Tag Archives: batteries

Last Days as a Power Plant Labor Crew Hand

Originally posted December 14, 2012:

I have heard the relationship between Bill Rivers and Sonny Kendrick referred to as the “Punch and Judy Show”. Ok. I thought. Punch and Judy. Sounds like a show from the early 50’s. Must have been a comedy. I thought that for a long time until one day I ran across a brief history of the Punch and Judy Show. It turned out that Punch and Judy was a puppet show from the time of Queen Anne of England. She was queen of England from 1702 to 1714. I could only find a painting of Queen Anne. Didn’t anyone ever think about taking her photograph?

Queen Anne of England

Queen Anne of England

Anyway, once I learned more about Punch and Judy, I realized that this was probably a better description of the Rivers – Sonny relationship than those people realized. It turns out in the first version of the Punch and Judy show, Punch actually strangles his child and beats his wife Judy to death and beats up on other people as well. I suppose that was “entertainment” back then. Now we only have things like “The Terminator”!

Punch and Judy

Punch and Judy Puppet Show

I carpooled with Bill Rivers at this particular time when I was a janitor and while I was on labor crew (except during the summer when I carpooled with my summer help buddies). Each day Bill Rivers would explain about some trick he had played on Sonny that day. The one thing that amazed Bill the most was that every day he could play a joke on Sonny, and each day, Sonny would fall for it.

This reminded me of when I was in Rockbridge High School in Columbia, Missouri and I used to borrow a pencil from my friend Bryan Treacy each day and each day I would chew it up to the point where it was practically useless. I had to come up with different diversionary tactics each day, but somehow I was able to coax a wooden pencil from my friend. Before he would realize what he had done, I had already chewed it up from one end to the next. I liked to think that I was tricking Bryan each day, but I also thought that it was odd that Bryan would have a new pencil every time, and he probably made sure that his mom kept a full stock of pencils just for my enjoyment in eating them (I also wondered if I was getting lead poisoning from all the yellow paint I was ingesting).

Bryan Treacy today is a doctor living in Moore Oklahoma. I would like to drop by his office without seeing him some time just to see if he has any wooden pencils laying about that I could leave all chewed up. I wonder if he would realize I had been there. He might read this blog from time-to-time, so I may have just blown my cover.

I mentioned Bill Rivers and Sonny Kendrick because they were the first two electricians that I worked for before becoming an electrician. I worked on the precipitator while I was on the Labor Crew. See the Post:

Angel of Death Passes by the Precipitator Door

I also mentioned before that I owe my decision to become a Power Plant Electrician to Charles Foster an Electrical B Foreman at the time. I was a janitor and cleaning the electric shop office and lab were part of my duty. How I came to be the janitor of the electric shop is explained further in the post:

Power Plant Spider Wars and Bugs in the Basement

I had found the floor scrubbing machine in ill repair. Charles helped me put it back in running condition. He explained how to take care of the batteries and to keep them properly charged.

We had a Clarke Floor scrubber similar to this one

We had a Clarke Floor scrubber similar to this one

When the electric shop had an opening they tried to recruit me while I was still a janitor, but the Evil Plant Manager had a rule at the time that when you were a janitor, the only place you could go from there was onto the Labor Crew. That was when Mike Rose was hired to become a backup for Jim Stevenson that worked on the air conditioning and freeze protection. I knew about the janitor ruling so I didn’t have my hopes up. Besides, at the time I didn’t have any electrical background.

Charles asked me to take the electrical courses that were offered by the company. The company offered correspondence courses, and in about 3 weeks, I had signed up for them, read the books, and taken the tests. While I was on the labor crew I signed up for a House wiring course at the Vo-Tech. I was taking that course when I learned that Larry Burns was moving from our electric shop to go to another plant. It was then that I applied for the job as a plant electrician.

The main power transformer for Unit 1 had been destroyed by the heat wave that summer (1983) when the plant had tested it’s durability on the hottest day. The unit was offline for a couple of months while GE created a new transformer and shipped it to us.

A Main Power Transformer

A Main Power Transformer

After the main power transformer was destroyed and it took so long to ship in a new one, it was decided that we would keep a spare on hand. That way if it went bad again, we could swap them out quickly. That is probably the best assurance that we wouldn’t lose that transformer again. We had that spare transformer sitting around for years collecting taxes. I’m sure we must have paid for it a few times over again.

During the time that the unit was offline, and we weren’t shaking boiler tubes or cutting the ash out of the economizer tubes, I was working with Bill Rivers and Sonny Kendrick on the precipitator. The precipitator (by the way), is what takes the smoke (ash) out of the exhaust, so you don’t see smoke coming out of the smokestacks.

Bill and Sonny were pretty well sure that I was going to be selected to fill the opening in the Electric Shop, so they were already preparing me to work on the precipitator. Of all the jobs in the electric shop, this one had more to do with electronics than any of the others. That gave “being an electrician” a whole new dimension. I was even looking forward to taking an Electronics course at the Vo-Tech in the spring.

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

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

I was getting updates from Bill and Sonny about the progress of the job opening and they were telling me about the battle that was going on between the Evil Plant Manager and the Electrical Supervisor. Eldon Waugh, the plant manager at the time wanted Charles Peavler to be chosen as the electrician. He had an electrical background, because he had wired his barn once.

The ultimate reason why the plant manager wanted Charles Peavler to be the new electrician was because I had been placed on the blacklist due to the incident that took place earlier that I had described in the post:

Take a Note Jan Said the Manager of Power Production

Thanks to Larry Riley’s performance review, and his purposeful procrastination of the Plant Manager’s request to modify my performance review, and Charles Foster’s insistence that they follow the procedures that were laid out in the new Employee Application Program (known as the EAP), the argument stopped with Charles Foster’s statement: “Let’s just take whoever has the best performance rating as it is laid out in the company policy and leave it at that.” I was chosen to fill the position for the opening in the Electric Shop.

I was actually called to Eldon Waugh’s office while I was sandblasting the Sand Filter Tank. See Post:

Power Plant Safety as Interpreted by Curtis Love

When I arrived in Eldon’s office I was covered from head to toe in sandblast dust. My hair was all disheveled and my shirt was soaked with sweat. Jack Ballard (the head of HR) was sitting there along with Leroy Godfrey and Charles Foster. I knew what it was about because according to Bill Rivers on the way home the day before, they had already decided that they were going to accept me for the position.

Eldon Waugh explained that I was being offered the job that I had applied for in the electric shop. I felt really humbled at the time. Even though I was expecting it, I felt surprised that it was actually happening. To me, being an electrician was like the greatest job in the world. The electricians were like an elite team of super heroes.

I had the occasion to watch the electricians while I was a janitor in their shop and many of them were like these super intelligent beings that could quickly look at a blueprint and grab their tool bucket and head out to fix the world. I was very grateful for the opportunity, and at the same time apprehensive. I wasn’t sure if I had the quality of character and intelligence to become a part of this team. This was truly a dream come true for me.

