and told Bill Rivers that Charles wanted me to help him find the hum in the PA system and he could have responded by saying, “Oh really? Good luck with that!” Instead he said, “Let’s go play a game. ‘Treasure Hunt!” This attitude had set the stage for me as a Power Plant Electrician: “Let’s go have some fun and fix something today!” Where would that cook have been today if the power had gone out in his restaurant that morning all because an attitude had gotten in the way….. I wonder…
Comments from the original post:
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Great story! It’s neat how God puts us in teams to “fix stuff” and make life happen.
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I wonder why they don’t make ‘em bright yellow or some other color easy to spot in an emergency? Anyway, I remember this one gray phone/speaker we had & when you’d wash down the basement if you accidentally got water in it, it would bellow throughout the plant like a sick cow moose until it finally dried out!
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Thanks Monty, I remember having to stuff putty down the end of conduit from a cable tray to gray phones so that water wouldn’t run down them during washdown. We pulled a gray phone out of the box one day and water just poured out of it. We took to drilling a small hole in the bottom of some of them just to let the water drain out (as I mentioned above).
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Destruction of a Power Plant God
Sometimes we unknowingly end up worshiping things we never intend. It isn’t until those things are destroyed before we realize what has happened. We have a natural tendency to worship something. It’s built into our DNA to worship God just as sure as the God Particle converts energy into matter and subsequently atoms into earth and water. I’m not sure when my obsession began, but I definitely know the day when it was destroyed. August 5, 1996.
The day of realization began as a normal day, as Scott Hubbard and I were driving to the plant. It seemed like an extra dark morning considering it was the middle of the summer. Perhaps it was because by this time we were working four tens, which meant we arrived at the plant before 7:00 am so we left Stillwater, Oklahoma at 6:15 to drive to the coal-fired Power Plant in North Central Oklahoma.
When we topped the overpass to the turnpike at 6:32 we thought we could see something strange at the Power Plant off in the distance. The sun was going to rise in the next few minutes (at 6:42), yet, the sky seemed darker than usual. It must have been a cloudy morning.
Power Plant at sunset (only we were arriving before sunrise)
We thought we could see red and blue flashing lights coming from one end of the plant. It was only momentary, because once over the overpass, we were too low to see that section of the plant. We weren’t really sure what we had seen. It became even more confusing as we approached the entrance to the plant.
There seemed to be a little more activity happening at the front gate than usual. there was a guard or an operator standing out there. He waved us through the gate. about 300 yards past the main gate, we had a clear view of the plant grounds laying before us as we made our way to the parking lot. It was here that the significance of the flashing lights suddenly caused us to gasp. We were stunned into silence.
The area around the Unit 1 main power transformer was flashing with the red and blue lights of several fire trucks. They seemed to be pulling away just about that time. Some of the siding on the Turbine-Generator room was missing, some was blackened from smoke as it had poured out of the windows along the turbine room floor. The real shock to me came as we approached the parking lot and I looked up through where a window used to be and I could see the sky. I could see the sky where the T-G roof should have been.
We were directed to go into the maintenance garage to avoid the fire trucks who that were backing away. We met with our team and Alan Kramer told us that there had been an explosion during the night when an overspeed test was being performed on the Unit 1 Boiler Feed Pump Turbine (BFPT). The number one question we all wanted answered was quickly given to us…. No one was hurt in the explosion.
Alan mentioned that in our recent fire fighter training, we had learned that a large percentage of companies that have a major fire (such as ours) goes out of business within the next year. That was not going to happen to us even though the damage was extensive. Our job was to put everything back to the way it was before the fire.
Here is the story as it happened, as much as I know:
The explosion occurred when an operator (I’ll let one of the operators remind me who it was) was running an overspeed test on the BFPT. Suddenly he heard a loud pop and then the turbine winding up out of control. He took off running and was around the corner of a concrete pillar when the turbine exploded. The turning gear shot out like a top and flew across the mezzanine floor, hit the corner of the north stairway, and still spinning like a top, tore up the stairway as it made the turn halfway down and ended up in middle of the the T-G basement where it finally came to rest. This turning gear weighs somewhere in the ballpark of a thousand pounds (I’m guessing).
Turning Gear
At this point steam was shooting out of the Boiler Feed Pump Turbine. The oil pumps that keep the bearings lubricated were spraying oil into the steam which burst into flames. The flames shot up to the concrete floor 40 feet above. The fire was so hot that it melted the metal structure holding up the floor and the rebar in the concrete. The Turbine Room Floor literally melted away as the oil fire shot the flames up toward the roof another 80 feet above the turbine room floor melting the roof as if it was butter. The asbestos siding on the T-G floor was falling off because the bolts that held them to the brackets literally melted away.
The same reservoir that feeds the oil to the the Boiler Feed Pump Turbine bearings also fed the Main Turbine Generator. This is the same generator that makes the electricity that causes the light bulb to glow in your house when you turn it on. The Main Turbine Generator tripped when the explosion occurred, as it should. As it slowed down to a stop, the oil for the bearings was all gone. It had been creating the large fire ball that was melting down the T-G floor.
Normally, when the Turbine-Generator comes to a stop, it is put on a turning gear while the shaft cools down otherwise the shaft will become warped under it’s own weight. The Turning gear slowing rotates the turbine for a day or so while it cools. Without bearing oil, the turning gear would not be able to turn the turbine generator. The bearings require a layer of oil to function properly.
Unit 1 Turbine-Generator
Charles Patton, one of the Maintenance foremen was called out, and he took cans of STP Oil Treatment and for hours poured them onto the bearings and manually rotated the 50 ton turbine generator (Ray, help me out with the actual weights). Through the heroic efforts of Charles and others that were there to help, the Turbine Generator was spared from even more damage.
Charles Patton
By the time we arrived that morning, the fire was out, things were cooling down. Unit 2 was still running, and it was our job to keep it going.
Unit 2 Turbine-Generator
As I walked out onto the T-G floor everything went into slow motion. I don’t know if that has ever happened to you before. There have been a few times in my life when I was in a near death situation where my surroundings all seem to switch into a slow motion mode. I think it happens because your brain kicks into high gear in order to process what is happening and to put as much effort forward as possible to avoid danger.
The first time I think that happened to me was when I was with some friends climbing around on some cliffs by the Missouri River. One boy was falling back after the ledge he was on gave way and was going to fall most likely to his death when everything switched into slow motion even before I realized what was wrong. I was able to make quick decisions that allowed me to push him back onto the ledge and grab onto a branch that luckily kept me from the same fate.
