In Memory of Sonny Karcher – Power Plant Man
Added a new beginning on 11/11/2021
This was originally posted on January 7, 2012
I remember on January 12, 1980 I had decided that November 11, 2011 was going to be a very special day for me. For almost 32 years I waited for that day to arrive. If I had been paying more attention at the time, I should have realized that it was going to be a day walking down memory lane as well as a day of death.
My roommate, Mark Sarmento in the private dorm “Mark Twain’s Residence Hall” at the University of Missouri in Columbia had just returned from his Christmas holiday and he had quite the tale to tell me as soon as he walked in the door. He told me a story about how his friend had told him over the holiday that he kept seeing the numbers 1111 (eleven eleven) or 111 (one eleven). It kept showing up at the oddest places. Too often to just be a coincidence. Then a few days later after Mark’s friend had told him about seeing all the ones, he died suddenly when he had a seizure while taking a shower.
Mark had just been to his friends funeral the day before on (get this) January 11 (1/11). Mark returned from his vacation and now Mark was seeing the numbers 1111 and 111 everywhere. I have to admit that over the next semester, Mark had some very interesting encounters with these two numbers. Even to the point where he was on flight 111 when he went home for spring break. He wondered what this could mean.
To me, I knew what it meant. I had decided that day in January 1980 that no matter where I was or what I was doing, I was going to find Mark Sarmento and give him a call on November 11, 2011 at 11:11am (or 11/11/11 11:11). You can see now why I was looking forward to that day. It went off without a hitch. I called his company and told the receptionist that I was an old friend of Mark’s and I have been waiting 32 years to call him on this day. I had called him at 10:11 since he was in the Eastern Time Zone while I was in the Central Time Zone. He called me back an hour later, at 11:11.
Two days later, a power plant man sent me an email informing me that Sonny Karcher had died on November 11, 2011 (11/11/11). I wondered if it was at the same time I was talking to Mark on the phone. I had met my roommate Mark Sarmento exactly 111 days after I had met Sonny Karcher. Another interesting coincidence.
It wasn’t my idea to go work at a power plant for a summer job in 1979. My dad called me in my dorm room one night during the Spring Semester at Oklahoma University in Norman Oklahoma before I decided to go back to Missouri. I had figured I would go back to working in a restaurant during the summer as that had been my “go to” job in the past.
Dad said that a fellow Deacon from the Catholic Church in Stillwater, who was the assistant plant manager had asked him if I would be interested in being a summer help at a new power plant the electric company was building 25 miles north of Stillwater. Without giving it much thought, I told him, “Sure”. Not really knowing at the time that my simple answer to that question sent me on a journey that lasted for over 22 years.
The next Monday after school was over, I took my mom’s station wagon and drove north out of Stillwater on Hwy 177. It wasn’t until I topped the hill just before Bill’s corner that I realized that this was actually happening. I had figured up to that point that someone was going to change their mind, and I would go back to Sirloin Stockade and work for my old manager Ken Low. But, “No.” This was actually happening.
Now, 42 years later, I cherish the memories of the days I spent working at the plant as a summer help during the summers of 1979 through 1982, when I became a full time Janitor at the plant. I later worked my way into the Labor Crew, and eventually ending up in the Electric Shop, where I was an electrician for 18 years.
When I heard the sad news of the death of my very first mentor at the plant, Sonny Karcher on 11/11/11 (November 11, 2011), I wished I had been able to attend his funeral. I did reserve some amount of time that night when I heard about his death to remember the times I have spent with Sonny. All of them good, as Sonny was always pleasant to be with even when he was mad about something. Here are some of the first and last things I remember:
When I first worked at the Sooner power plant the summer of 1979, The first two mechanics I worked with were Sonny and Larry Riley. They taught me how things worked at the plant at that time. Both of the units were still under construction, so there was no electricity being generated.
The first job we were to work on was on my second day at the plant, since the first day was taking a safety class, and getting my hard hat and safety glasses and getting fitted for ear plugs. We were supposed to work on a stuck check valve in the dumper sump pump pit. Not only did I not know what a check valve was, I wasn’t too sure what was meant by a dumper sump, though I did recognize the word “pump”.
It took us about an hour to take the truck to the coal yard, as a coal yard foreman Richard Nix had the key and wasn’t going to give it to us until one of his hands was ready to go with us. So we sat in the truck parked in the north entrance of the maintenance shop for almost an hour. When the guy was finally ready, and he had climbed in the back of the pickup, it turned out that he only needed to go as far as the parking lot… about 200 yards away (as the parking lot was at the Engineer’s shack at the time). We dropped him off and drove up to the coal yard, and made our way down belt 2 to the sump pump pit at the tail end of the belt.
We tested the pump and saw that the water would run back into the sump once the pump stopped running. So, it was determined that the check valve was stuck. We drove back to the plant and took the morning break. That’s when I learned that a check valve keeps the water from running backward down a pipe.
About an hour later, Sonny told me to go to the tool room and get the following items (which I thought was a joke, because he gave me such a strange list of tools that I didn’t recognize): Two ¾ box ends (pronounced “three quarter box ends”), One four foot soft choker, a ¾ ton come-along, a ¾ shackle, a two foot steel choker a large flat bastard file, a large channel lock, and two pry bars (I did recognize Pry Bars and shackle, which I believed was thrown in there just to make the list sound legitimate). – I wrote down the list, because I recognized right away that a joke was being played on me and I was going to play right along.
So, I went to the tool room and when I saw Bud Schoonover (a very large tall and easy going man at the time) I wondered if he was perchance the large flat bastard file that was on my list. I thought maybe when I came to “Flat Bastard File” on my list, he would fly into a rage and pick me up by the neck and throw me to the ground (unlikely, I know, but at that time, I didn’t know what to expect). I told him, “I need a ¾ come-along (I thought I would choose the most ridiculous item on the list first, just to get on with the punch line of the joke…).
Well. Bud turned around, walked to the back wall, took a come-along off the top of a pallet full of what appeared to be a bunch of junk, and laid it across the tool room gate window (The tool room was still being “organized” at the time and the gate was actually a window in A foreman’s office next to the tool room). — not the regular gate that has been in the tool room for the past 35 years.
So, I asked for two ¾ box ends (this was before anyone had been issued toolboxes by the way, that’s why we had to go to the tool room for these things). Well, you know the rest of this part of the story. These are all legitimate items, and I learned a lot that day and the next few weeks about the names of various tools. I kept that list in my wallet for over 10 years until it finally disintegrated as a reminder to myself of when I first came to the plant, and how much I didn’t know then.
So, Larry, Sonny and I went up to the coal yard, and went down to the tail end of #2 belt and removed the check valve from the discharge pipe and brought it back to the maintenance shop to repair. When we returned, we went to lunch. During lunch Sonny told me about how he was hired at Sooner plant.