Few times in my life has this happened to me. The day I was married. The day I became a Father. The day I drove to Dell to begin my first day as a Programmer Analyst. These were all major milestones in my life. The first major milestone was the day I became an electrician. Because of the way that I am (I don’t know…. maybe it’s because I’m half Italian), I just wanted to break out in tears and hug Eldon Waugh and cry on his shoulder. Instead, I just managed to crack a small smile.

I thanked them and started to leave. Then Jack Ballard said something interesting. As I was leaving he asked, “Uh…. Do you accept the offer?” Oh. In my surprise and elation, I hadn’t said anything but “Thank You”. Jack’s expression was that it wasn’t official until it was official. So, I replied, “Yes. I accept the offer”. “Ok then,” Jack replied. And I left to go crawl back in my hole and continue sandblasting the Sand Filter tank.

My last day on the Labor Crew was on November 4, 1983. I was leaving my Labor Crew Family behind and moving onto a new life in the electric shop. This was hard for me because I really did consider most of the people on the Labor Crew as family. Fred Crocker, Ron Luckey, Jim Kanelakos, and Ronnie Banks. Curtis Love and Chuck Moreland. Doretta Funkhouser and Charles Peavler. Jody Morse and Bob Lillibridge.

Most of all, I knew I was going to miss Larry Riley. I had worked with Larry from the day I had first arrived as a summer help in 1979. Now it was November, 1983. Larry was a hero to me. I love him dearly and if I had ever had an older brother I would have liked someone with the character and strength of Larry Riley. He remains in my prayers to this day.

Larry Riley 20 years after I first met him. He has a much newer hardhat in this picture

Larry Riley 20 years after I first met him

The last day on the labor crew I suspected foul play. Mainly because the last day that Bill Cook was on the Labor Crew, he had asked us if we would throw Larry in the intake as a going away gift. I had worked with Bill when we were summer help together and I felt like I owed him one, so I told him I would help.

As we were driving from the Coalyard Maintenance building (the home of the labor crew) to the plant maintenance shop that day, Bill Cook, who was driving, suddenly turned toward the intake pumps and stopped the truck. By the time Larry had figured out what was going on, we had dragged Larry out of the truck and I was carrying him over to the Intake and getting ready to throw him in.

Larry had worked with me long enough to know that once I had set my mind on something, there was no turning back. He had tried to escape from my grip, but I had him where he couldn’t escape. As I climbed with him over the guard rail and headed toward the edge of the water, Larry said the only possible thing that could make me stop in my tracks. He said, “Please Kevin. Don’t do this.”

I was paralyzed. Stuck between my word with Bill Cook that I would help him throw Larry in the brink, and a plea from someone who meant the world to me. There wasn’t but one choice to make. I set Larry down. I walked back to the truck and I told Bill, “I’m sorry. I can’t do it.” I returned to my seat in the back of the crew cab. Without my help, no one else had the resolve and strength to follow through with Bill’s wish. We drove on to the Maintenance Shop.

So, on my last day on the Labor Crew, I thought that something similar might be planned for me. As soon as we left to go to work that morning, I headed up Belt 10 and 11. That is the long belt on the left side of the power Plant picture on the upper right side of this post…. Ok. I’ll post it here:

Power Plant view when looking through the wrong end of the binoculars

The long belts run from the coalyard to the plant. Oh. And this is the intake. Just across from here is where I was going to toss Larry in the lake

Once up 10 & 11 and 12 & 13, I was in the Surge bin tower. (The Surge Bin Tower is the white building you can see between the two boilers near the top that has the conveyor belt entering it from the left). From there, I roamed around looking for some coal to clean up. I figured I would stay far away from my labor crew buddies that day.

At the end of the day, I traveled back down belts 10 & 11 and headed into the office in the Coalyard Maintenance building to fill out my last timecard as a Laborer. Beginning next Monday on November 7, I would be an “Electrician.” Along with the empty feeling at the bottom of my heart was a feeling of excitement for the new adventure that awaited me.

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Importance of Power Plant Backup Battery Preventative Maintenance

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

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

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

An emergency light

An emergency light

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

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

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

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

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

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

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

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

A battery used in a large dozer

A battery used in a large dozer

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Back to the Station Batteries:

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

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

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

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

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

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

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

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

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

Last Days as a Power Plant Labor Crew Hand

Originally posted December 14, 2012:

I have heard the relationship between Bill Rivers and Sonny Kendrick referred to as the “Punch and Judy Show”. Ok. I thought. Punch and Judy. Sounds like a show from the early 50’s. Must have been a comedy. I thought that for a long time until one day I ran across a brief history of the Punch and Judy Show. It turned out that Punch and Judy was a puppet show from the time of Queen Anne of England. She was queen of England from 1702 to 1714. I could only find a painting of Queen Anne. Didn’t anyone ever think about taking her photograph?

Queen Anne of England

Queen Anne of England

Anyway, once I learned more about Punch and Judy, I realized that this was probably a better description of the Rivers – Sonny relationship than those people realized. It turns out in the first version of the Punch and Judy show, Punch actually strangles his child and beats his wife Judy to death and beats up on other people as well. I suppose that was “entertainment” back then. Now we only have things like “The Terminator”!

Punch and Judy

Punch and Judy Puppet Show

I carpooled with Bill Rivers at this particular time when I was a janitor and while I was on labor crew (except during the summer when I carpooled with my summer help buddies). Each day Bill Rivers would explain about some trick he had played on Sonny that day. The one thing that amazed Bill the most was that every day he could play a joke on Sonny, and each day, Sonny would fall for it.

This reminded me of when I was in Rockbridge High School in Columbia, Missouri and I used to borrow a pencil from my friend Bryan Treacy each day and each day I would chew it up to the point where it was practically useless. I had to come up with different diversionary tactics each day, but somehow I was able to coax a wooden pencil from my friend. Before he would realize what he had done, I had already chewed it up from one end to the next. I liked to think that I was tricking Bryan each day, but I also thought that it was odd that Bryan would have a new pencil every time, and he probably made sure that his mom kept a full stock of pencils just for my enjoyment in eating them (I also wondered if I was getting lead poisoning from all the yellow paint I was ingesting).

Bryan Treacy today is a doctor living in Moore Oklahoma. I would like to drop by his office without seeing him some time just to see if he has any wooden pencils laying about that I could leave all chewed up. I wonder if he would realize I had been there. He might read this blog from time-to-time, so I may have just blown my cover.

I mentioned Bill Rivers and Sonny Kendrick because they were the first two electricians that I worked for before becoming an electrician. I worked on the precipitator while I was on the Labor Crew. See the Post:

Angel of Death Passes by the Precipitator Door

I also mentioned before that I owe my decision to become a Power Plant Electrician to Charles Foster an Electrical B Foreman at the time. I was a janitor and cleaning the electric shop office and lab were part of my duty. How I came to be the janitor of the electric shop is explained further in the post:

Power Plant Spider Wars and Bugs in the Basement

I had found the floor scrubbing machine in ill repair. Charles helped me put it back in running condition. He explained how to take care of the batteries and to keep them properly charged.