When I walked onto the T-G floor and saw the devastation, I think my mind was trying to take everything in all at once. The Turbine Generator was covered in soot and debris. I flashed back to the days when I was a janitor and used to keep the turbines waxed so that they would shine. It was at this moment that I realized I actually worshiped the Turbine Generators in a way similar to the way the religious cult worshiped the alpha-omega doomsday bomb in “Beneath the Planet of the Apes”.
Bomb Worshipers in Beneath the Planet of the Apes
The near destruction of the Turbine Generator made me realize the importance I had placed on it. I felt as if I had almost lost my close friend like the boy climbing on the cliff. I used to stand on the sides of the Turbines when I was a janitor with my dust mop and after spraying furniture polish on the mop, I would caress the turbines as if I was running my fingers through someone’s hair.
Like this only with a mop handle
We began the clean up by taking fire hoses and washing down the siding on the Unit 2 side to try to bring some normalcy back to a surreal situation. The soot didn’t just wash off. Not long after we had dragged out the fire hoses and were blasting away at the siding, Alan Kramer asked Charles Foster and I to look at the air duct to the Instrument room on the north side of the Turbine room. The room was getting too hot and the air conditioner seemed to have frozen.
We climbed into the air duct on the roof of the instrument room and replaced the filters that were packed with soot stopping the air flow for the Air Conditioner. This seemed like one task in 100,000 that would need to be done to put this puzzle back together again. All the electric cables that ran through the Unit 1 Mezzanine had melted away, everything had been utterly destroyed.
The thought was too overwhelming. I felt like Scarlet O’Hara in “Gone With the Wind” when she said, “I can’t think about that right now. If I do, I’ll go crazy. I’ll think about that tomorrow.”
Vivian Leigh as Scarlett O’Hara in Gone With the Wind
With everything on the T-G floor covered in soot, everyone was quickly black from head to toe. Are clothes were now black. We looked like Johnny Cash impersonators
Johnny Cash Man in Black
literally with Al Jolsen Black Face as the soot was pitch black.
Al Jolson dressed in Black Face (Google Image)
We had just climbed out of the air duct and were making our way to the electric shop when Glenn Rowland approached me and said, “You Lucky Dog!” I thought he must be making a comment about my appearance seeing how I was covered in soot. Then he explained. “For the next 10 weeks you have to report to Oklahoma City to work on an SAP project. You’re a lucky dog because you are going to miss all the fun of cleaning up this mess.”
Did I ever mention that I’m one of the luckiest people in the world? Well. I am. I had just come to grips with my false God, and now I had been rescued from two and a half months of working in soot and grime to go work in an air conditioned office building in Oklahoma City.
Here is a post about how lucky I am: Power Plant Men’s Club Prizes and a Story of Luck.
Now for the hard part of the story to write about:
So, why did the Boiler Feed Pump Turbine fail the overspeed test? What happened to cause the explosion?
The first attempt to place the blame where it didn’t belong was to blame Sonny Kendrick who had worked on the controls during the last outage. The same person that would accuse me of purposely causing any little opacity problem on the precipitator even when I was on vacation, was now blaming Sonny Kendrick for the multi-million dollar destruction of the Turbine Room Floor.
Sonny Kendrick must have looked like an easy target. A soft-spoken man that works alone most of the time. No one really understands some of the things he works on. Maybe they thought he wouldn’t be able to explain the changes he had made to the controls in enough detail in order to blame him for the explosion. I use the word “target” because someone else had to be “blamed” for the explosion instead of the person responsible. The person they picked as the “fall guy” was Sonny Kendrick:
Sonny Kendrick
You see… someone was directly responsible for the explosion. Someone who continuously used “Risk Management” as an excuse to cut corners. I wonder if everything was completely on the unconscious level, or did this person ever realize the impact of his decisions. You see, I haven’t completely decided.
There appears to have been a conspiracy to cover up the truth about the explosion that took three months to recover. The first clue was to try to blame Sonny Kendrick without any proof. I don’t know if Sonny was eventually cleared as the fall guy because he was able to clearly show how all of his wiring changes had no impact on an overspeed test, or someone who knew about the actual cause threatened to come out with the truth if they continued to pursue Sonny as the fall guy. You see… there was more to this equipment failure than met the eye.
The turbine exploded because the coupling to the pump shattered. That’s the part that connects the steam turbine to the boiler feed pump. When the coupling broke the turbine, no longer having any resistance, began to rotate at a rate much faster than it was ever designed to rotate until it flew apart.
A large coupling
It was known at the end of the last outage that the coupling was damaged. It would have delayed bringing the unit online another 2 or 3 days in order change out the coupling. In the name of “Risk Management” it was decided to “risk it” until the next outage. The decision was made without using any type of risk assessment tool… obviously.
I know about the conversations that took place because one of the people involved confided in me. The person that told me the details of the conversations said that even under oath he would never tell anyone else the truth. This is the second clue that made me think that a concerted effort was made to cover up the knowledge that it was known that a faulty coupling was operating on the Boiler Feed Pump Turbine and it had been decided to leave it in place. You see… everyone who was on the team that found the damage knew about it.
The third clue this was a “conspiracy to cover up the truth” was that when an investigation was performed to look into the cause of the explosion, the person responsible for keeping the bad coupling in place played a major role in the investigation. Like the Fox guarding the Hen House.
Because the truth about the coupling never came to light, the insurance company ended up paying the entire bill for the outage. It was ruled as “equipment failure”. Our plant manager Bill Green remarked one day that we actually came out ahead when the insurance company paid for the outage, because they paid our lost revenue without taking all the operating costs into account.
I know sometimes that things just happen and sometimes bad things happen. Sometimes when everything is done correctly, something still goes wrong. I know that. That is why when this explosion first happened it made me step back and think twice about the dangers lurking around a Power Plant. A tremendously large amount of energy is being converted from coal into electricity. Somewhere, some time, something is going to go wrong and someone is going to be hurt or killed.
That is also why when this explosion happened, it never occurred to me to place the blame on anyone. To me it was just one of those things that happens every now and then. My bubble of innocence was burst the day I heard about the decision to keep a defective coupling in place on such an important piece of equipment.
On one hand I was angry that someone would make a decision that could have ended with the death of an operator, on the other hand, I was relieved to know that accidents like this don’t just happen. It was only when someone decided to cut corners that this explosion occurred. It gave me a little of my faith back in the system. When things are done right, we can work safely without the fear that something is likely to explode in our face.
All right, so I never really worshiped the Turbine Generator. I just exaggerated that part a bit. But let me ask this question… Who in this story did? Who was it that was willing to sacrifice the life of an operator to keep from delaying the “go-live”? Who thought that having the Generator produce electricity two or three days sooner than it should have been was more important? That is the person that really needs to re-evaluate their priorities and take another look at which God they worship.
The question is never, “Is there a God?” The real question is “Which God do you worship?”