He said he lived a few miles down the road and had heard that someone was building a lake up on top of the hill he could see from his property. So, he went on over to see who was dumb enough to build a lake on top of a hill, and while he was looking around Orville Ferguson came up to him and asked him if he was looking for a job.
Sonny said that he liked to mow grass, and Orville said that he would hire him to mow grass then. Sonny said, if I remember correctly, that he was hired at the same time that Linda Shiever, the timekeeper, was hired and that they were the first two new hires at the plant. The rest were already company employees that had transferred there.
After lunch we went down to the shop and took the check valve apart and what do you know…. There was a piece of coal stuck in the check valve keeping it open. We cleaned it up and put it back together. When we were finished, we took our afternoon break. After break we drove back up to the coal yard and went down to the tail end of #2 Conveyor belt and put the check valve back in the discharge pipe. When we returned to the maintenance shop, we returned the tools to the tool room and filled out our time cards. A day’s worth of work cleaning a check valve.
I did many other things that first summer, since Sooner Plant didn’t have a yard crew yet and that was what a typical non-educated summer help usually did, I worked most of the time in the maintenance shop bouncing around from crew to crew helping out. I also did a lot of coal cleanup (especially on weekends), since the conveyor system didn’t work correctly when they started it up when they were starting to fire up unit 1. See the post “Spending Long Weekends with Power Plant Men Shoveling Coal“.
The second day before I left at the end of the summer to go back to school, I worked again with Larry Riley and Sonny Karcher to fix the exact same check valve. This time we jumped in a truck (we had a lot more trucks now…. Which is another story — See the post: “Experiencing Maggots, Mud and Motor Vehicles with Dee Ball“), went to the coal yard, went down #2 tunnel to the tail end of #2 Conveyor, pulled out the check valve, removed the piece of coal, put the check valve back in, went back up to the truck and back to the maintenance shop just in time for morning break. Sooner Plant had improved a lot in the short three months I worked that summer.
I worked many years with Sonny Karcher in the garage, and fixing coal handling equipment, and just about anything else. He finally left the plant to go mow grass, when after a battle to move to the garage from coal yard maintenance to mow grass, he was told that he was going to have to go back to the coal yard to be a coal yard mechanic, because he was real good at that and they just needed him up there. So he left the plant.
He talked to me about it before he went, that’s how I know what was on his mind. He said, “Kev, you remember when you first came here and I told you how they hired me to mow grass? Well, that’s what I want to do. Mow grass. So I’m going to have to go back home and do just that.”
After that, the only times I remember seeing Sonny was when he was mowing grass down at Bill’s corner, with a smile on his face waving at the Sooner plant employees on their way home from work.
During the summer of 2018, while I went through Stillwater on my way to Columbia Missouri to attend my 40th High School Reunion, I took a couple of days visiting friends from the plant. I went to the Morrison Cemetery hoping to find Sonny Karcher’s grave. I was not able to find it. I searched other nearby cemeteries including the Sumner cemetery close to his house, and I was never able to find his grave.
Regardless, I can see Sonny talking to St. Peter at the gates of heaven now….. The only words I can hear Sonny saying is, “I like to mow grass”… and St. Peter nodding with approval and points out that they have a lot of green pastures as he lets him through the gates.
Sonny Karcher
In Memory of Sonny Karcher – Power Plant Man
Favorites Post #68
This was originally posted on January 7, 2012
When I heard the sad news of the death of Sonny Karcher on 11/11/11 (November 11, 2011), I wished I had been able to attend his funeral. I did reserve some amount of time that night when I heard about his death to remember the times I have spent with Sonny. All of them good, as Sonny was always pleasant to be with even when he was mad about something. Here are some of the first and last things I remember:
When I first worked at the Sooner power plant the summer of 1979, The first two mechanics I worked with were Sonny and Larry Riley. They taught me how things were at the plant at that time. Both of the units were still under construction, so there was no electricity being generated.
The first job we were to work on was on second day at the plant, since the first day was taking a safety class, and getting my hard hat and safety glasses and getting fitted for ear plugs. We were supposed to work on a stuck check valve in the dumper sump pump pit. Not only did I not know what a check valve was, I wasn’t too sure what was meant by a dumper sump, though I did recognize the word “pump”.
It took us about an hour to take the truck to the coal yard, as a coal yard foreman Richard Nix had the key and wasn’t going to give it to us until one of his hands was ready to go with us. So we sat in the truck parked in the north entrance of the maintenance shop for almost an hour. When the guy was finally ready, and he had climbed in the back of the pickup, it turned out that he only needed to go as far as the parking lot… about 200 yards away (as the parking lot was at the Engineer’s shack at the time). We dropped him off and drove up to the coal yard, and made our way down belt 2 to the sump pump pit at the tail end of the belt.
We tested the pump and saw that the water would run back into the sump once the pump stopped running. So, it was determined that the check valve was stuck. We drove back to the plant and took the morning break.
About an hour later, Sonny told me to go to the tool room and get the following items (which I thought was a joke, because he gave me such a strange list of tools that I didn’t recognize): Two ¾ box ends (pronounced “three quarter box ends”), One four foot soft choker, a ¾ come-along, a ¾ shackle, a two foot steel choker a flat bastard file, a large channel lock, and two pry bars (I did recognize Pry Bars and shackle, which I believed was thrown in there just to make the list sound legitimate). – I wrote down the list, because I recognized right away that a joke was being played on me and I was going to play right along.
So, I went to the tool room and I asked Bud Schoonover (a very large tall and easy going man at the time), “I need a ¾ come-along (I thought I would choose the most ridiculous item on the list first, just to get on with the punch line of the joke…). Well. Bud turned around, walked to the back wall, took a come-along off the top of a pallet full of what appeared to be a bunch of junk, and laid it across the tool room gate window (The tool room was still being “organized” at the time and the gate was actually a window in A foreman’s office next to the tool room). — not the regular gate that has been in the tool room for the past 35 years.
So, I asked for two ¾ box ends (this was before anyone had been issued toolboxes by the way, that’s why we had to go to the tool room for these things). Well, you know the rest of this part of the story. These are all legitimate items, and I learned a lot that day and the next few weeks about the names of various tools. I kept that list in my wallet for over 10 years as a reminder to myself of when I first came to the plant, and how much I didn’t know then.
So, Larry, Sonny and I went up to the coal yard, and went down to the tail end of #2 belt and removed the check valve from the discharge pipe and brought it back to the maintenance shop to repair. When we returned, we went to lunch. During lunch Sonny told me about how he was hired at Sooner plant.