We had a Clarke Floor scrubber similar to this one

We had a Clarke Floor scrubber similar to this one

When the electric shop had an opening they tried to recruit me while I was still a janitor, but the Evil Plant Manager had a rule at the time that when you were a janitor, the only place you could go from there was onto the Labor Crew. That was when Mike Rose was hired to become a backup for Jim Stevenson that worked on the air conditioning and freeze protection. I knew about the janitor ruling so I didn’t have my hopes up. Besides, at the time I didn’t have any electrical background.

Charles asked me to take the electrical courses that were offered by the company. The company offered correspondence courses, and in about 3 weeks, I had signed up for them, read the books, and taken the tests. While I was on the labor crew I signed up for a House wiring course at the Vo-Tech. I was taking that course when I learned that Larry Burns was moving from our electric shop to go to another plant. It was then that I applied for the job as a plant electrician.

The main power transformer for Unit 1 had been destroyed by the heat wave that summer (1983) when the plant had tested it’s durability on the hottest day. The unit was offline for a couple of months while GE created a new transformer and shipped it to us.

A Main Power Transformer

A Main Power Transformer

After the main power transformer was destroyed and it took so long to ship in a new one, it was decided that we would keep a spare on hand. That way if it went bad again, we could swap them out quickly. That is probably the best assurance that we wouldn’t lose that transformer again. We had that spare transformer sitting around for years collecting taxes. I’m sure we must have paid for it a few times over again.

During the time that the unit was offline, and we weren’t shaking boiler tubes or cutting the ash out of the economizer tubes, I was working with Bill Rivers and Sonny Kendrick on the precipitator. The precipitator (by the way), is what takes the smoke (ash) out of the exhaust, so you don’t see smoke coming out of the smokestacks.

Bill and Sonny were pretty well sure that I was going to be selected to fill the opening in the Electric Shop, so they were already preparing me to work on the precipitator. Of all the jobs in the electric shop, this one had more to do with electronics than any of the others. That gave “being an electrician” a whole new dimension. I was even looking forward to taking an Electronics course at the Vo-Tech in the spring.

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

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

I was getting updates from Bill and Sonny about the progress of the job opening and they were telling me about the battle that was going on between the Evil Plant Manager and the Electrical Supervisor. Eldon Waugh, the plant manager at the time wanted Charles Peavler to be chosen as the electrician. He had an electrical background, because he had wired his barn once.

The ultimate reason why the plant manager wanted Charles Peavler to be the new electrician was because I had been placed on the blacklist due to the incident that took place earlier that I had described in the post:

Take a Note Jan Said the Manager of Power Production

Thanks to Larry Riley’s performance review, and his purposeful procrastination of the Plant Manager’s request to modify my performance review, and Charles Foster’s insistence that they follow the procedures that were laid out in the new Employee Application Program (known as the EAP), the argument stopped with Charles Foster’s statement: “Let’s just take whoever has the best performance rating as it is laid out in the company policy and leave it at that.” I was chosen to fill the position for the opening in the Electric Shop.

I was actually called to Eldon Waugh’s office while I was sandblasting the Sand Filter Tank. See Post:

Power Plant Safety as Interpreted by Curtis Love

When I arrived in Eldon’s office I was covered from head to toe in sandblast dust. My hair was all disheveled and my shirt was soaked with sweat. Jack Ballard (the head of HR) was sitting there along with Leroy Godfrey and Charles Foster. I knew what it was about because according to Bill Rivers on the way home the day before, they had already decided that they were going to accept me for the position.

Eldon Waugh explained that I was being offered the job that I had applied for in the electric shop. I felt really humbled at the time. Even though I was expecting it, I felt surprised that it was actually happening. To me, being an electrician was like the greatest job in the world. The electricians were like an elite team of super heroes.

I had the occasion to watch the electricians while I was a janitor in their shop and many of them were like these super intelligent beings that could quickly look at a blueprint and grab their tool bucket and head out to fix the world. I was very grateful for the opportunity, and at the same time apprehensive. I wasn’t sure if I had the quality of character and intelligence to become a part of this team. This was truly a dream come true for me.

Few times in my life has this happened to me. The day I was married. The day I became a Father. The day I drove to Dell to begin my first day as a Programmer Analyst. These were all major milestones in my life. The first major milestone was the day I became an electrician. Because of the way that I am (I don’t know…. maybe it’s because I’m half Italian), I just wanted to break out in tears and hug Eldon Waugh and cry on his shoulder. Instead, I just managed to crack a small smile.

I thanked them and started to leave. Then Jack Ballard said something interesting. As I was leaving he asked, “Uh…. Do you accept the offer?” Oh. In my surprise and elation, I hadn’t said anything but “Thank You”. Jack’s expression was that it wasn’t official until it was official. So, I replied, “Yes. I accept the offer”. “Ok then,” Jack replied. And I left to go crawl back in my hole and continue sandblasting the Sand Filter tank.

My last day on the Labor Crew was on November 4, 1983. I was leaving my Labor Crew Family behind and moving onto a new life in the electric shop. This was hard for me because I really did consider most of the people on the Labor Crew as family. Fred Crocker, Ron Luckey, Jim Kanelakos, and Ronnie Banks. Curtis Love and Chuck Moreland. Doretta Funkhouser and Charles Peavler. Jody Morse and Bob Lillibridge.

Most of all, I knew I was going to miss Larry Riley. I had worked with Larry from the day I had first arrived as a summer help in 1979. Now it was November, 1983. Larry was a hero to me. I love him dearly and if I had ever had an older brother I would have liked someone with the character and strength of Larry Riley. He remains in my prayers to this day.

Larry Riley 20 years after I first met him.  He has a much newer hardhat in this picture

Larry Riley 20 years after I first met him

The last day on the labor crew I suspected foul play. Mainly because the last day that Bill Cook was on the Labor Crew, he had asked us if we would throw Larry in the intake as a going away gift. I had worked with Bill when we were summer help together and I felt like I owed him one, so I told him I would help.

As we were driving from the Coalyard Maintenance building (the home of the labor crew) to the plant maintenance shop that day, Bill Cook, who was driving, suddenly turned toward the intake pumps and stopped the truck. By the time Larry had figured out what was going on, we had dragged Larry out of the truck and I was carrying him over to the Intake and getting ready to throw him in.

Larry had worked with me long enough to know that once I had set my mind on something, there was no turning back. He had tried to escape from my grip, but I had him where he couldn’t escape. As I climbed with him over the guard rail and headed toward the edge of the water, Larry said the only possible thing that could make me stop in my tracks. He said, “Please Kevin. Don’t do this.”

I was paralyzed. Stuck between my word with Bill Cook that I would help him throw Larry in the brink, and a plea from someone who meant the world to me. There wasn’t but one choice to make. I set Larry down. I walked back to the truck and I told Bill, “I’m sorry. I can’t do it.” I returned to my seat in the back of the crew cab. Without my help, no one else had the resolve and strength to follow through with Bill’s wish. We drove on to the Maintenance Shop.