Psychological Profile of a Power Plant Control Room Operator
Originally posted on July 6, 2012:
I suppose that many parents while raising their children would hear them say, “Dad, can you read that story to us again about the pirates that go to the island to find the treasure but Jim Hawkins fights them single-handed?” Or their children might say to their mother, “Will you tell us the story again about how you met daddy?” In my household, my children would say, “Dad, tell us another story about how you played a joke on Gene Day when you were working at the Coal-Fired Power Plant in Oklahoma? Those are always the best!”
As I pointed out in my third post this year called “Power Plant Humor And Joking With Gene Day” the first time I met Gene Day, I could tell that he was the type of person that would take a joke well, or so I thought…. One of the favorite stories my daughter would like for me to tell her as she was growing up was the one where I had created a Psychological Profile of Gene Day, who at that time was an Auxiliary Operator.
It began one day when I was leaving the electric shop through the Turbine Generator (T-G) building ground floor. A very noisy location as large steam pipes wound around under the Turbines where the steam caused a rumbling or whining sound. It was normal when walking through this area to reach up to the ear plugs that were draped over your shoulders and put them in your ears because the decibels were dangerously high if you were exposed earplugless too long.
Earplugs on a cord that can be draped over your shoulders when not in use.
I stepped from the landing leading from the electric shop and started toward number 1 boiler when I spied Gene Day making his way around the first floor of the T-G building inspecting equipment and marking his documents indicating that they were operating correctly. As I saw him turn toward my direction I quickly dodged behind the nearest metal pillar (I-Beam). I peaked my head out from behind the pillar and took out the notepad that was in my back pocket, and the pen from my vest pocket pocket protector.
A pocket protector is a must for electricians and computer nerds who need a place to keep their small tools.
Gene saw me and gave me a suspicious look as I began feverishly writing in my notepad while looking from my notepad back to Gene and then back to what I was writing. After I had done this for about 10 seconds or so, I put my pad away, my pen back in the pocket protector and strolled away toward unit 1 to continue my work.
A notepad like this
It happened that this particular week was Gene’s week to monitor the equipment in the T-G building, so throughout the week he would be making his way somewhere around the T-G building with his clipboard in hand. Each time I encountered him I would do the same thing. I would visibly hide behind a beam and write notes in my notepad. I saw Gene rather frequently during the week because the majority of the time, I left the electric shop by going through the T-G room to one of the boilers and then to the precipitators, where I spent most of my time working at this time in my career (but that is another story for a later time).
Each time, Gene would watch me suspiciously knowing that I was just messing with him, but not exactly sure what I was “up to”. At the time, I wasn’t sure either. So I just wrote down what I saw Gene doing, that way, if he ran over and grabbed my notepad from me, it wouldn’t say anything other than what I saw.
It had happened at the plant a few years earlier when I was a janitor that the company had hired an efficiency expert to monitor the employees at the plant. He would walk around the plant with a stopwatch observing the employees. When he saw them he would write notes on his clipboard. It became very unnerving because you would walk around the corner and there he would be standing writing something down about you.
I went to the Assistant Plant Manager Bill Moler and told him that this creepy guy keeps showing up in the main switchgear by the janitors closet. And every time he sees me, he writes something down. I told Bill that it really bothered me. He explained that he is an efficiency expert and he has a certain path that he takes throughout the day and takes a snapshot of what the workers are doing at that moment and writes it down. By doing that he calculates how efficient we are. It seemed pretty silly to me, because most mechanics when they saw him coming put their tools down and did nothing while he walked by until he was out of sight again.
When I was on the labor crew a few weeks later, and I was blowing coal dust off of all the I-Beams above the bowl mills with a high pressure air hose, I looked down, and through my fogged up goggles I could see this guy standing directly under me. I was about 50 feet above him crawling across an I-Beam with the air hose blowing black dust everywhere. He had crossed my barrier tape to go into the bowl mill area to see how efficient I was being.
This is the type of barrier tape I was using. It is made of woven plastic fibers.
I was so mad I turned off my air hose, climbed down the wall Spiderman-like (no. not head first) and went straight into the A-Foreman’s office and told Marlin McDaniel that the Efficiency Expert had crossed my barrier tape and was standing directly under me as I was blowing down the beams with air.
It turned out that the Efficiency Expert had gone upstairs to complain that some guy in the bowl mill had dumped a bunch of coal dust on him while he was monitoring him from below. Evidently, he wasn’t expert enough to know you weren’t supposed to cross someone’s barrier tape without permission, as was indicated on the caution tags that were tied to the barrier tape. From that point on, the efficiency expert (now in lowercase) had to be accompanied by someone from the plant to make sure he wasn’t breaking any safety rules and putting himself at harm.
To make a long side story short, we turned out to be so efficient, people came from all over the world to study us. Somebody downtown hired the efficiency expert full time, but later he was laid off during the first downsizing.
He reminds me of a person on an episode of Star Trek The Next Generation where this guy Lieutenant Commander Remmick comes aboard the Enterprise and he walks around inspecting everything and asking everyone questions that make them uncomfortable and at the end asks Picard if he could come work on the Enterprise. He looked so much like him, that I thought maybe our efficiency expert went to Hollywood to become an actor.
Lieutenant Commander Remmick
Back to Gene Day. I suppose the thought of the efficiency expert may have been going through my mind as I was taking notes about Gene Day at work. Like I said, at the time, I didn’t know what I was going to do with it.
It finally came to me on Thursday morning. This was the last day that Gene was going to be on the day shift, so I figured I might as well do something about it. So when I entered the shop that morning, I sat down at the desk of my foreman Andy Tubbs and began to write. The title at the top of the page was: “The Psychological Profile of Gene Day”.
Using the notes I had taken during the week, I wrote things like the following: “Gene Day walks around the Turbine Generator building with a clipboard in his hand trying desperately to look like he’s doing something important. He constantly hopes that someone is watching him because he dislikes doing so much work to act busy for no reason.
At times Gene Day gets paranoid and believes that he sees people spying on him from behind every corner (especially I-Beams). Sometimes Gene Day stands in the middle of the T-G floor staring up into space as if he forgot what he was supposed to be doing.” I’m sure I wrote more, but I don’t remember everything… but I do remember the second from the last sentence. I will save that for a couple of paragraphs from now.
I took my Psychological Profile of Gene Day and went up to the Control Room. I noticed out of the corner of my eye that Gene had just walked over toward the break room behind the Auxiliary Control Panel so I walked over by the Shift Supervisor’s office and I leaned against the top of the large Blue Monitor and placed the Psychological Profile on the top of the monitor in front of me.
Less than a minute later Gene came walking around behind me and seeing the paper on the top of the monitor came up behind me and looked over my shoulder and began to read….. He wasn’t trying to hide the fact that he was reading the paper, and I obviously knew he was there, and the title in large bold letters did say, “The Psychological Profile of Gene Day”. So, he read on.