He said he lived a few miles down the road and had heard that someone was building a lake up on top of the hill he could see from his property. So, he went on over to see who was dumb enough to build a lake on top of a hill, and while he was looking around Orville Ferguson came up to him and asked him if he was looking for a job. Sonny said that he liked to mow grass, and Orville said that he would hire him to mow grass then. Sonny said, if I remember correctly, that he was hired at the same time that Linda Shiever, the timekeeper, was hired and that they were the first two new hires at the plant. The rest were already company employees that had transferred there.
After lunch we went down to the shop and took the check valve apart and what do you know…. There was a piece of coal stuck in the check valve keeping it open. We cleaned it up and put it back together. When we were finished, we took our afternoon break. After break we drove back up to the coal yard and went down to the tail end of #2 Conveyor belt and put the check valve back in the discharge pipe. When we returned to the maintenance shop, we returned the tools to the tool room and filled out our time cards. A day’s worth of work cleaning a check valve.
I did many other things that first summer, since Sooner Plant didn’t have a yard crew yet, I worked most of the time in the maintenance shop bouncing around from crew to crew helping out. I also did a lot of coal cleanup (especially on weekends), since the conveyor system didn’t work correctly when they started it up when they were starting to fire up unit 1. See the post “Spending Long Weekends with Power Plant Men Shoveling Coal“.
The second day before I left at the end of the summer to go back to school, I worked again with Larry Riley and Sonny Karcher to fix the exact same check valve. This time we jumped in a truck (we had a lot more trucks now…. Which is another story — See the post: “Experiencing Maggots, Mud and Motor Vehicles with Dee Ball“), went to the coal yard, went down #2 tunnel to the tail end of #2 Conveyor, pulled out the check valve, removed the piece of coal, put the check valve back in, went back up to the truck and back to the maintenance shop just in time for morning break. Sooner Plant had improved a lot in the short three months I worked that summer.
I worked many years with Sonny Karcher in the garage, and fixing coal handling equipment, and just about anything else. He finally left the plant to go mow grass, when after a battle to move to the garage from coal yard maintenance to mow grass, he was told that he was going to have to go back to the coal yard to be a coal yard mechanic, because he was real good at that and they just needed him up there. So he left the plant.
He talked to me about it before he went, that’s how I know what was on his mind. He said, “Kev, you remember when you first came here and I told you how they hired me to mow grass? Well, that’s what I want to do. Mow grass. So I’m going to have to go back home and do just that.”
After that, the only times I remember seeing Sonny was when he was mowing grass down at Bill’s corner, with a smile on his face waving at the Sooner plant employees on their way home from work.
I can see Sonny talking to St. Peter at the gates of heaven now….. The only words I can hear Sonny saying is, “I like to mow grass”… and St. Peter nodding with approval and points out that they have a lot of green pastures as he lets him through the gates.
Sonny Karcher
In Memory of Sonny Karcher – Power Plant Man
this was originally posted on January 7, 2012. Added a picture of Sonny Karcher:
When I heard the sad news of the death of Sonny Karcher on 11/11/11, I wished I had been able to attend his funeral. I did reserve some amount of time that night when I heard about his death to remember the times I have spent with Sonny. All of them good, as Sonny was always pleasant to be with even when he was mad about something. Here are some of the first and last things I remember:
When I first worked at the Sooner power plant the summer of 1979, Sonny and Larry Riley were the first two mechanics I was assigned to work with. They taught me how things were at the plant at that time. Both of the units were still under construction, so there was no electricity being generated.
The first job we were to work on (my second day at the plant, since the first day was taking a safety class, and getting my hard hat and safety glasses and getting fitted for ear plugs) was a stuck check valve in the dumper sump pump pit (Not only did I not know what a check valve was, I wasn’t too sure what was meant by a dumper sump, though I did know “pump”).
It took us about an hour to take the truck to the coal yard, as a coal yard foreman Richard Nix had the key and wasn’t going to give it to us until one of his hands was ready to go with us. So we sat in the truck parked in the north entrance of the maintenance shop for almost an hour. When the guy was finally ready, and he had climbed in the back of the pickup, it turned out that he only needed to go as far as the parking lot… about 200 yards away (as the parking lot was at the Engineer’s shack at the time). We dropped him off and drove up to the coal yard, and made our way down belt 2 to the sump pump pit at the tail end of the belt.
We tested the pump and saw that the water would run back into the sump once the pump stopped running. So, it was determined that the check valve was stuck. We drove back to the plant and took the morning break.
About an hour later, Sonny told me to go to the tool room and get the following items (which I thought was a joke, because he gave me such a strange list of tools that I didn’t recognize): Two ¾ box ends (pronounced “three quarter box ends”), One four foot soft choker, a ¾ come-along, a ¾ shackle, a two foot steel choker a flat bastard file, a large channel lock, and two pry bars (I did recognize Pry Bars and shackle, which I believed was thrown in there just to make it sound legitimate). – I wrote down the list, because I recognized right away that a joke was being played on me and I was going to play right along.
So, I went to the tool room and I asked Bud Schoonover (a very large tall and easy going man at the time), “I need a ¾ come-along (I thought I would choose the most ridiculous item on the list first, just to get on with the joke…). Well. Bud turned around, walked to the back wall, took a come-along off the top of a pallet full of what appeared to be a bunch of junk, and laid it across the tool room gate window (The tool room was still being “organized” at the time and the gate was actually a window in the office next to the tool room).
So, I asked for two ¾ box ends (this was before anyone had been issued toolboxes by the way, that’s why we had to go to the tool room for these things). Well, you know the rest of this part of the story. These are all legitimate items, and I learned a lot that day and the next few weeks about the names of various tools. I kept that list in my wallet for over 10 years as a reminder to myself of when I first came to the plant, and how much I didn’t know then.
So, Larry, Sonny and I went up to the coal yard, and went down to the tail end of #2 belt and removed the check valve from the discharge pipe and brought it back to the maintenance shop to repair. When we returned, we went to lunch. During lunch Sonny told me about how he was hired at Sooner plant.
He said he lived a few miles down the road and had heard that someone was building a lake up on top of the hill he could see from his property. So, he went on over to see who was dumb enough to build a lake on top of a hill, and while he was looking around Orville Ferguson came up to him and asked him if he was looking for a job. Sonny said that he liked to mow grass, and Orville said that he would hire him to mow grass then. Sonny said, if I remember correctly, that he was hired at the same time that Linda Shiever, the timekeeper, was hired and that they were the first two new hires at the plant. The rest were already company employees that had transferred there.
After lunch we went down to the shop and took the check valve apart and what do you know…. There was a piece of coal stuck in the check valve keeping it open. We cleaned it up and put it back together. When we were finished, we took our afternoon break. After break we drove back up to the coal yard and went down to the tail end of #2 Conveyor belt and put the check valve back in the discharge pipe. When we returned to the maintenance shop, we returned the tools to the tool room and filled out our time cards. A day’s worth of work cleaning a check valve.
