Again I'm struggling with all that's happened and trying to sort through what I want to write and how. It seems for me that the hard part is just getting started. Once I get past the first few sentences it becomes easier, at least usually.
The two months or so while my gal was out on maternity leave were insane, and it's not really showing any signs of getting less so. I've learned so much it's crazy. I'm learning about all the different systems in the plant and what they do and how they work. I'm learning how to get over/around my fears of going to talk to people I don't know and, gasp, make phone calls. It's crazy and stressful and there's still a long way to go, but most days I'm glad I'm getting this opportunity to learn so much outside my normal field.
So much has happened and I don't remember all the details or what order things happened in, but I'll try to explain the gist of it. This mirror insulation is rigid, meaning it doesn't bend or anything, and it is engineered, which means each piece of it is specifically designed to go in a certain spot. Now if all the pipe it was going on was out in the open away from other stuff, that'd be great, super easy. But it's not. It's crammed into the bowels of a power plant with thousands of other things all over the place around it. The super cool thing is the people designing the insulation live in Chicago. I don't know if they've ever even been in a power plant, let alone this one. So they have a guy here going out and looking at all the pipes they have to insulate and trying to find all the stuff that is in the space or "envelope" that the insulation will be occupying. He then sends this information to his folks in Chicago and they design a notch in the insulation to provide room for whatever it is that's in the way.
I've found there is so much wrong with this method it's not even funny. For one thing, they've been doing these "walkdowns" for almost four years. So much has changed in the plant in four years the info they gathered at the beginning is worse than useless. The're going to have notched around things that aren't there anymore (letting more heat out, reducing efficiency, and ultimately costing money) and they're not going to have a clue about all the stuff that's been installed since then.
Another huge issue is that when things get hot, they move, sometimes a LOT. Some of these pipes can move upwards of six inches when they heat up. Six inches! With no apparent outside force! To a Civil, this is mind boggling. Anyway, nobody has been taking this into account when they're looking at what is in the way and what isn't. If the insulation is three inches thick and something is five inches from the pipe you'd think it wouldn't be a problem, but if the pipe moves another three inches in that direction, you suddenly have an issue!
Yet another kind of big issue is what if the *thing* that's in that envelope would be damaged by getting hot? Well the people putting all the other stuff in the plant don't always realize just how hot some pipes will get, in their defense they have a lot on their minds. But you have to think, ok my item can handle temperatures up to 300 degrees, this pipe operates at 540 degrees, maybe I don't want to be one inch away from it... So now we have who knows how many notches around things that can't be allowed to get that hot.
If we go back to the moving pipes thing again, heat isn't the only thing that'll cause movements in the plant. It's possible for there to be an earthquake and then stuff will move all over the place. So what happens if something fragile is inside a notch in this insulation and everything starts moving? It's going to get banged up! I'm just a "dirt herder" so I don't know what can handle being smashed up and what can't, and the people who do know, don't think about this stuff.
All of these issues combine into one big nasty world of hurt. Every time I think we've gotten to the end of the problems, another one pops up. I've been really struggling to understand the whole picture because it is all so far outside my realm of experience I feel like everybody is speaking a foreign language half the time. I've been trying to offer suggestions based on my experience and what I see in the field. Some of my suggestions have worked, and unfortunately some of them have made things worse.
The super fun part of all this is I'm not the first person to bring up these issues or ask these questions. There's these two guys who's whole job it is to look at how all the stuff in the plant interacts with all the other stuff. Four years ago they brought up all these questions. They pointed out to management how ugly things could get if it wasn't dealt with soon (this was FOUR years ago!). Management said "Nah, don't worry about it, it's all good." And look where we are now! It just totally boggles my mind that they could be so... nearsighted as to ignore something this big. And because they were shot down so hard, and the implications of these issues are huge, I've been running into a lot of resistance.
Now, some of you may not know this, but I'm really stubborn. When somebody pushes back on me, or tries to brush me off, I lower my head and charge in even harder and deeper than the last time. Most times, when I feel the issue is important (and protecting the people in and around this plant is of utmost importance) I absolutely refuse to back down. Unfortunately I've also never been accused of having any tact. Sometimes the bulldozer method isn't the best, but it's really all I know how to get things done. I'm sure it's shocking that I've made some people somewhat unhappy with me. Lucky for me, I've also impressed some people.