I heard a few chuckles as he read through my interpretation of what he had done during the week. Then he came to the “Second from the Last Sentence”, as I could hear him reading quietly in my ear… The sentence read, “Gene Day sneaks up behind people and reads their private material over their shoulder!” — Bingo! I had him!
When he read that he grabbed me by the throat and started to Throttle me! Shaking me back and forth. This would have been a humdinger of a joke at that point, but I had one more sentence up my sleeve… ur… I mean on the paper….
As I was waivering (is that a word?) back and forth between life and death I managed to eke out something like: “Wait! There’s More!”…. Gene Day let up on me a little and looked down at the page and read the last sentence…… It read….. “Gene Day tries to strangle people who are only trying to help him by creating his Psychological Profile.”
That was all it took. Another perfect joke played on Gene Day, and I was able to live to tell about it. When Gene read that he was stunned into dismay. Giggling as hard as he could he retreated shaking his head in defeat.
Now, I know that Gene reads these posts, and he may remember this story a little differently, and I’ll give him that because Gene is older than dirt and his memory isn’t that good. But I was the one that was being strangled, and I still have a vivid image of those few moments. Not only do I, but so do my children, who will one day tell their children, who will say, “Mommy, will you tell us that story again about how Grandpa was strangled by Gene Day that time in the Control Room at the Coal-Fired Power Plant in Oklahoma?”
Wax On Wax Off and Other Power Plant Janitorial Secrets
Orignally Posted on October 12, 2012:
Two years before the movie Karate Kid came out at the movies in 1984, I had learned the secret of “Wax On, Wax Off”. One that made a significant difference to my Power Plant Janitorial Powers!
The Student Learns from the Master…. “Wax On… Wax Off”
My Janitorial Master was Pat Braden. He is the same age as my father. As I mentioned in an earlier post, Pat Braden reminded me of a rounder version of Red Skelton:
This Picture of Red Skelton reminds me of Pat Braden
Pat was one of the kindest people you would ever meet. He was the head janitor when I became a janitor at the Coal-Fired Power Plant. I had worked with him off and on during the 4 summers when I had worked as a summer help. So I was glad to actually be on his crew as one of the team.
When we had a big waxing job to do, we would schedule a weekend to come in and do it. That way we could wax an entire area without interruption. We could strip off the old wax with the stripping chemicals, then neutralize it, then add the sealer, and finally end up with waxing the floors with the best wax we could buy. As I mentioned in the post “How Many Power Plant Men Can You Put in a 1982 Honda Civic“, we used Johnson Wax’s best wax: Showplace.
The Best Floor Wax money can buy!
We had been “certified” by Johnson and Johnson to wax floors properly. This included the proper buffing techniques once the wax had been applied and had properly dried. A properly waxed and buffed floor is shiny but not a slippery floor.
Floor buffer, used to strip the wax off and buff the wax once it has been applied. The black pad is used with the stripper.
We decided to spend one weekend waxing the Engineering shack. It was a tin building like a Metal Butler Building that the inspectors from Corporate Headquarters would use when they had projects at the plant. In 1982, that was pretty well all of the time, as John Blake and Gene Titus were permanent residents of the Engineers Shack.
A simple metal building sort of like this. Only it was green.
The floor in this building had a regular tile floor like you would see in an office building in the 1960’s. Just the plain square tiles. It looked like it had never been waxed before, and was probably built on the plant grounds long before the power plant existed. The floor had been worn out by the traffic over the years. This was one building that I was expected to keep swept and mopped as part of my daily janitorial responsibilities.
Our Janitor crew consisted of Pat Braden, Doris Voss, James Kanelakos, Ronnie Banks and Curtis Love (and myself of course). We had decided a couple of days before that for lunch we would eat baked onions. “Ok”, I thought. I knew we didn’t get paid much as janitors and we had to be frugal, but I didn’t really think that we were so bad off that we had to resort to eating onions for lunch. But since no one really asked me for my vote (which would have been to bring in some pizza from Ponca City), we were having baked onions for lunch.
We spent the morning removing all the furniture from the building, and then stripping the floor (even though it looked like it had never been waxed before). Then we mopped it a couple of times. By that time it was lunch time, and we headed up to the plant break room where Doris was just finishing up baking our um…. er….. onions. Yeah.. Baked Onions….
It turned out that these were Purple Onions. The ends had been cut off of them and butter and salt and pepper had been put on each end as they were wrapped up in tinfoil like a baked potato, and then baked in the oven just as if they were baked potatoes.
oh yum… a purple onion…
Well. I was never one to complain about food, and I was determined not to show my lack of enthusiasm at the thought of eating an onion for lunch, so I sat down and put on my eager hungry expression as I waited for our (uh) feast. — Well. The joke was on me. As I began to eat the baked onion, I realized right away that it didn’t taste like any onion I had ever eaten. It was kind of sweet and…. well…. it was rather tasty! Power Plant Culture never ceases to amaze me.
Anyway, after I had eaten my share of onions, we were ready to go back to work waxing the engineers shack. We spent the rest of the day doing that (and burping onions) and when we had decided that the wax had dried enough, we carefully brought the furniture back in and put everything back in order.
So, why am I boring you with all this detail about waxing the floor in a metal building that doesn’t even exist today? Well. I have told you now about the “Wax On” part. Now comes the “Wax Off” part. The second part of my training to becoming a Jedi Janitor (hmm… snuck in a Star Wars reference I see).
Here is what happened the next Monday when I wheeled the buffing machine out of the janitor closet in the Engineer’s shack. Gene Titus (who always reminded me of Jerry Reed):
Jerry Reed trying to look like Gene Titus
and John Blake, both were very pleased with their new shiny floor. They looked like they were anxious to show it off to someone… anyone that would come by. I was about to really impress them (I thought) with my fine buffing skills that was “really” going to make their floor shine. So, they watched closely as I attached the red buffing pad on the bottom of the buffer:
The black buffing pad is for stripping the wax. The red one is for normal heavy buffing and the white one is for polishing
I began at the far end of the room from the doors and began buffing…. The first thing I noticed was that the buffer was literally removing the wax from the floor. Yep. It was taking it right off. Wax On…. Wax Off….. I realized that for all our stripping and neutralizing, we hadn’t taken into account the years of dirt and grime that was embedded in the tiles.
Normally John Blake was a likable sensible person. I had carpooled with him for two summers when I was a summer help. But when he saw me removing the wax from the floor he had a very concerned expression, and well, I perceived that a sort of extreme hatred was rising up in his demeanor…. I was glad that John was a quiet mild-mannered sort of person, otherwise, I think he would have walloped me one for ruining the floor that he was so proud of minutes before.