I did many other things that first summer, since Sooner Plant didn’t have a yard crew yet, I worked most of the time in the maintenance shop bouncing around from crew to crew helping out. I also did a lot of coal cleanup (especially on weekends), since the conveyor system didn’t work correctly when they started it up when they were starting to fire up unit 1.
The second day before I left at the end of the summer to go back to school, I worked again with Larry Riley and Sonny Karcher to fix the exact same check valve. This time we jumped in a truck (we had a lot more trucks now…. Which is another story), went to the coal yard, went down #2 tunnel to the tail end of #2 Conveyor, pulled out the check valve, removed the piece of coal, put the check valve back in, went back up to the truck and back to the maintenance shop just in time for morning break. Sooner Plant had improved a lot in the short three months I worked that summer.
I worked many years with Sonny Karcher in the garage, and fixing coal handling equipment, and just about anything else. He finally left the plant to go mow grass, when after a battle to move to the garage from coal yard maintenance to mow grass, he was told that he was going to have to go back to the coal yard to be a coal yard mechanic, because he was real good at that and they just needed him up there. So he left.
He talked to me about it before he went, that’s how I know what was on his mind. He said, “Kev, you remember when you first came here and I told you how they hired me to mow grass? Well, that’s what I want to do. Mow grass. So I’m going to have to go back home and do just that.”
After that, the only times I remember seeing Sonny was when he was mowing grass down at Bill’s corner, with a smile on his face waving at the Sooner plant employees on their way home from work.
I can see Sonny talking to St. Peter at the gates of heaven now….. The only words I can hear Sonny saying is, “I like to mow grass”… and St. Peter nodding with approval and points out that they have a lot of green pastures as he lets him through the gates.
Sonny Karcher
Cracking a Boiled Egg in the Boiler and Other Days You Wish You Could Take Back
Originally Posted on April 13, 2012:
There are some days you wish you could take back after making a grand decision that turns out to look really dumb when your decision fails. It is important to think outside the box to break new ground as long as you bring common sense along for the ride.
It seemed that during the days when I was a summer help, and even when I was a laborer on Labor Crew that in order to be promoted you had to come up with one grand idea that set you apart from the others and that also failed miserably.
It was said that the electrical supervisor there before Leroy Godfrey (I can see his face, but his name escapes me. Jackie somebody), was promoted to that position after he caused the destruction of one of the Intake pump motors (a very large pump that can pump 189,000 gallons of water per minute).
To name a couple of minor “Faux Pas” (how do you pluralize that word? I don’t know — Faux Pauses?), let me start out with the least embarrassing and less dangerous and work my way to the most embarrassing and most dangerous of three different stories of someone thinking out of the box while leaving common sense somewhere behind and maybe wishing they could take back that day.
The first two stories both involve the Electrical Supervisors of two different Power Plants.
Tom Gibson, the Electrical Supervisor from our plant was trying to find a way to keep moisture out of the Bottom Ash Overflow Sump Pumps. This was a recurring problem that required a lot of man hours to repair. The bell shaped pump would have to be pulled, the motor would have to be disassembled and dried, and new seals would have to be put in the pump to keep it from leaking.
A Bottom Ash Overflow Sump Pump or BAOSP for Short
So, Tom Gibson decided that he was going to fill the motor and pump cavity with turbine oil. All electricians knew that oil used in turbines is an insulator so electrically it wouldn’t short anything out. But something in the back of your mind automatically says that this isn’t going to work.
I remember helping to fill the motor up with oil in the Maintenance shop and hooking up some motor leads from the nearby Maintenance shop 480 volt switchgear. Needless to say, as soon as the pump was turned on, it tripped the breaker and oil began leaking from the cable grommet.
That’s when common sense tells you that the all the oil causes too much drag on the rotor which will cause a 480 motor to trip very quickly. After removing some of the oil and trying it again with a larger breaker and still having the same result Tom was satisfied that this just wasn’t going to work.
The pump and motor was sent away to a nearby electric shop to be rewound and other ways were developed by the help of our top notch machinist genius Randy Dailey who came up with a positive air pressure way to keep water out of the Bottom Ash Overflow Sump Pump and motor (also known as the BAOSP). Not much harm done and Tom Gibson didn’t feel too bad for trying something that the rest of us sort of thought was mildly insane.
The next story was told to me by my dear friend Bob Kennedy when I was working at a Gas Powered Plant in Midwest City and he was my acting foreman and backed up by the rest of the electricians as they sat there nodding their heads as Bob told this story.
So I didn’t witness this myself. This one was a little more dangerous, but still thankfully, no one was hurt. Ellis Rooks, the Electrical Supervisor needed to bump test a 4200 Volt motor and wanted to do it in place (bump testing is when you switch something on and off quickly. Usually to see which way it turns). For some reason he was not able to use the existing cables, maybe because that was the reason the motor was offline. Because one of the cables had gone to ground.
So, he decided that since the motor only pulled 5 to 10 amps he could use #10 wire (the size wire in your home) and string three of them (for the three phases of the motor) from the main High Voltage switchgear across the turbine room floor over to the motor. Now, most electricians know how many amps different size wires can generally handle. It goes like this: #14 – 15 amps, #12 – 20 amps, #10 – 30 amps, #8 – 50 amps and on down (smaller numbers mean bigger wires).
So, Ellis thought that since the motor only pulls around 5 amps, and he only wanted to bump the motor (that is, turn it on and off quickly) to watch it rotate, he thought that even though there was normally three 3 – 0 cables (pronounced three aught for 3 zeroes, very large wire) wired to the motor, this would be all right because he was only going to bump it.
This works when you are using is 120 or 220 volts
Needless to say, but I will anyway, when the motor was bumped, all that was left of the #10 wires were three black streaks of carbon across the turbine room floor where the wire used to exist before it immediately vaporized.
You see, common sense tells you that 4200 volts times 5 amps = 21,000 watts of power. However, the starting amps on a motor like this may be around 50 to 100 amps, which would equal 210 to 420 Kilowatts of power (that is, 420,000 watts or more than 2/5 of a Megawatt). Thus vaporizing the small size 10 wire that is used to wire your house.
I think until the day that Ellis Rooks retired he was still trying to figure out where he went wrong. There must have been something defective with those wires.
All right. I have given you two relatively harmless stories and now the one about cracking the boiled egg in the boiler. This happened when I was still a janitor but was loaned to the Labor Crew during outages. When the boiler would come offline for an outage, the labor crew would go in the boiler and knock down clinkers and shake tubes to clean out clinkers that had built up around the boiler tubes in the intermediate pressure area of the boiler.