So, on my last day on the Labor Crew, I thought that something similar might be planned for me. As soon as we left to go to work that morning, I headed up Belt 10 and 11. That is the long belt on the left side of the power Plant picture on the upper right side of this post…. Ok. I’ll post it here:

Power Plant view when looking through the wrong end of the binoculars

The long belts run from the coalyard to the plant. Oh. And this is the intake. Just across from here is where I was going to toss Larry in the lake

Once up 10 & 11 and 12 & 13, I was in the Surge bin tower. (The Surge Bin Tower is the white building you can see between the two boilers near the top that has the conveyor belt entering it from the left). From there, I roamed around looking for some coal to clean up. I figured I would stay far away from my labor crew buddies that day.

At the end of the day, I travelled back down belts 10 & 11 and headed into the office in the Coalyard Maintenance building to fill out my last timecard as a Laborer. Beginning next Monday on November 7, I would be an “Electrician.” Along with the empty feeling at the bottom of my heart was a feeling of excitement for the new adventure that awaited me.

Importance of Power Plant Backup Battery Preventative Maintenance

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

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

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

An emergency light

An emergency light

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

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

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

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

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

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

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

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

A battery used in a large dozer

A battery used in a large dozer

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Back to the Station Batteries:

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

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

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

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

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

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

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

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

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

Last Days as a Power Plant Labor Crew Hand — Repost

Originally posted December 14, 2012:

I have heard the relationship between Bill Rivers and Sonny Kendrick referred to as the “Punch and Judy Show”. Ok. I thought. Punch and Judy. Sounds like a show from the early 50’s. Must have been a comedy. I thought that for a long time until one day I ran across a brief history of the Punch and Judy Show. It turned out that Punch and Judy was a puppet show from the time of Queen Anne of England. She was queen of England from 1702 to 1714. I could only find a painting of Queen Anne. Didn’t anyone ever think about taking her photograph?

Queen Anne of England

Queen Anne of England

Anyway, once I learned more about Punch and Judy, I realized that this was probably a better description of the Rivers – Sonny relationship than those people realized. It turns out in the first version of the Punch and Judy show, Punch actually strangles his child and beats his wife Judy to death and beats up on other people as well. I suppose that was “entertainment” back then. Now we only have things like “The Terminator”!

Punch and Judy

Punch and Judy Puppet Show

I carpooled with Bill Rivers at this particular time when I was a janitor and while I was on labor crew (except during the summer when I carpooled with my summer help buddies). Each day Bill Rivers would explain about some trick he had played on Sonny that day. The one thing that amazed Bill the most was that every day he could play a joke on Sonny, and each day, Sonny would fall for it.

This reminded me of when I was in Rockbridge High School in Columbia, Missouri and I used to borrow a pencil from my friend Bryan Treacy each day and each day I would chew it up to the point where it was practically useless. I had to come up with different diversionary tactics each day, but somehow I was able to coax a wooden pencil from my friend. Before he would realize what he had done, I had already chewed it up from one end to the next. I liked to think that I was tricking Bryan each day, but I also thought that it was odd that Bryan would have a new pencil every time, and he probably made sure that his mom kept a full stock of pencils just for my enjoyment in eating them (I also wondered if I was getting lead poisoning from all the yellow paint I was ingesting).

Bryan Treacy today is a doctor living in Moore Oklahoma. I would like to drop by his office without seeing him some time just to see if he has any wooden pencils laying about that I could leave all chewed up. I wonder if he would realize I had been there. He might read this blog from time-to-time, so I may have just blown my cover.

I mentioned Bill Rivers and Sonny Kendrick because they were the first two electricians that I worked for before becoming an electrician. I worked on the precipitator while I was on the Labor Crew. See the Post:

Angel of Death Passes by the Precipitator Door (or almost dying twice in one day

I also mentioned before that I owe my decision to become a Power Plant Electrician to Charles Foster an Electrical B Foreman at the time. I was a janitor and cleaning the electric shop office and lab were part of my duty. How I came to be the janitor of the electric shop is explained further in the post:

Power Plant Spider Wars and Bugs in the Basement

I had found the floor scrubbing machine in ill repair. Charles helped me put it back in running condition. He explained how to take care of the batteries and to keep them properly charged.

We had a Clarke Floor scrubber similar to this one

We had a Clarke Floor scrubber similar to this one

When the electric shop had an opening they tried to recruit me while I was still a janitor, but the Evil Plant Manager had a rule at the time that when you were a janitor, the only place you could go from there was onto the Labor Crew. That was when Mike Rose was hired to become a backup for Jim Stevenson that worked on the air conditioning and freeze protection. I knew about the janitor ruling so I didn’t have my hopes up. Besides, at the time I didn’t have any electrical background.

Charles asked me to take the electrical courses that were offered by the company. The company offered correspondence courses, and in about 3 weeks, I had signed up for them, read the books, and taken the tests. While I was on the labor crew I signed up for a House wiring course at the Vo-Tech. I was taking that course when I learned that Larry Burns was moving from our electric shop to go to another plant. It was then that I applied for the job as a plant electrician.

The main power transformer for Unit 1 had been destroyed by the heat wave that summer (1983) when the plant had tested it’s durability on the hottest day. The unit was offline for a couple of months while GE created a new transformer and shipped it to us.

A Main Power Transformer

A Main Power Transformer

After the main power transformer was destroyed and it took so long to ship in a new one, it was decided that we would keep a spare on hand. That way if it went bad again, we could swap them out quickly. That is probably the best assurance that we wouldn’t lose that transformer again. We had that spare transformer sitting around for years collecting taxes. I’m sure we must have paid for it a few times over again.

During the time that the unit was offline, and we weren’t shaking boiler tubes or cutting the ash out of the economizer tubes, I was working with Bill Rivers and Sonny Kendrick on the precipitator. The precipitator (by the way), is what takes the smoke (ash) out of the exhaust, so you don’t see smoke coming out of the smokestacks.

Bill and Sonny were pretty well sure that I was going to be selected to fill the opening in the Electric Shop, so they were already preparing me to work on the precipitator. Of all the jobs in the electric shop, this one had more to do with electronics than any of the others. That gave “being an electrician” a whole new dimension. I was even looking forward to taking an Electronics course at the Vo-Tech in the spring.

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

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

I was getting updates from Bill and Sonny about the progress of the job opening and they were telling me about the battle that was going on between the Evil Plant Manager and the Electrical Supervisor. Eldon Waugh, the plant manager at the time wanted Charles Peavler to be chosen as the electrician. He had an electrical background, because he had wired his barn once.