I began thinking to myself what I should do. After all. The floor really did need buffing, and buffing the floor was removing the wax. So as the buffer moved back and forth erasing the shine and bringing back the dull tiles, I thought as hard as I could muster my brain what I should do next….
I figured I would go ahead and buff the entire main room, as if I knew exactly what I was doing, not looking concerned. I don’t know if the confidence that I exhibited while removing the wax relaxed John just enough so that he could leave the building and continue his job, or if he actually stormed out in distress hoping to drown his sorrows in his morning cup of coffee…
When I finished the room with the red pad… I did what I would have done if the wax had buffed up correctly and had actually still existed on the floor…. I put the white pad on the buffer. I thought in my mind that the floor was probably so infiltrated with dust that we hadn’t done a proper job (if it was even possible) to clean the floor before applying the wax on Saturday.
So I thought I would try something that they hadn’t taught us in waxing class… I took a spray bottle and filled it with wax. Then I started in the same corner where I had begun removing the pride and glory of John Blake’s newly waxed dreams. I sprayed some wax and buffed it into the floor. As I guided the buffer back and forth with one hand, I sprayed the floor with the other. To my surprise, not only did it start to leave a shiny polished floor, but it left a polish that was much more clear than before. One that was almost like a mirror.
A plain spray bottle like this
As I buffed the room from one end to the next, the entire room became brighter as the lights from the ceiling reflected from the hard polished wax. I was nearly finished with the room when John walked back in. He was immediately stunned by the brightly polished floor.
I could see his uncharacteristic desire to kill me melt away and his pleasure with his new Shangri-La abode become immediately evident. John Blake from that moment on viewed me with the respect that most Power Plant janitors normally deserve.
I was so impressed with how well the floor looked when I was done, that I went to the Brown and Root building next door and did the same thing there.
I began to wonder what other uses I could make out of this discovery… Spraying wax on the floor and buffing it right in. It finally occurred to me that the floor cleaning machine that I used to clean the Turbine room floor might benefit by adding some wax to the mixture. It had the same type of red buffer pads on it.
We had a Clarke Floor scrubber similar to this one
So, after I had scrubbed the Turbine Generator floor using the regular detergent. I cleaned out the scrubber and put just water in there and about 1/2 gallon of wax. Then I went to try out my experiment. Sure enough…. The bright red Turbine Room floor began to glow. The bright lights overhead were clearly reflected off the floor. This was very successful.
This is a picture of the red turbine room floor, only not with the nice wax job. After I had waxed it, you could see the light bulbs in the floor
So, my next test was to sweep off the turbine-Generators themselves with a red dust mop. Then spray watered down Johnson Wax directly on the dust mop and mop away on the turbine generators:
Like this only with a mop handle
The Turbine Generators took on the same polished shine.
I distinctly remember one Power Plant Operator that gave me a very nice complement one day for keeping the T-G floor so nicely polished. His name was Michael Hurst. He was a True Power Plant Operator.
Michael Hurst is the second Brave Power Plant Operator on the right
As a lowly janitor in a plant of heroes, I found that I was treated with the same respect as everyone else. I would never forget that complement from him because I could see his earnest sincerity.
A few years ago on December 19, 2008 Michael Hurst died in Oklahoma City. What was said about Michael after his death was this: “He had a great sense of humor and a big heart… Many have been blessed with his generosity and his genuine love for people.”
I can include myself in this statement. I know that everyone shown in the picture above from Joe Gallahar (on the left) to Doris Voss (in the middle) to Pat Quiring (on the right) would agree with that testament about Michael.
There was another sentence after this one that stands on it’s own. One that is a sign of a True Power Plant Man. It was also said of Michael Hurst: “Above all else, the most important thing to him was his family.” Though I don’t have a picture of Michael’s immediately family. I believe that I have included a picture above of at least some of his extended family.
Comment from previous post:
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Thanks, Kevin.
Did you know that (years ago) John Blake’s dad was Manager of Power Production (Generation Dept. in those days)? I remember Martin Louthan and other “old” Power Plant Men speak of “Mr. Blake” with respect.-
I didn’t know that. I do know that everyone seemed to treat John with respect. Which he deserved in his own right. We carpooled together my second summer as a summer help with Stanley Elmore.
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Comment from previous repost
My father managed a bowling alley when I was young. I remember large mops, all kinds of pads and rags and a buffing machine. Before he would let me use the machine on the alleys, he had me do the lobby floor. He not only inspected my work, he watched my technique. This brought back some of those memories, thanks.
In Pursuit of the Power Plant Gai-tronics Gray Phone Ghost
Originally Posted June 14, 2013:
When I first watched the movie “The Goonies”, I recognized right away that the script was inspired from another Pirate treasure movie I had watched when I was a child. I have never seen the movie again, and it was probably a made for TV movie or something that has been lost in the archives years ago. I’m sure that Steven Spielberg when he was growing up must have been inspired by this movie when he wrote the script to Goonies, because this was a movie that had inspired us when we were young.
The Goonies looking at the treasure map
You see… In the movie I had watched as a kid, some children that were trying to save their family or an old house or something similar to the Goonies story, found a clue to where a Pirate treasure was buried. The clue had something to do with a “crow’s nest”. It turned out that the model of a ship that had been sitting on the mantle piece in the old house had another clue in the pole holding the crow’s nest. This clue had holes in the paper, and when held up to a certain page in a certain book, it gave them another clue to where there was a hidden passageway. Which led them one step closer to the treasure.
Anyway. As a child, this inspired us (and I’m sure a million other kids) to play a game called “Treasure Hunt”. It was where you placed clues all around the house, or the yard, or the neighborhood (depending on how ambitious of a treasure hunt you were after), with each clue leading to the other clue, and eventually some prize at the end.
Why am I telling you this story about this movie that I watched when I was a child? Well, because I felt this same way all over again when I became an electrician at a coal-fired power plant out in the country in north central Oklahoma. Here is why.
I used to carpool to work from Stillwater, Oklahoma to the power plant 25 miles north of town with another electrician named Bill Rivers. He had kept urging me to become an electrician along with Charles Foster, who had suggested that I take some electric courses to prepare for the job. Once I became an electrician, Charles Foster, my foreman, would often send me with Bill Rivers to repair anything that had to do with electronics. Bill Rivers was good at troubleshooting electronic equipment, and well, he was generally a good troubleshooter when he wasn’t getting himself into trouble.
I remember the morning when Charles told me to go with Bill to go fix the incessant humming that was coming over the PA system…. “What?” I asked him. “I can’t hear you over the loud hum coming over the PA system.” — No not really… We called the Gai-tronics PA system the “Gray Phone” because the phones all over the plant where you could page people and talk on 5 different lines was gray.