Clinkers are a hard buildup of ash that can become like large rocks, and when they fall and hit you on the head, depending on the size, can knock you to the floor, which makes wearing your hardhat a must. Your hardhat doesn’t help much when the clinkers falling from some 30 feet above hits you on your shoulder, so I always tried to suck my shoulders up under my hardhat (like a turtle pulling in his arms and legs) so that only my arms were left unprotected.
It wasn’t easy looking like a pole with no shoulders, but I tried my best. I think Fred Crocker the tallest and thinnest person on Labor Crew was the best at this. This is the Reheater area of the boiler in the diagram below:
Diagram of a boiler
Before we could get into the boiler to start shaking tubes, the dynamiters would go in there first and blow up the bigger clinkers. So, for a couple of days some times, at the beginning of an overhaul, you would hear someone come over the PA system about every 20 minutes saying, “Stand Clear of Number One Boiler, We’re Gonna Blast!!!” This became so common to hear over the years that unless you were up on the boiler helping out, you didn’t pay any attention to it.
This is something that is only done at a Coal-fired Power Plant because Gas Plants don’t create Ash that turns into Clinkers. Maybe some Soot, I don’t know, but not Ash. Which brings to mind a minor joke we played on Reginald Deloney one day when he came from a gas plant to work on overhaul. Reggie automatically reminded you of Richard Pryor. He had even developed a “Richard Pryor” way of talking.
Richard Pryor trying to look like Reggie Deloney
We were going to work on a Bowl Mill motor first thing, which is down next to the boiler structure in an enclosed area. We brought our roll around large toolbox and other equipment over to the motor. Andy Tubbs and Diana Brien were there with Reggie and I. I think Gary Wehunt was there with us also.
When someone came over the PA system saying, “Stand Clear of Number Two Boiler, We’re Gonna Blast”, all of us dropped everything and ran for the door as if it was an emergency. Reggie, not knowing what was going on ran like the dickens to get out in time only to find us outside laughing at the surprised look on his face.
Like this
Anyway. That wasn’t the day that someone wished they could take back, but I thought I would throw that one in anyway so that now Reggie will wish that he could take back that day.
When I was on Labor Crew, and we were waiting on the boiler for the dynamiters to blast all the large clinkers, the engineer in charge, Ed Hutchins decided that things would go a lot quicker if all the laborers would go into the boiler and shake tubes while the dynamiters were setting their charges (which wasn’t the normal procedure. Normally we waited until the dynamiters were all done). Then we would climb out when they were ready to blast, and then go back in. So, we did that.
All 10 or so of us climbed into the boiler, and went to work rattling boiler tubes until we heard someone yell, “Fire In The Hole!!!” Then we would all head for the one entrance and climb out and wait for the blast.
The extra time it took to get all of us in the boiler and back out again actually slowed everything down. We weren’t able to get much work done each time, and everyone spent most of their time climbing in and out instead of working, including the dynamiters.
So Ed had another brilliant idea. What if we stayed in the boiler while the dynamite exploded? Then we wouldn’t be wasting valuable time climbing in and out and really wouldn’t have to stop working at all.
Of course, common sense was telling us that we didn’t want to be in an enclosed boiler while several sticks worth of dynamite all exploded nearby, so the engineer decided to prove to us how safe it was by standing just inside the entrance of the boiler with his ear plugs in his ears while the dynamite exploded.
The dynamiters at first refused to set off the charges, but after Ed and the labor crew convinced them (some members on the labor crew were anxious for Ed to try out his “brilliant idea”) that there really wouldn’t be much lost if the worst happened, they went ahead and set off the dynamite.
Needless to say…. Ed came wobbling his way out of the boiler like a cracked boiled egg and said in a shaky voice, “I don’t think that would be such a good idea.” All of us on the Labor Crew said to each other, “..As if we needed him to tell us that.” I think that may be a day that Ed Hutchins would like to take back. The day he learned the real meaning of “Concussion”. I think he was promoted shortly after that and went to work in Oklahoma City at Corporate Headquarters.
Comments from Original Post:
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eideard April 21, 2012
When you have pallets double-stacked, you should only move them about with a pallet jack. The bottom pallet – and whatever is stacked on it – is thoroughly supported. And even if the pallet jack is powered, you aren’t likely to get in trouble with rapid acceleration.
As you would with a fork lift truck.
And the double stacked pallets are truck mirrors boxed for shipment to retailers. A couple hundred mirrors. And I dumped both pallets when I went to back up and turn into the warehouse aisle.
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jackcurtis May 5, 2012
Modern parables like these are much too good to waste! They should be included in every freshman Congressman’s Washington Welcome Kit when he first takes office and new ‘reminder’ versions again every time he wins an election. These are wonderful essays on unintended consequences, at which our Congress is among the best!
Comments from Previous repost:
In Memory of Sonny Karcher – Power Plant Man
this was originally posted on January 7, 2012. Added a picture of Sonny Karcher:
When I heard the sad news of the death of Sonny Karcher on 11/11/11, I wished I had been able to attend his funeral. I did reserve some amount of time that night when I heard about his death to remember the times I have spent with Sonny. All of them good, as Sonny was always pleasant to be with even when he was mad about something. Here are some of the first and last things I remember:
When I first worked at the Sooner power plant the summer of 1979, Sonny and Larry Riley were the first two mechanics I was assigned to work with. They taught me how things were at the plant at that time. Both of the units were still under construction, so there was no electricity being generated.
The first job we were to work on (my second day at the plant, since the first day was taking a safety class, and getting my hard hat and safety glasses and getting fitted for ear plugs) was a stuck check valve in the dumper sump pump pit (Not only did I not know what a check valve was, I wasn’t too sure what was meant by a dumper sump, though I did know “pump”).
It took us about an hour to take the truck to the coal yard, as a coal yard foreman Richard Nix had the key and wasn’t going to give it to us until one of his hands was ready to go with us. So we sat in the truck parked in the north entrance of the maintenance shop for almost an hour. When the guy was finally ready, and he had climbed in the back of the pickup, it turned out that he only needed to go as far as the parking lot… about 200 yards away (as the parking lot was at the Engineer’s shack at the time). We dropped him off and drove up to the coal yard, and made our way down belt 2 to the sump pump pit at the tail end of the belt.
We tested the pump and saw that the water would run back into the sump once the pump stopped running. So, it was determined that the check valve was stuck. We drove back to the plant and took the morning break.
About an hour later, Sonny told me to go to the tool room and get the following items (which I thought was a joke, because he gave me such a strange list of tools that I didn’t recognize): Two ¾ box ends, One four foot soft choker, a ¾ come-along, a ¾ shackle, a two foot steel choker a flat bastard file, a large channel lock, and two pry bars (I did recognize Pry Bars and shackle, which I believed was thrown in there just to make it sound legitimate). – I wrote down the list, because I recognized right away that a joke was being played on me and I was going to play right along.