The ultimate reason why the plant manager wanted Charles Peavler to be the new electrician was because I had been placed on the blacklist due to the incident that took place earlier that I had described in the post:

Take a Note Jan Said the Manager of Power Production

Thanks to Larry Riley’s performance review, and his purposeful procrastination of the Plant Manager’s request to modify my performance review, and Charles Foster’s insistence that they follow the procedures that were laid out in the new Employee Application Program (known as the EAP), the argument stopped with Charles Foster’s statement: “Let’s just take whoever has the best performance rating as it is laid out in the company policy and leave it at that.” I was chosen to fill the position for the opening in the Electric Shop.

I was actually called to Eldon Waugh’s office while I was sandblasting the Sand Filter Tank. See Post:

Power Plant Safety as Interpreted by Curtis Love

When I arrived in Eldon’s office I was covered from head to toe in sandblast dust. My hair was all disheveled and my shirt was soaked with sweat. Jack Ballard (the head of HR) was sitting there along with Leroy Godfrey and Charles Foster. I knew what it was about because according to Bill Rivers on the way home the day before, they had already decided that they were going to accept me for the position.

Eldon Waugh explained that I was being offered the job that I had applied for in the electric shop. I felt really humbled at the time. Even though I was expecting it, I felt surprised that it was actually happening. To me, being an electrician was like the greatest job in the world. The electricians were like an elite team of super heroes.

I had the occasion to watch them while I was a janitor in their shop and many of them were like these super intelligent beings that could quickly look at a blueprint and grab their tool bucket and head out to fix the world. I was very grateful for the opportunity, and at the same time apprehensive. I wasn’t sure if I had the quality of character and intelligence to become a part of this team. This was truly a dream come true for me.

Few times in my life has this happened to me. The day I was married. The day I became a Father. The day I drove to Dell to begin my first day as a Programmer Analyst. These were all major milestones in my life. The first major milestone was the day I became an electrician. Because of the way that I am (I don’t know…. maybe it’s because I’m half Italian), I just wanted to break out in tears and hug Eldon Waugh and cry on his shoulder. Instead, I just managed to crack a small smile.

I thanked them and started to leave. Then Jack Ballard said something interesting. As I was leaving he asked, “Uh…. Do you accept the offer?” Oh. In my surprise and elation, I hadn’t said anything but “Thank You”. Jack’s expression was that it wasn’t official until it was official. So, I replied, “Yes. I accept the offer”. “Ok then,” Jack replied. And I left to go crawl back in my hole and continue sandblasting the Sand Filter tank.

My last day on the Labor Crew was on November 4, 1983. I was leaving my Labor Crew Family behind and moving onto a new life in the electric shop. This was hard for me because I really did consider most of the people on the Labor Crew as family. Fred Crocker, Ron Luckey, Jim Kanelakos, and Ronnie Banks. Curtis Love and Chuck Moreland. Doretta Funkhouser and Charles Peavler. Jody Morse and Bob Lillibridge.

Most of all, I knew I was going to miss Larry Riley. I had worked with Larry from the day I had first arrived as a summer help in 1979. Now it was November, 1983. Larry was a hero to me. I love him dearly and if I had ever had an older brother I would have liked someone with the character and strength of Larry Riley. He remains in my prayers to this day.

The last day on the labor crew I suspected foul play. Mainly because the last day that Bill Cook was on the Labor Crew, he had asked us if we would throw Larry in the intake as a going away gift. I had worked with Bill when we were summer help together and I felt like I owed him one, so I told him I would help.

As we were driving from the Coalyard Maintenance building (the home of the labor crew) to the plant maintenance shop that day, Bill Cook, who was driving, suddenly turned toward the intake pumps and stopped the truck. By the time Larry had figured out what was going on, we had dragged him out of the truck and I was carrying him over to the Intake and getting ready to throw him in.

Larry had worked with me long enough to know that once I had set my mind on something, there was no turning back. He had tried to escape from my grip, but I had him where he couldn’t escape. As I climbed with him over the guard rail and headed toward the edge of the water, Larry said the only possible thing that could make me stop in my tracks. He said, “Please Kevin. Don’t do this.”

I was paralyzed. Stuck between my word with Bill Cook that I would help him throw Larry in the brink, and a plea from someone who meant the world to me. There wasn’t but one choice to make. I set Larry down. I walked back to the truck and I told Bill, “I’m sorry. I can’t do it.” I returned to my seat in the back of the crew cab. Without my help, no one else had the resolve and strength to follow through with Bill’s wish. We drove on to the Maintenance Shop.

So, on my last day on the Labor Crew, I thought that something similar might be planned for me. As soon as we left to go to work that morning, I headed up Belt 10 and 11. That is the long belt on the left side of the power Plant picture on the upper right side of this post…. Ok. I’ll post it here:

Power Plant view when looking through the wrong end of the binoculars

The long belts run from the coalyard to the plant. Oh. And this is the intake. Just across from here is where I was going to toss Larry in the lake

Once up 10 & 11 and 12 & 13, I was in the Surge bin tower. (The Surge Bin Tower is the white building you can see between the two boilers near the top that has the conveyor belt entering it from the left). From there, I roamed around looking for some coal to clean up. I figured I would stay far away from my labor crew buddies that day.

At the end of the day, I travelled back down belts 10 & 11 and headed into the office in the Coalyard Maintenance building to fill out my last timecard as a Laborer. Beginning next Monday on November 7, I would be an “Electrician.” Along with the empty feeling at the bottom of my heart was a feeling of excitement for the new adventure that awaited me.

Importance of Power Plant Backup Battery Preventative Maintenance — Repost

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

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

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

An emergency light

An emergency light

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

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

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

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

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

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

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

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

A battery used in a large dozer

A battery used in a large dozer

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Back to the Station Batteries:

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

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

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

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

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

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

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

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

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

Last Days as a Power Plant Labor Crew Hand — Repost

Originally posted December 14, 2012:

I have heard the relationship between Bill Rivers and Sonny Kendrick referred to as the “Punch and Judy Show”.  Ok.  I thought.  Punch and Judy.  Sounds like a show from the early 50’s.  Must have been a comedy.  I thought that for a long time until one day I ran across a brief history of the Punch and Judy Show.  It turned out that Punch and Judy was a puppet show from the time of Queen Anne of England.  She was queen of England from 1702 to 1714.  I could only find a painting of Queen Anne.  Didn’t anyone ever think about taking her photograph?

Queen Anne of England

Queen Anne of England

Anyway, once I learned more about Punch and Judy, I realized that this was probably a better description of the Rivers – Sonny relationship than those people realized.  It turns out in the first version of the Punch and Judy show, Punch actually strangles his child and beats his wife Judy to death and beats up on other people as well.  I suppose that was “entertainment” back then.  Now we only have things like “The Terminator”!

Punch and Judy

Punch and Judy Puppet Show

I carpooled with Bill Rivers at this particular time when I was a janitor and while I was on labor crew (except during the summer when I carpooled with my summer help buddies).  Each day Bill Rivers would explain about some trick he had played on Sonny that day.  The one thing that amazed Bill the most was that every day he could play a joke on Sonny, and each day, Sonny would fall for it.