Gaitronics Gray Phone
I walked into the electric lab where Bill Rivers was usually hanging out causing Sonny Kendrick grief. I hadn’t been in the electric shop very long at this point. I think it was before the time when I went to work on the Manhole pumps (see the post Power Plant Manhole Mania). In the lab there was an electric cord going from a plug-in on the counter up into the cabinet above as if something inside the cabinet was plugged in…. which was true. I asked Bill what was plugged in the cabinet and he explained that it was the coffee maker.
An old Coffee pot like this
You see, our industrious plant manager had decided that all coffee at the plant had to come from the authorized coffee machines where a dime had to be inserted before dispensing the cup of coffee. This way the “Canteen committee” could raise enough money to…. uh…. pay for the coffee. So, all rogue coffee machines had to go. There was to be no free coffee at the plant.
So, of course, the most logical result of this mandate was to hide the coffee maker in the cabinet in case a wandering plant manager or one of his undercover coffee monitors were to enter the lab unexpectedly. Maintaining the free flow of coffee to those electricians that just had to silently protest the strong arm tactics of the Power Plant Coffee Tax by having a sort of… “Tea Party” or was it a “Coffee Party”.
I told Bill Rivers that Charles wanted me to help him fix the hum on the gray phones. Bill Rivers said, “Great! Then let us play a game. let’s call it, ‘Treasure Hunt’.”
Bill reached up in one of the cabinets and pulled out a blue telephone test set. I’m sure you must have seen a telephone repairman with one of these hanging from his hip. ” Oh boy.” I thought. “A new toy!”
Power Plant Telephone Test Set
I grabbed my tool bucket from the shop and followed Bill Rivers out into the T-G basement. This is a loud area where the steam pipes carry the steam to the Turbine to spin the Generator. It is called T-G for Turbine Generator. Bill walked over to a junction box mounted near the north exit going to unit 1. He explained that except for the gray phones in the Control-room section of the plant, all the other gray phones go through this one junction box.
Bill said that the game was to find the Gray Phone ghost. Where is the hum coming from? He showed me how the different cables coming into this one box led to Unit 1, Unit 2, the office area and the coal yard. I just had to figure out which way the hum came from. So, I went to work lifting wires off of the terminal blocks. We could hear the hum over the gray phone speakers near us, so if I were to lift the right wires, we should know right away that I had isolated the problem.
Power Plant Gray Phone Speaker
We determined that the noise was coming from Unit 1. So we took the elevator halfway up the boiler to another junction box, and then another where we traced the problem to a gray phone under the surge bin tower. It took 4 screws to remove the phone from the box. When I did, I could clearly see the problem. The box was full of water. Water had run down the conduit and into the phone box.
Bill Rivers told me that now that we found the problem, we wanted to make sure it didn’t happen again, so we drilled a small weep hole in the bottom of the box, and we took plumbers putty and stuffed it into the top of the conduit where it opened into a cable tray.
A tub of Power Plant Plumbers Putty
The box would fill with water when the labor crew would do coal cleanup. On labor crew we would spray the entire surge bin tower down with high powered water hoses to wash off all the coal dust. Each time, some water would end up going down the conduit into the gray phone until it grounded the circuit enough to cause a hum.
Bill and I continued searching throughout the plant for phones that were causing a hum. Most were caused by water in the box. Some were caused by circuits that had gone bad (most likely because they had water in them at some point). Those we took to the electric shop lab where we played a different kind of treasure hunt. — Let’s call it…. Finding the bad component. It reminded me of an old video game I had bought for my brother for Christmas that winter when I gave him an Intellivision (so I could play with it). It was the latest greatest video game console at the time.
An Intellivision Game Console
I had given my brother a game called “Bomb Squad”. Where you had a certain amount of time to diffuse a bomb by going through a circuit board cutting out components with some snippers. If you cut the wrong connection, you had to hurry up and solder it back on before the bomb blew up.
Bomb Squad. It even talked to you and a siren went off if you were going to blow yourself up.
That’s what we were doing with the Gray Phones. We were testing the different components until we found one that wasn’t working correctly. Then we would replace that transistor, or capacitor, or resistor, or diode, and then test the phone by plugging it in the switchgear gray phone box and calling each other.
I have a story later about someone using this technique while fixing gray phones, only he would call himself on the gray phone where I would call Bill and Bill would call me. Someone misinterpreted this and thought the person was trying to make everyone think he was more important because he was always being paged, when he was only paging himself. He was removed from fixing gray phones for this reason, even though he was only person at the plant in Mustang Oklahoma that knew a transistor from a capacitor.
So, why am I going on about a seemingly boring story about fixing a hum on a PA system? I think it’s because to me it was like a game. It was like playing a treasure hunt. From the day I started as an electrician, we would receive trouble tickets where we needed to go figure something out. We had to track down a problem and then find a solution on how to fix it. As I said in previous posts, it was like solving a puzzle.
Each time we would fix something, someone was grateful. Either the operator or a mechanic, or the Shift Supervisor, or the person at home vacuuming their carpet, because the electricity was still flowing through their house. How many people in the world can say that they work on something that impacts so many people?
Well… I used to feel like I was in a unique position. I was able to play in a labyrinth of mechanical and electrical equipment finding hidden treasures in the form of some malfunction. As I grew older, I came to realize that the uniqueness was limited only to the novelty of my situation. If you took all the power plant men in the country, they could probably all fit in one large football stadium. But the impact on others was another thing altogether.
The point I am trying to make is that it was obvious to me that I was impacting a large portion of people in the state of Oklahoma by helping to keep the plant running smoothly by chasing down the boiler ghosts and exorcising the Coalyard demons from the coal handling equipment. Even though it isn’t so obvious to others, like the janitor, or the laborer or the person that fills the vending machine. Everyone in some way helps to support everyone else.
A cook in a restaurant is able to cook the food because the electricity and the natural gas is pumped into the restaurant by others. Then the cook feeds the mailman, who delivers that mail, that brings the check to the person waiting to go to the grocery store so they can buy food that was grown by some farmer who plowed his field on a tractor made in a huge tractor factory by a machinist after driving there in a car made by a manufacturer in Detroit who learned how to use a lathe in a Vocational school taught by a teacher who had a degree from a university where each day this person would walk to class during the winter snow wearing boots that came from a clothes store where the student had bought them from a store clerk that greeted people by saying “Good Morning! How are you today?” Cheering up all the people that they met.