So, I went to the tool room and I asked Bud Schoonover (a very large tall and easy going man at the time), “I need a ¾ come-along (I thought I would choose the most ridiculous item on the list first, just to get on with the joke…). Well. Bud turned around, walked to the back wall, took a come-along off the top of a pallet full of what appeared to be a bunch of junk, and laid it across the tool room gate window (The tool room was still being “organized” at the time).
So, I asked for two ¾ box ends (this was before anyone had been issued toolboxes by the way, that’s why we had to go to the tool room for these things). Well, you know the rest of this part of the story. These are all legitimate items, and I learned a lot that day and the next few weeks about the names of various tools. I kept that list in my wallet for over 10 years as a reminder to myself of when I first came to the plant, and how much I didn’t know then.
So, Larry, Sonny and I went up to the coal yard, and went down to the tail end of #2 belt and removed the check valve from the discharge pipe and brought it back to the maintenance shop to repair. When we returned, we went to lunch. During lunch Sonny told me about how he was hired at Sooner plant.
He said he lived a few miles down the road and had heard that someone was building a lake up on top of the hill he could see from his property. So, he went on over to see who was dumb enough to build a lake on top of a hill, and while he was looking around Orville Ferguson came up to him and asked him if he was looking for a job. Sonny said that he liked to mow grass, and Orville said that he would hire him to mow grass then. Sonny said, if I remember correctly, that he was hired at the same time that Linda Shiever, the timekeeper, was hired and that they were the first two new hires at the plant. The rest were already company employees that had transferred there.
After lunch we went down to the shop and took the check valve apart and what do you know…. There was a piece of coal stuck in the check valve keeping it open. We cleaned it up and put it back together. When we were finished, we took our afternoon break. After break we drove back up to the coal yard and went down to the tail end of #2 Conveyor belt and put the check valve back in the discharge pipe. When we returned to the maintenance shop, we returned the tools to the tool room and filled out our time cards. A day’s worth of work cleaning a check valve.
I did many other things that first summer, since Sooner Plant didn’t have a yard crew yet, I worked most of the time in the maintenance shop bouncing around from crew to crew helping out. I also did a lot of coal cleanup (especially on weekends), since the conveyor system didn’t work correctly when they started it up when they were starting to fire up unit 1.
The second day before I left at the end of the summer to go back to school, I worked again with Larry Riley and Sonny Karcher to fix the exact same check valve. This time we jumped in a truck (we had a lot more trucks now…. Which is another story), went to the coal yard, went down #2 tunnel to the tail end of #2 Conveyor, pulled out the check valve, removed the piece of coal, put the check valve back in, went back up to the truck and back to the maintenance shop just in time for morning break. Sooner Plant had improved a lot in the short three months I worked that summer.
I worked many years with Sonny Karcher in the garage, and fixing coal handling equipment, and just about anything else. He finally left the plant to go mow grass, when after a battle to move to the garage from coal yard maintenance to mow grass, he was told that he was going to have to go back to the coal yard to be a coal yard mechanic, because he was real good at that and they just needed him up there. So he left.
He talked to me about it before he went, that’s how I know what was on his mind. He said, “Kev, you remember when you first came here and I told you how they hired me to mow grass? Well, that’s what I want to do. Mow grass. So I’m going to have to go back home and do just that.”
After that, the only times I remember seeing Sonny was when he was mowing grass down at Bill’s corner, with a smile on his face waving at the Sooner plant employees on their way home from work.
I can see Sonny talking to St. Peter at the gates of heaven now….. The only words I can hear Sonny saying is, “I like to mow grass”… and St. Peter nodding with approval as he lets him through the gates.
Sonny Karcher
Cracking a Boiled Egg in the Boiler and Other Days You Wish You Could Take Back
Originally Posted on April 13, 2012:
There are some days you wish you could take back after making a grand decision that turns out to look really dumb when your decision fails. It is important to think outside the box to break new ground as long as you bring common sense along for the ride. It seemed that during the days when I was a summer help, and even when I was a laborer on Labor Crew that in order to be promoted you had to come up with one grand idea that set you apart from the others and that also failed miserably.
It was said that the electrical supervisor there before Leroy Godfrey (I can see his face, but his name escapes me), was promoted to that position after he caused the destruction of one of the Intake pump motors (a very large pump that can pump 189,000 gallons of water per minute).
To name a couple of minor “Faux Pas” (how do you pluralize that word? I don’t know), let me start out with the least embarrassing and less dangerous and work my way to the most embarrassing and most dangerous of three different stories of someone thinking out of the box while leaving common sense somewhere behind and maybe wishing they could take back that day.
The first two stories both involve the Electrical Supervisors of two different Power Plants.
Tom Gibson, the Electrical Supervisor from our plant was trying to find a way to keep moisture out of the Bottom Ash Overflow Sump Pumps. This was a reoccurring problem that required a lot of man hours to repair. The bell shaped pump would have to be pulled, the motor would have to be disassembled and dried, and new seals would have to be put in the pump to keep it from leaking.
A Bottom Ash Overflow Sump Pump or BAOSP for Short
So, Tom Gibson decided that he was going to fill the motor and pump cavity with turbine oil. All electricians knew that oil used in turbines is an insulator so electrically it wouldn’t short anything out. But something in the back of your mind automatically says that this isn’t going to work. I remember helping to fill the motor up with oil in the Maintenance shop and hooking up some motor leads from the nearby Maintenance shop 480 volt switchgear. Needless to say, as soon as the pump was turned on, it tripped the breaker and oil began leaking from the cable grommet.
That’s when common sense tells you that the all the oil causes too much drag on the rotor which will cause a 480 motor to trip very quickly. After removing some of the oil and trying it again with a larger breaker and still having the same result Tom was satisfied that this just wasn’t going to work. The pump and motor was sent away to a nearby electric shop to be rewound and other ways were developed by the help of our top notch machinist genius Randy Dailey who came up with a positive air pressure way to keep water out of the Bottom Ash Overflow Sump Pump and motor (also known as the BAOSP). Not much harm done and Tom Gibson didn’t feel too bad for trying something that the rest of us sort of thought was mildly insane.
The next story was told to me by my dear friend Bob Kennedy when I was working at a Gas Powered Plant in Midwest City and he was my acting foreman. So I didn’t witness this myself. This one was a little more dangerous, but still thankfully, no one was hurt. Ellis Rooks, the Electrical Supervisor needed to bump test a 4200 Volt motor and wanted to do it in place. For some reason he was not able to use the existing cables, maybe because that was the reason the motor was offline. Because one of the cables had gone to ground.