This reminded me of when I was in Rockbridge High School in Columbia, Missouri and I used to borrow a pencil from my friend Bryan Treacy each day and each day I would chew it up to the point where it was practically useless.  I had to come up with different diversionary tactics each day, but somehow I was able to coax a wooden pencil from my friend.  Before he would realize what he had done, I had already chewed it up from one end to the next.  I liked to think that I was tricking Bryan each day, but I also thought that it was odd that Bryan would have  a new pencil every time, and he probably made sure that his mom kept a full stock of pencils just for my enjoyment in eating them.

Bryan Treacy today is a doctor living in Moore Oklahoma.  I would like to drop by his office without seeing him some time just to see if  he has any wooden pencils laying about that I could leave all chewed up.  I wonder if he would realize I had been there.  He might read this blog from time-to-time, so I may have just blown my cover.

I mentioned Bill Rivers and Sonny Kendrick because they were the first two electricians that I worked for before becoming an electrician.  I worked on the precipitator while I was on the Labor Crew.  See the Post:

Angel of Death Passes by the Precipitator Door (or almost dying twice in one day

I also mentioned before that I owe my decision to become a Power Plant Electrician to Charles Foster an Electrical B Foreman at the time.  I was a janitor and cleaning the electric shop office and lab were part of my duty.  How I came to be the janitor of the electric shop is explained further in the post:

Power Plant Spider Wars and Bugs in the Basement

I had found the floor scrubbing machine in ill repair.  Charles helped me put it back in running condition.  He explained how to take care of the batteries and to keep them properly charged.

We had a Clarke Floor scrubber similar to this one

We had a Clarke Floor scrubber similar to this one

When the electric shop had an opening they tried to recruit me while I was still a janitor, but the Evil Plant Manager had a rule at the time that when you were a janitor, the only place you could go from there was onto the Labor Crew.  That was when Mike Rose was hired to become a backup for Jim Stevenson that worked on the air conditioning and freeze protection.  I knew about the janitor ruling so I didn’t have my hopes up.  Besides,  at the time I didn’t have any electrical background.

Charles asked me to take the electrical courses that were offered by the company.  The company offered correspondence courses, and in about 3 weeks, I had signed up for them, read the books, and taken the tests.  While I was on the labor crew I signed up for a House wiring course at the Vo-Tech.  I was taking that course when I learned that Larry Burns was moving from our electric shop to go to another plant.  It was then that I applied for the job as a plant electrician.

The main power transformer for Unit 1 had been destroyed by the heat wave that summer (1983) when the plant had tested it’s durability on the hottest day.  The unit was offline for a couple of months while GE created a new transformer and shipped it to us.

A Main Power Transformer

A Main Power Transformer

After the main power transformer was destroyed and it took so long to ship in a new one, it was decided that we would keep a spare on hand.  That way if it went bad again, we could swap them out quickly.  That is probably the best assurance that we wouldn’t lose that transformer again.  We had that spare transformer sitting around for years collecting taxes.  I’m sure we must have paid for it a few times over again.

During the time that the unit was offline, and we weren’t shaking boiler tubes or cutting the ash out of the economizer tubes, I was working with Bill Rivers and Sonny Kendrick on the precipitator.  The precipitator (by the way), is what takes the smoke (ash) out of the exhaust, so you don’t see smoke coming out of the smokestacks.

Bill and Sonny were pretty well sure that I was going to be selected to fill the opening in the Electric Shop, so they were already preparing me to work on the precipitator.  Of all the jobs in the electric shop, this one had more to do with electronics than any of the others.  That gave “being an electrician” a whole new dimension.  I was even looking forward to taking an Electronics course at the Vo-Tech in the spring.

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

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

I was getting updates from Bill and Sonny about the progress of the job opening and they were telling me about the battle that was going on between the Evil Plant Manager and the Electrical Supervisor.  Eldon Waugh, the plant manager at the time wanted Charles Peavler to be chosen as the electrician.  He had an electrical background, because he had wired his barn once.

The ultimate reason why the plant manager wanted Charles Peavler to be the new electrician was because I had been placed on the blacklist due to the incident that took place earlier that I had described in the post:

Take a Note Jan Said the Manager of Power Production

Thanks to Larry Riley’s performance review, and his purposeful procrastination of the Plant Manager’s request to modify my performance review, and Charles Foster’s insistence that they follow the procedures that were laid out in the new Employee Application Program (known as the EAP), the argument stopped with Charles Foster’s statement:  “Let’s just take whoever has the best performance rating as it is laid out in the company policy and leave it at that.”  I was chosen to fill the position for the opening in the Electric Shop.

I was actually called to Eldon Waugh’s office while I was sandblasting the Sand Filter Tank.  See Post:

Power Plant Safety as Interpreted by Curtis Love

When I arrived in Eldon’s office I was covered from head to toe in sandblast dust.  My hair was all disheveled and my shirt was soaked with sweat.  Jack Ballard (the head of HR) was sitting there along with Leroy Godfrey and Charles Foster.  I knew what it was about because according to Bill Rivers on the way home the day before, they had already decided that they were going to accept me for the position.

Eldon Waugh explained that I was being offered the job that I had applied for in the electric shop.  I felt really humbled at the time.  Even though I was expecting it, I felt surprised that it was actually happening.  To me, being an electrician was like the greatest job in the world.  The electricians were like an elite team of super heroes.

I had the occasion to watch them while I was a janitor in their shop and many of them were like these super intelligent beings that could quickly look at a blueprint and grab their tool bucket and head out to fix the world.  I was very grateful for the opportunity, and at the same time apprehensive.  I wasn’t sure if I had the quality of character and intelligence to become a part of this team.  This was truly a dream come true for me.

Few times in my life has this happened to me.  The day I was married.  The day I became a Father.  The day I drove to Dell to begin my first day as a Programmer Analyst.  These were all major milestones in my life.  The first major milestone was the day I became an electrician.  Because of the way that I am (I don’t know…. maybe it’s because I’m half Italian), I just wanted to break out in tears and hug Eldon Waugh and cry on his shoulder. Instead, I just managed to crack a small smile.

I thanked them and started to leave.  Then Jack Ballard said something interesting.  As I was leaving he asked, “Uh…. Do you accept the offer?”  Oh.  In my surprise and elation, I hadn’t said anything but “Thank You”.  Jack’s expression was that it wasn’t official until it was official.  So, I replied, “Yes.  I accept the offer”.  “Ok then,” Jack replied.  And I left to go crawl back in my hole and continue sandblasting the Sand Filter tank.

My last day on the Labor Crew was on November 4, 1983.  I was leaving my Labor Crew Family behind and moving onto a new life in the electric shop.  This was hard for me because I really did consider most of the people on the Labor Crew as family.  Fred Crocker, Ron Luckey, Jim Kanelakos, and Ronnie Banks.  Curtis Love and Chuck Moreland.  Doretta Funkhouser and Charles Peavler.  Jody Morse and Bob Lillibridge.