I could have walked into the lab and told Bill Rivers that Charles wanted me to help him find the hum in the PA system and he could have responded by saying, “Oh really? Good luck with that!” Instead he said, “Let’s go play a game. ‘Treasure Hunt!” This attitude had set the stage for me as a Power Plant Electrician: “Let’s go have some fun and fix something today!” Where would that cook have been today if the power had gone out in his restaurant that morning all because an attitude had gotten in the way….. I wonder…
Comments from the original post:
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Great story! It’s neat how God puts us in teams to “fix stuff” and make life happen.
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I wonder why they don’t make ‘em bright yellow or some other color easy to spot in an emergency? Anyway, I remember this one gray phone/speaker we had & when you’d wash down the basement if you accidently got water in it, it would bellow throughout the plant like a sick cow moose until it finally dried out!
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Thanks Monty, I remember having to stuff putty down the end of conduit from a cable tray to gray phones so that water wouldn’t run down them during washdown. We pulled a gray phone out of the box one day and water just poured out of it. We took to drilling a small hole in the bottom of some of them just to let the water drain out.
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Destruction of a Power Plant God
Sometimes we unknowingly end up worshiping things we never intend. It isn’t until those things are destroyed before we realize what has happened. We have a natural tendency to worship something. It’s built into our DNA to worship God just as sure as the God Particle converts energy into matter and subsequently atoms into earth and water. I’m not sure when my obsession began, but I definitely know the day when it was destroyed. August 5, 1996.
The day of realization began as a normal day, as Scott Hubbard and I were driving to the plant. It seemed like an extra dark morning considering it was the middle of the summer. Perhaps it was because by this time we were working four tens, which meant we arrived at the plant before 7:00 am so we left Stillwater, Oklahoma at 6:15 to drive to the coal-fired Power Plant in North Central Oklahoma.
When we topped the overpass to the turnpike at 6:32 we thought we could see something strange at the Power Plant off in the distance. The sun was going to rise in the next few minutes (at 6:42), yet, the sky seemed darker than usual. It must have been a cloudy morning.
Power Plant at sunset (only we were arriving before sunrise)
We thought we could see red and blue flashing lights coming from one end of the plant. It was only momentary, because once over the overpass, we were too low to see that section of the plant. We weren’t really sure what we had seen. It became even more confusing as we approached the entrance to the plant.
There seemed to be a little more activity happening at the front gate than usual. there was a guard or an operator standing out there. He waved us through the gate. about 300 yards past the main gate, we had a clear view of the plant grounds laying before us as we made our way to the parking lot. It was here that the significance of the flashing lights suddenly caused us to gasp. We were stunned into silence.
The area around the Unit 1 main power transformer was flashing with the red and blue lights of several fire trucks. They seemed to be pulling away just about that time. Some of the siding on the Turbine-Generator room was missing, some was blackened from smoke as it had poured out of the windows along the turbine room floor. The real shock to me came as we approached the parking lot and I looked up through where a window used to be and I could see the sky. I could see the sky where the T-G roof should have been.
We were directed to go into the maintenance garage to avoid the fire trucks who that were backing away. We met with our team and Alan Kramer told us that there had been an explosion during the night when an overspeed test was being performed on the Unit 1 Boiler Feed Pump Turbine (BFPT). The number one question we all wanted answered was quickly given to us…. No one was hurt in the explosion.
Alan mentioned that in our recent fire fighter training, we had learned that a large percentage of companies that have a major fire (such as ours) goes out of business within the next year. That was not going to happen to us even though the damage was extensive. Our job was to put everything back to the way it was before the fire.
Here is the story as it happened, as much as I know:
The explosion occurred when an operator (I’ll let one of the operators remind me who it was) was running an overspeed test on the BFPT. Suddenly he heard a loud pop and then the turbine winding up out of control. He took off running and was around the corner of a concrete pillar when the turbine exploded. The turning gear shot out like a top and flew across the mezzanine floor, hit the corner of the north stairway, and still spinning like a top, tore up the stairway as it made the turn halfway down and ended up in middle of the the T-G basement where it finally came to rest. This turning gear weighs somewhere in the ballpark of a thousand pounds (I’m guessing).
Turning Gear
At this point steam was shooting out of the Boiler Feed Pump Turbine. The oil pumps that keep the bearings lubricated were spraying oil into the steam which burst into flames. The flames shot up to the concrete floor 40 feet above. The fire was so hot that it melted the metal structure holding up the floor and the rebar in the concrete. The Turbine Room Floor literally melted away as the oil fire shot the flames up toward the roof another 80 feet above the turbine room floor melting the roof as if it was butter. The asbestos siding on the T-G floor was falling off because the bolts that held them to the brackets literally melted away.
The same reservoir that feeds the oil to the the Boiler Feed Pump Turbine bearings also fed the Main Turbine Generator. This is the same generator that makes the electricity that causes the light bulb to glow in your house when you turn it on. The Main Turbine Generator tripped when the explosion occurred, as it should. As it slowed down to a stop, the oil for the bearings was all gone. It had been creating the large fire ball that was melting down the T-G floor.
Normally, when the Turbine-Generator comes to a stop, it is put on a turning gear while the shaft cools down otherwise the shaft will become warped under it’s own weight. The Turning gear slowing rotates the turbine for a day or so while it cools. Without bearing oil, the turning gear would not be able to turn the turbine generator. The bearings require a layer of oil to function properly.
Unit 1 Turbine-Generator
Charles Patton, one of the Maintenance foremen was called out, and he took cans of STP Oil Treatment and for hours poured them onto the bearings and manually rotated the 50 ton turbine generator (Ray, help me out with the actual weights). Through the heroic efforts of Charles and others that were there to help, the Turbine Generator was spared from even more damage.
Charles Patton
By the time we arrived that morning, the fire was out, things were cooling down. Unit 2 was still running, and it was our job to keep it going.
Unit 2 Turbine-Generator
As I walked out onto the T-G floor everything went into slow motion. I don’t know if that has ever happened to you before. There have been a few times in my life when I was in a near death situation where my surroundings all seem to switch into a slow motion mode. I think it happens because your brain kicks into high gear in order to process what is happening and to put as much effort forward as possible to avoid danger.
The first time I think that happened to me was when I was with some friends climbing around on some cliffs by the Missouri River. One boy was falling back after the ledge he was on gave way and was going to fall most likely to his death when everything switched into slow motion even before I realized what was wrong. I was able to make quick decisions that allowed me to push him back onto the ledge and grab onto a branch that luckily kept me from the same fate.
When I walked onto the T-G floor and saw the devastation, I think my mind was trying to take everything in all at once. The Turbine Generator was covered in soot and debris. I flashed back to the days when I was a janitor and used to keep the turbines waxed so that they would shine. It was at this moment that I realized I actually worshiped the Turbine Generators in a way similar to the way the religious cult worshiped the alpha-omega doomsday bomb in “Beneath the Planet of the Apes”.