So, he decided that since the motor only pulled 5 to 10 amps he could use #10 wire and string three of them (for the three phases of the motor) from the main High Voltage switchgear across the turbine room floor over to the motor. Now, most electricians know how many amps different size wires can generally handle. It goes like this: #14 – 15 amps, #12 – 20 amps, #10 – 30 amps, #8 – 50 amps and on down (smaller numbers mean bigger wires).
So, Ellis thought that since the motor only pulls around 5 amps, and he only wanted to bump the motor (that is, turn it on and off quickly) to watch it rotate, he thought that even though there was normally three 3 – 0 cables (pronounced three aught for 3 zeroes, very large wire) wired to the motor, this would be all right because he was only going to bump it.
This works when you are using is 120 or 220 volts
Needless to say, but I will anyway, when the motor was bumped, all that was left of the #10 wires were three black streaks of carbon across the turbine room floor where the wire used to exist before it immediately vaporized. You see, common sense tells you that 4200 volts times 5 amps = 21,000 watts of power. However, the starting amps on a motor like this may be around 50 to 100 amps, which would equal 210 to 420 Kilowatts of power (or about 1/5 to 2/5 of a Megawatt). Thus vaporizing the small size 10 wire that is used to wire your house.
All right. I have given you two relatively harmless stories and now the one about cracking the boiled egg in the boiler. This happened when I was still a janitor but was loaned to the Labor Crew during outages. When the boiler would come offline for an outage, the labor crew would go in the boiler and knock down clinkers and shake tubes to clean out clinkers that had built up around the boiler tubes in the intermediate pressure area of the boiler.
Clinkers are a hard buildup of ash that can become like large rocks, and when they fall and hit you on the head, depending on the size, can knock you to the floor, which makes wearing your hardhat a must. Your hardhat doesn’t help much when the clinkers falling from some 30 feet above hits you on your shoulder, so I always tried to suck my shoulders up under my hardhat (like a turtle pulling in his arms and legs) so that only my arms were left unprotected.
It wasn’t easy looking like a pole with no shoulders, but I tried my best. I think Fred Crocker the tallest and thinnest person on Labor Crew was the best at this. This is the Reheater area of the boiler in the diagram below:
Diagram of a boiler
Before we could get into the boiler to start shaking tubes, the dynamiters would go in there first and blow up the bigger clinkers. So, for a couple of days some times, at the beginning of an overhaul, you would hear someone come over the PA system about every 20 minutes saying, “Stand Clear of Number One Boiler, We’re Gonna Blast!!!” This became so common to hear over the years that unless you were up on the boiler helping out, you didn’t pay any attention to it.
This is something that is only done at a Coal-fired Power Plant because Gas Plants don’t create Ash that turns into Clinkers. Maybe some Soot, I don’t know, but not Ash. Which brings to mind a minor joke we played on Reginald Deloney one day when he came from a gas plant to work on overhaul. Reggie automatically reminded you of Richard Pryor. He had even developed a “Richard Pryor” way of talking.
Richard Pryor trying to look like Reggie Deloney
We were going to work on a Bowl Mill motor first thing, which is down next to the boiler structure in an enclosed area. We brought our large toolbox and other equipment over to the motor. Andy Tubbs and Diana Brien were there with Reggie and I. I think Gary Wehunt was there with us also.
When someone came over the PA system saying, “Stand Clear of Number Two Boiler, We’re Gonna Blast”, all of us dropped everything and ran for the door as if it was an emergency. Reggie, not knowing what was going on ran like the dickens to get out in time only to find us outside laughing at the surprised look on his face.
Like this
Anyway. That wasn’t the day that someone wished they could take back, but I thought I would throw that one in anyway so that now Reggie will wish that he could take back that day.
When I was on Labor Crew, and we were waiting on the boiler for the dynamiters to blast all the large clinkers, the engineer in charge, Ed Hutchins decided that things would go a lot quicker if all the laborers would go into the boiler and shake tubes while the dynamiters were setting their charges. Then we would climb out when they were ready to blast, and then go back in. So, we did that. All 10 or so of us climbed into the boiler, and went to work rattling boiler tubes until we heard someone yell, “Fire In The Hole!!!” Then we would all head for the one entrance and climb out and wait for the blast.
The extra time it took to get all of us in the boiler and back out again actually slowed everything down. We weren’t able to get much work done each time, and everyone spent most of their time climbing in and out instead of working, including the dynamiters. So Ed had another brilliant idea. What if we stayed in the boiler while the dynamite exploded? Then we wouldn’t be wasting valuable time climbing in and out and really wouldn’t have to stop working at all.
Of course, common sense was telling us that we didn’t want to be in an enclosed boiler while several sticks worth of dynamite all exploded nearby, so the engineer decided to prove to us how safe it was by standing just inside the entrance of the boiler with his ear plugs in his ears while the dynamite exploded. The dynamiters at first refused to set off the charges, but after Ed and the labor crew convinced them (some members on the labor crew were anxious for Ed to try out his “brilliant idea) that there really wouldn’t be much lost if the worst happened, they went ahead and set off the dynamite.
Needless to say…. Ed came wobbling his way out of the boiler like a cracked boiled egg and said in a shaky voice, “I don’t think that would be such a good idea.” All of us on the Labor Crew said to each other, “..As if we needed him to tell us that.” I think that may be a day that Ed Hutchins would like to take back. The day he learned the real meaning of “Concussion”. I think he was promoted shortly after that and went to work in Oklahoma City at Corporate Headquarters.
Comments from Original Post:
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eideard April 21, 2012
When you have pallets double-stacked, you should only move them about with a pallet jack. The bottom pallet – and whatever is stacked on it – is thoroughly supported. And even if the pallet jack is powered, you aren’t likely to get in trouble with rapid acceleration.
As you would with a fork lift truck.
And the double stacked pallets are truck mirrors boxed for shipment to retailers. A couple hundred mirrors. And I dumped both pallets when I went to back up and turn into the warehouse aisle.
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jackcurtis May 5, 2012
Modern parables like these are much too good to waste! They should be included in every freshman Congressman’s Washington Welcome Kit when he first takes office and new ‘reminder’ versions again every time he wins an election. These are wonderful essays on unintended consequences, at which our Congress is among the best!
Comments from Previous repost:
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I worked with Ed on the Precipitator control replacement project (84 controls X 2) in 2006 I think. He was getting ready to retire at the time. He was a good engineer and a tough customer. I was working for the control supplier and those 168 controls were the first installation of a brand new control design. I had lead the design team for the controls and this was the culmination of our work. I spend more days and nights than I can remember going up and down the aisles of controls loading software fixes into the processors! Anyway, great people at the plant and great memories… including a rapper control cabinet that took the express route to the ground elevation from the precip roof! (ouch, it really is the sudden stop that gets you!)