Most of all, I knew I was going to miss Larry Riley.  I had worked with Larry from the day I had first arrived as a summer help in 1979.  Now it was November, 1983.  Larry was a hero to me.  I love him dearly and if I had ever had an older brother I would have liked someone with the character and strength of Larry Riley.  He remains in my prayers to this day.

The last day on the labor crew I suspected foul play.  Mainly because the last day that Bill Cook was on the Labor Crew, he had asked us if we would throw Larry in the intake as a going away gift.  I had worked with Bill when we were summer help together and I felt like I owed him one, so I told him I would help.

As we were driving from the Coalyard Maintenance building (the home of the labor crew) to the plant maintenance shop that day, Bill Cook, who was driving, suddenly turned toward the intake pumps and stopped the truck.  By the time Larry had figured out what was going on, we had dragged him out of the truck and I was carrying him over to the Intake and getting ready to throw him in.

Larry had worked with me long enough to know that once I had set my mind on something, there was no turning back.  He had tried to escape from my grip, but I had him where he couldn’t escape.  As I climbed with him over the guard rail and headed toward the edge of the water, Larry said the only possible thing that could make me stop in my tracks.  He said, “Please Kevin.  Don’t do this.”

I was paralyzed.  Stuck between my word with Bill Cook that I would help him throw Larry in the brink, and a plea from someone who meant the world to me.  There wasn’t but one choice to make.  I set Larry down.  I walked back to the truck and I told Bill, “I’m sorry.  I can’t do it.”  I returned to my seat in the back of the crew cab.  Without my help, no one else had the resolve and strength to follow through with Bill’s wish.  We drove on to the Maintenance Shop.

So, on my last day on the Labor Crew, I thought that something similar might be planned for me.  As soon as we left to go to work that morning, I headed up Belt 10 and 11.  That is the long belt on the left side of the power Plant picture on the upper right side of this post…. Ok.  I’ll post it here:

Power Plant view when looking through the wrong end of the binoculars

The long belts run from the coalyard to the plant.  Oh.  And this is the intake.  Just across from here is where I was going to toss Larry in the lake

Once up 10 & 11 and 12 & 13, I was in the Surge bin tower.  (The Surge Bin Tower is the white building you can see between the two boilers near the top that has the conveyor belt entering it from the left).  From there, I roamed around looking for some coal to clean up.  I figured I would stay far away from my labor crew buddies that day.

At the end of the day, I travelled back down belts 10 & 11 and headed into the office in the Coalyard Maintenance building to fill out my last timecard as a Laborer.  Beginning next Monday on November 7, I would be an “Electrician.”  Along with the empty feeling at the bottom of my heart was a feeling of excitement for the new adventure that awaited me.

Importance of Power Plant Backup Battery Preventative Maintenance

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

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

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

An emergency light

An emergency light

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

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

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

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

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

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

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

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

A battery used in a large dozer

A battery used in a large dozer

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Back to the Station Batteries:

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

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

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

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

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

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

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

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

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

Last Days as a Power Plant Labor Crew Hand

I have heard the relationship between Bill Rivers and Sonny Kendrick referred to as the “Punch and Judy Show”.  Ok.  I thought.  Punch and Judy.  Sounds like a show from the early 50’s.  Must have been a comedy.  I thought that for a long time until one day I ran across a brief history of the Punch and Judy Show.  It turned out that Punch and Judy was a puppet show from the time of Queen Anne of England.  She was queen of England from 1702 to 1714.  I could only find a painting of Queen Anne.  Didn’t anyone ever think about taking her photograph?

Queen Anne of England

Queen Anne of England

Anyway, once I learned more about Punch and Judy, I realized that this was probably a better description of the Rivers – Sonny relationship than those people realized.  It turns out in the first version of the Punch and Judy show, Punch actually strangles his child and beats his wife Judy to death and beats up on other people as well.  I suppose that was “entertainment” back then.  Now we only have things like “The Terminator”!

Punch and Judy

Punch and Judy Puppet Show

I carpooled with Bill Rivers at this particular time when I was a janitor and while I was on labor crew (except during the summer when I carpooled with my summer help buddies).  Each day Bill Rivers would explain about some trick he had played on Sonny that day.  The one thing that amazed Bill the most was that every day he could play a joke on Sonny, and each day, Sonny would fall for it.

This reminded me of when I was in Rockbridge High School in Columbia, Missouri and I used to borrow a pencil from my friend Bryan Treacy each day and each day I would chew it up to the point where it was practically useless.  I had to come up with different diversionary tactics each day, but somehow I was able to coax a wooden pencil from my friend.  Before he would realize what he had done, I had already chewed it up from one end to the next.  I liked to think that I was tricking Bryan each day, but I also thought that it was odd that Bryan would have  a new pencil very time, and he probably made sure that his mom kept a full stock of pencils just for my enjoyment in eating them.

Bryan Treacy today is a doctor living in Moore Oklahoma.  I would like to drop by his office without seeing him some time just to see if  he has any wooden pencils laying about that I could leave all chewed up.  I wonder if he would realize I had been there.  He might read this blog from time-to-time, so I may have just blown my cover.

I mentioned Bill Rivers and Sonny Kendrick because they were the first two electricians that I worked for before becoming an electrician.  I worked on the precipitator while I was on the Labor Crew.  See the Post:

Angel of Death Passes by the Precipitator Door (or almost dying twice in one day)

I also mentioned before that I owe my decision to become a Power Plant Electrician to Charles Foster an Electrical B Foreman at the time.  I was a janitor and cleaning the electric shop office and lab were part of my duty.  How I came to be the janitor of the electric shop is explained further in the post:

Power Plant Spider Wars and Bugs in the Basement

I had found the floor scrubbing machine in ill repair.  Charles helped me put it back in running condition.  He explained how to take care of the batteries and to keep them properly charged.

We had a Clarke Floor scrubber similar to this one

We had a Clarke Floor scrubber similar to this one

When the electric shop had an opening they tried to recruit me while I was still a janitor, but the Evil Plant Manager had a rule at the time that when you were a janitor, the only place you could go from there was onto the Labor Crew.  That was when Mike Rose was hired to become a backup for Jim Stevenson that worked on the air conditioning and freeze protection.  I knew about the janitor ruling so I didn’t have my hopes up.  Besides,  at the time I didn’t have any electrical background.

Charles asked me to take the electrical courses that were offered by the company.  The company offered correspondence courses, and in about 3 weeks, I had signed up for them, read the books, and taken the tests.  While I was on the labor crew I signed up for a House wiring course at the Vo-Tech.  I was taking that course when I learned that Larry Burns was moving from our electric shop to go to another plant.  It was then that I applied for the job as a plant electrician.

The main power transformer for Unit 1 had been destroyed by the heat wave that summer (1983) when the plant had tested it’s durability on the hottest day.  The unit was offline for a couple of months while GE created a new transformer and shipped it to us.