Bomb Worshipers in Beneath the Planet of the Apes
The near destruction of the Turbine Generator made me realize the importance I had placed on it. I felt as if I had almost lost my close friend like the boy climbing on the cliff. I used to stand on the sides of the Turbines when I was a janitor with my dust mop and after spraying furniture polish on the mop, I would caress the turbines as if I was running my fingers through someone’s hair.
Like this only with a mop handle
We began the clean up by taking fire hoses and washing down the siding on the Unit 2 side to try to bring some normalcy back to a surreal situation. The soot didn’t just wash off. Not long after we had dragged out the fire hoses and were blasting away at the siding, Alan Kramer asked Charles Foster and I to look at the air duct to the Instrument room on the north side of the Turbine room. The room was getting too hot and the air conditioner seemed to have frozen.
We climbed into the air duct on the roof of the instrument room and replaced the filters that were packed with soot stopping the air flow for the Air Conditioner. This seemed like one task in 100,000 that would need to be done to put this puzzle back together again. All the electric cables that ran through the Unit 1 Mezzanine had melted away, everything had been utterly destroyed.
The thought was too overwhelming. I felt like Scarlet O’Hara in “Gone With the Wind” when she said, “I can’t think about that right now. If I do, I’ll go crazy. I’ll think about that tomorrow.”
Vivian Leigh as Scarlett O’Hara in Gone With the Wind
With everything on the T-G floor covered in soot, everyone was quickly black from head to toe. Are clothes were now black. We looked like Johnny Cash impersonators
Johnny Cash Man in Black
literally with Al Jolsen Black Face as the soot was pitch black.
Al Jolson dressed in Black Face (Google Image)
We had just climbed out of the air duct and were making our way to the electric shop when Glenn Rowland approached me and said, “You Lucky Dog!” I thought he must be making a comment about my appearance seeing how I was covered in soot. Then he explained. “For the next 10 weeks you have to report to Oklahoma City to work on an SAP project. You’re a lucky dog because you are going to miss all the fun of cleaning up this mess.”
Did I ever mention that I’m one of the luckiest people in the world? Well. I am. I had just come to grips with my false God, and now I had been rescued from two and a half months of working in soot and grime to go work in an air conditioned office building in Oklahoma City.
Now for the hard part of the story to write about:
So, why did the Boiler Feed Pump Turbine fail the overspeed test? What happened to cause the explosion?
The first attempt to place the blame where it didn’t belong was to blame Sonny Kendrick who had worked on the controls during the last outage. The same person that would accuse me of purposely causing any little opacity problem on the precipitator even when I was on vacation, was now blaming Sonny Kendrick for the multi-million dollar destruction of the Turbine Room Floor.
Sonny Kendrick must have looked like an easy target. A soft-spoken man that works alone most of the time. No one really understands some of the things he works on. Maybe they thought he wouldn’t be able to explain the changes he had made to the controls in enough detail in order to blame him for the explosion. I use the word “target” because someone else had to be “blamed” for the explosion than the person responsible. The person they picked as the “fall guy” was Sonny Kendrick:
Sonny Kendrick
You see… someone was directly responsible for the explosion. Someone who continuously used “Risk Management” as an excuse to cut corners. I wonder if everything was completely on the unconscious level, or did this person ever realize the impact of his decisions. You see, I haven’t completely decided.
There appears to have been a conspiracy to cover up the truth about the explosion that took three months to recover. The first clue was to try to blame Sonny Kendrick without any proof. I don’t know if Sonny was eventually cleared as the fall guy because he was able to clearly show how all of his wiring changes had no impact on an overspeed test, or someone who knew about the actual cause threatened to come out with the truth if they continued to pursue Sonny as the fall guy. You see… there was more to this equipment failure than met the eye.
The turbine exploded because the coupling to the pump shattered. That’s the part that connects the steam turbine to the boiler feed pump. When the coupling broke the turbine, no longer having any resistance, began to rotate at a rate much faster than it was ever designed to rotate until it flew apart.
A large coupling
It was known at the end of the last outage that the coupling was damaged. It would have delayed bringing the unit online another 2 or 3 days in order change out the coupling. In the name of “Risk Management” it was decided to “risk it” until the next outage. The decision was made without using any type of risk assessment tool… obviously.
I know about the conversations that took place because one of the people involved confided in me. The person that told me the details of the conversations said that even under oath he would never tell anyone else the truth. This is the second clue that made me think that a concerted effort was made to cover up the knowledge that it was known that a faulty coupling was operating on the Boiler Feed Pump Turbine and it had been decided to leave it in place. You see… everyone who was on the team that found the damage knew about it.
The third clue this was a “conspiracy to cover up the truth” was that when an investigation was performed to look into the cause of the explosion, the person responsible for keeping the bad coupling in place played a major role in the investigation. Like the Fox guarding the Hen House.
Because the truth about the coupling never came to light, the insurance company ended up paying the entire bill for the outage. It was ruled as “equipment failure”. Our plant manager Bill Green remarked one day that we actually came out ahead when the insurance company paid for the outage, because they paid our lost revenue without taking all the operating costs into account.
I know sometimes that things just happen and sometimes bad things happen. Sometimes when everything is done correctly, something still goes wrong. I know that. That is why when this explosion first happened it made me step back and think twice about the dangers lurking around a Power Plant. A tremendously large amount of energy is being converted from coal into electricity. Somewhere, some time, something is going to go wrong and someone is going to be hurt or killed.
That is also why when this explosion happened, it never occurred to me to place the blame on anyone. To me it was just one of those things that happens every now and then. My bubble of innocence was burst the day I heard about the decision to keep a defective coupling in place on such an important piece of equipment.
On one hand I was angry that someone would make a decision that could have ended with the death of an operator, on the other hand, I was relieved to know that accidents like this don’t just happen. It was only when someone decided to cut corners that this explosion occurred. It gave me a little of my faith back in the system. When things are done right, we can work safely without the fear that something is likely to explode in our face.
All right, so I never really worshiped the Turbine Generator. I just exaggerated that part a bit. But let me ask this question… Who in this story did? Who was it that was willing to sacrifice the life of an operator to keep from delaying the “go-live”? Who thought that having the Generator produce electricity two or three days sooner than it should have been was more important? That is the person that really needs to re-evaluate their priorities and take another look at which God they worship.
The question is never, “Is there a God?” The real question is “Which God do you worship?”
Power Plant Men 
Thanks, Kevin.
Did you know that (years ago) John Blake’s dad was Manager of Power Production (Generation Dept. in those days)? I remember Martin Louthan and other “old” Power Plant Men speak of “Mr. Blake” with respect.
I didn’t know that. I do know that everyone seemed to treat John with respect. Which he deserved in his own right. We carpooled together my second summer as a summer help with Stanley Elmore.