Back to these two guys who have some ungodly number of years of experience at figuring out how all the different things in the plant interact with each other. One of them gave this training class several months ago, basically a crash course on what to look for when installing new items to make sure they wouldn't negatively impact anything else. At the time I had absolutely nothing to do with anything new being installed and I was really irritated at being made to go to this training. Long story short, I acted like a petulant child to him through the whole class and did my best to ignore everything he was saying. Hindsight blah, blah blah right? Anyway, back to when I start actually caring about new stuff being installed and how it interacts with everything else. These two guys actually sit in the same trailer as I do, although they're in a different area. I was working up the courage to go ask them to explain something to me, hoping that the guy who taught the class maybe didn't remember how much of a bitch I had been. So I finally go over there and explain what I'm doing and ask my question and their response totally shocked and confused me.
I expected one of them to respond somewhat negatively and the other to probably be neutral. What I didn't expect was the one to respond negatively was the one I'd never dealt with before, and the one I was bitchy to was actually really nice and friendly towards me! Anyway, over the days and weeks I went back to them more and more as I realized just what a valuable resource they were. I tried to be nothing but polite and respectful to both of them and express my gratitude for their assistance.
Quick aside here, I'm gonna give these guys names so it's easier to explain. The one who taught the class and seemed to get over his first bad experience with me, I'll call Rocky (don't ask, it's not my story to tell). The one who, for no apparent reason, treated me like I was beneath him, I'll call Stuffed Shirt. Anyway, back to the story.
As I pestered them more and more, Rocky and I started being somewhat like friends. While Stuffed Shirt rarely gave me any help without burying it in a lot of really negative opinions and rants and whatnot. I quickly found that he, at least to all appearances, has a REALLY low opinion of Field Engineers. He also seemed to really not like me. After a couple weeks I finally straight up apologized to Rocky for that first day that we met. He kind of laughed and said he had been wondering about that. After that we really did become friends. Since he was able to give me a second chance, I was really confused as to why Stuffed Shirt took such a disliking to me, especially since I couldn't recall ever treating him with less than respect. I know I've run into people who don't like to work with me because I'm young and/or female, but this didn't feel like that. I complained several times to Rocky, since he and Stuffed Shirt seemed to be friends, and asked what I had done to deserve this treatment. Rocky always told me not to take it personally, that Stuffed Shirt was like that to everybody, but I knew there was something else there.
While working on one particular interference issue, I was having trouble getting a handle on the whole situation just looking at the pictures and sketches, so I tried to go out in the plant to look at it. Well, for the first time in my career I found it physically impossible for me to do something. I just flat out couldn't fit in the space to get a look at the situation! And it wasn't my fat getting in the way, (although I know there's more of that than there should be!) I was just plain too big! I was so frustrated and was complaining to somebody in the office, asking if they knew anybody smaller than me that would know what they were looking for when Stuffed Shirt came over and offered to go get more pictures for me (he's a rather slight guy). I hurriedly picked my jaw up off the floor and said I'd really appreciate it. As soon as he left I texted Rocky and was like WTF?! What the heck changed that Stuffed Shirt not only was NICE to me, he actually OFFERED to help without me even asking him to begin with! Well that's when the whole story came out.
Apparently Stuffed Shirt thinks that since I do not meet his ideal of a "professional appearance" he felt I was not worth his time. It wasn't that I'm young or female, it was my piercings, one visible tattoo, and my (fabulous) purple hair. Oh and my clothes (I wear scrub pants and t-shirts ever since the zip-tie incident, I'll explain later). When Rocky told me that, I wanted to cry. This guy didn't even want to give me the time of day because of how I look?! Why does it matter at all what I wear or what color my hair is?! I have a degree from a good school, my Professional Engineer license, and over six years experience as an Engineer. I've had tattoos and piercings the whole time, actually I've acquired more of both in the last six years! Those things have absolutely nothing to do with how well I do my job or how smart I am!
Anyway, the reason Stuffed Shirt suddenly decided to give me a chance is because Rocky asked him to. Which of course made me want to cry for a whole different reason. Here is this guy, who I made a really terrible first impression with, going out of his way to try to change somebody else's opinion of me! I really don't know what I did to deserve such a good friend, but I'm sure glad I have him!
I think that's enough for part two. Maybe I'll still be on a roll and make a part three tomorrow ;)