A Main Power Transformer

A Main Power Transformer

After the main power transformer was destroyed and it took so long to ship in a new one, it was decided that we would keep a spare on hand.  That way if it went bad again, we could swap them out quickly.  That is probably the best assurance that we wouldn’t lose that transformer again.  We had that spare transformer sitting around for years collecting taxes.  I’m sure we must have paid for it a few times over again.

During the time that the unit was offline, and we weren’t shaking boiler tubes or cutting the ash out of the economizer tubes, I was working with Bill Rivers and Sonny Kendrick on the precipitator.  The precipitator (by the way), is what takes the smoke (ash) out of the exhaust, so you don’t see smoke coming out of the smokestacks.

Bill and Sonny were pretty well sure that I was going to be selected to fill the opening in the Electric Shop, so they were already preparing me to work on the precipitator.  Of all the jobs in the electric shop, this one had more to do with electronics than any of the others.  That gave “being an electrician” a whole new dimension.  I was even looking forward to taking an Electronics course at the Vo-Tech in the spring.

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

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

I was getting updates from Bill and Sonny about the progress of the job opening and they were telling me about the battle that was going on between the Evil Plant Manager and the Electrical Supervisor.  Eldon Waugh, the plant manager at the time wanted Charles Peavler to be chosen as the electrician.  He had an electrical background, because he had wired his barn once.

The ultimate reason why the plant manager wanted Charles Peavler to be the new electrician was because I had been placed on the blacklist due to the incident that took place earlier that I had described in the post:

Take a Note Jan Said the Manager of Power Production

Thanks to Larry Riley’s performance review, and his purposeful procrastination of the Plant Manager’s request to modify my performance review, and Charles Foster’s insistence that they follow the procedures that were laid out in the new Employee Application Program (known as the EAP), the argument stopped with Charles Foster’s statement:  “Let’s just take whoever has the best performance rating as it is laid out in the company policy and leave it at that.”  I was chosen to fill the position for the opening in the Electric Shop.

I was actually called to Eldon Waugh’s office while I was sandblasting the Sand Filter Tank.  See Post:

Power Plant Safety as Interpreted by Curtis Love

When I arrived in Eldon’s office I was covered from head to toe in sandblast dust.  My hair was all disheveled and my shirt was soaked with sweat.  Jack Ballard (the head of HR) was sitting there along with Leroy Godfrey and Charles Foster.  I knew what it was about because according to Bill Rivers on the way home the day before, they had already decided that they were going to accept me for the position.

Eldon Waugh explained that I was being offered the job that I had applied for in the electric shop.  I felt really humbled at the time.  Even though I was expecting it, I felt surprised that it was actually happening.  To me, being an electrician was like the greatest job in the world.  The electricians were like an elite team of super heroes.

I had the occasion to watch them while I was a janitor in their shop and many of them were like these super intelligent beings that could quickly look at a blueprint and grab their tool bucket and head out to fix the world.  I was very grateful for the opportunity, and at the same time apprehensive.  I wasn’t sure if I had the quality of character and intelligence to become a part of this team.  This was truly a dream come true for me.

Few times in my life has this happened to me.  The day I was married.  The day I became a Father.  The day I drove to Dell to begin my first day as a Programmer Analyst.  These were all major milestones in my life.  The first major milestone was the day I became an electrician.  Because of the way that I am (I don’t know…. maybe it’s because I’m half Italian), I just wanted to break out in tears and hug Eldon Waugh and cry on his shoulder. Instead, I just managed to crack a small smile.

I thanked them and started to leave.  Then Jack Ballard said something interesting.  As I was leaving he asked, “Uh…. Do you accept the offer?”  Oh.  In my surprise and elation, I hadn’t said anything but “Thank You”.  Jack’s expression was that it wasn’t official until it was official.  So, I replied, “Yes.  I accept the offer”.  “Ok then,” Jack replied.  And I left to go crawl back in my hole and continue sandblasting the Sand Filter tank.

My last day on the Labor Crew was on November 4, 1983.  I was leaving my Labor Crew Family behind and moving onto a new life in the electric shop.  This was hard for me because I really did consider most of the people on the Labor Crew as family.  Fred Crocker, Ron Luckey, Jim Kanelakos, and Ronnie Banks.  Curtis Love and Chuck Moreland.  Doretta Funkhouser and Charles Peavler.  Jody Morse and Bob Lillibridge.

Most of all, I knew I was going to miss Larry Riley.  I had worked with Larry from the day I had first arrived as a summer help in 1979.  Now it was November, 1983.  Larry was a hero to me.  I love him dearly and if I had ever had an older brother I would have liked someone with the character and strength of Larry Riley.  He remains in my prayers to this day.

The last day on the labor crew I suspected foul play.  Mainly because the last day that Bill Cook was on the Labor Crew, he had asked us if we would throw Larry in the intake as a going away gift.  I had worked with Bill when we were summer help together and I felt like I owed him one, so I told him I would help.

As we were driving from the Coalyard Maintenance building (the home of the labor crew) to the plant maintenance shop that day, Bill Cook, who was driving, suddenly turned toward the intake pumps and stopped the truck.  By the time Larry had figured out what was going on, we had dragged him out of the truck and I was carrying him over to the Intake and getting ready to throw him in.

Larry had worked with me long enough to know that once I had set my mind on something, there was no turning back.  He had tried to escape from my grip, but I had him where he couldn’t escape.  As I climbed with him over the guard rail and headed toward the edge of the water, Larry said the only possible thing that could make me stop in my tracks.  He said, “Please Kevin.  Don’t do this.”

I was paralyzed.  Stuck between my word with Bill Cook that I would help him throw Larry in the brink, and a plea from someone who meant the world to me.  There wasn’t but one choice to make.  I set Larry down.  I walked back to the truck and I told Bill, “I’m sorry.  I can’t do it.”  I returned to my seat in the back of the crew cab.  Without my help, no one else had the resolve and strength to follow through with Bill’s wish.  We drove on to the Maintenance Shop.

So, on my last day on the Labor Crew, I thought that something similar might be planned for me.  As soon as we left to go to work that morning, I headed up Belt 10 and 11.  That is the long belt on the left side of the power Plant picture on the upper right side of this post…. Ok.  I’ll post it here:

Power Plant view when looking through the wrong end of the binoculars

The long belts run from the coalyard to the plant.  Oh.  And this is the intake.  Just across from here is where I was going to toss Larry in the lake

Once up 10 & 11 and 12 & 13, I was in the Surge bin tower.  (The Surge Bin Tower is the white building you can see between the two boilers near the top that has the conveyor belt entering it from the left).  From there, I roamed around looking for some coal to clean up.  I figured I would stay far away from my labor crew buddies that day.

At the end of the day, I travelled back down belts 10 & 11 and headed into the office in the Coalyard Maintenance building to fill out my last timecard as a Laborer.  Beginning next Monday on November 7, I would be an “Electrician.”  Along with the empty feeling at the bottom of my heart was a feeling of excitement for the new adventure that awaited me.