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Thanks for the comment John! It’s good to hear about improvements to the Precipitator and the control rooms I used to call home. I spend many weekends walking back and forth through those control rooms.
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OMG – The very thought of a group staying in the boiler when the dynamite went off! Thank goodness THAT didn’t happen. I felt the tension just reading that bit. I’m glad Ed came out of it all right.
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Cracking a Boiled Egg in the Boiler and Other Days You Wish You Could Take Back
Originally Posted on April 13, 2012:
There are some days you wish you could take back after making a grand decision that turns out to look really dumb when your decision fails. It is important to think outside the box to break new ground as long as you bring common sense along for the ride. It seemed that during the days when I was a summer help, and even when I was a laborer on Labor Crew that in order to be promoted you had to come up with one grand idea that set you apart from the others and that also failed miserably.
It was said that the electrical supervisor there before Leroy Godfrey (I can see his face, but his name escapes me), was promoted to that position after he caused the destruction of one of the Intake pump motors (a very large pump that can pump 189,000 gallons of water per minute).
To name a couple of minor “Faux Pas” (how do you pluralize that word? I don’t know), let me start out with the least embarrassing and less dangerous and work my way to the most embarrassing and most dangerous of three different stories of someone thinking out of the box while leaving common sense somewhere behind and maybe wishing they could take back that day.
The first two stories both involve the Electrical Supervisors of two different Power Plants.
Tom Gibson, the Electrical Supervisor from our plant was trying to find a way to keep moisture out of the Bottom Ash Overflow Sump Pumps. This was a reoccurring problem that required a lot of man hours to repair. The bell shaped pump would have to be pulled, the motor would have to be disassembled and dried, and new seals would have to be put in the pump to keep it from leaking.
A Bottom Ash Overflow Sump Pump or BAOSP for Short
So, Tom Gibson decided that he was going to fill the motor and pump cavity with turbine oil. All electricians knew that oil used in turbines is an insulator so electrically it wouldn’t short anything out. But something in the back of your mind automatically says that this isn’t going to work. I remember helping to fill the motor up with oil in the Maintenance shop and hooking up some motor leads from the nearby Maintenance shop 480 volt switchgear. Needless to say, as soon as the pump was turned on, it tripped the breaker and oil began leaking from the cable grommet. That’s when common sense tells you that the all the oil causes too much drag on the rotor which will cause a 480 motor to trip very quickly. After removing some of the oil and trying it again with a larger breaker and still having the same result Tom was satisfied that this just wasn’t going to work. The pump and motor was sent away to a nearby electric shop to be rewound and other ways were developed by the help of our top notch machinist genius Randy Dailey who came up with a positive air pressure way to keep water out of the Bottom Ash Overflow Sump Pump and motor (also known as the BAOSP). Not much harm done and Tom Gibson didn’t feel too bad for trying something that the rest of us sort of thought was mildly insane.
The next story was told to me by my dear friend Bob Kennedy when I was working at a Gas Powered Plant in Midwest City and he was my acting foreman. So I didn’t witness this myself. This one was a little more dangerous, but still thankfully, no one was hurt. Ellis Rooks, the Electrical Supervisor needed to bump test a 4200 Volt motor and wanted to do it in place. For some reason he was not able to use the existing cables, maybe because that was the reason the motor was offline. Because one of the cables had gone to ground. So, he decided that since the motor only pulled 5 to 10 amps he could use #10 wire and string three of them (for the three phases of the motor) from the main High Voltage switchgear across the turbine room floor over to the motor. Now, most electricians know how many amps different size wires can generally handle. It goes like this: #14 – 15 amps, #12 – 20 amps, #10 – 30 amps, #8 – 50 amps and on down (smaller numbers mean bigger wires). So, Ellis thought that since the motor only pulls around 5 amps, and he only wanted to bump the motor (that is, turn it on and off quickly) to watch it rotate, he thought that even though there was normally a 3 – 0 cable (pronounced three aught for 3 zeroes, very large wire), this would be ok because he was only going to bump it.
This works when you are using is 120 or 220 volts
Needless to say, but I will anyway, when the motor was bumped, all that was left were three black streaks of carbon across the turbine room floor where the wire used to exist before it immediately vaporized. You see, common sense tells you that 4200 volts times 5 amps = 21,000 watts of power. However, the starting amps on a motor like this may be around 50 to 100 amps, which would equal 210 to 420 Kilowatts of power (or about 1/5 to 2/5 of a Megawatt). Thus vaporizing the small size 10 wire that is used to wire your house.
All right. I have given you two relatively harmless stories and now the one about cracking the boiled egg in the boiler. This happened when I was still a janitor but was loaned to the Labor Crew during outages. When the boiler would come offline for an outage, the labor crew would go in the boiler and knock down clinkers and shake tubes to clean out clinkers that had built up around the boiler tubes in the intermediate pressure area of the boiler. Clinkers are a hard buildup of ash that can become like large rocks, and when they fall and hit you on the head, depending on the size, can knock you to the floor, which makes wearing your hardhat a must. Your hardhat doesn’t help much when the clinkers falling from some 30 feet above hits you on your shoulder, so I always tried to suck my shoulders up under my hardhat (like a turtle pulling in his arms and legs) so that only my arms were left unprotected. It wasn’t easy looking like a pole with no shoulders, but I tried my best. I think Fred Crocker the tallest and thinnest person on Labor Crew was the best at this. This is the Reheater area of the boiler in the diagram below:
Diagram of a boiler
Before we could get into the boiler to start shaking tubes, the dynamiters would go in there first and blow up the bigger clinkers. So, for a couple of days some times, at the beginning of an overhaul, you would hear someone come over the PA system about every 20 minutes saying, “Stand Clear of Number One Boiler, We’re Gonna Blast!!!” This became so common to hear over the years that unless you were up on the boiler helping out, you didn’t pay any attention to it.
This is something that is only done at a Coal-fired Power Plant because Gas Plants don’t create Ash that turns into Clinkers. Maybe some Soot, I don’t know, but not Ash. Which brings to mind a minor joke we played on Reginald Deloney one day when he came from a gas plant to work on overhaul. Reggie automatically reminded you of Richard Pryor. He had even developed a “Richard Pryor” way of talking.
Richard Pryor trying to look like Reggie Deloney
We were going to work on a Bowl Mill motor first thing, which is down next to the boiler structure in an enclosed area. We brought our large toolbox and other equipment over to the motor. Andy Tubbs and Diana Brien were there with Reggie and I. I think Gary Wehunt was there with us also. When someone came over the PA system saying, “Stand Clear of Number Two Boiler, We’re Gonna Blast”, all of us dropped everything and ran for the door as if it was an emergency. Reggie, not knowing what was going on ran like the dickens to get out in time only to find us outside laughing at the surprised look on his face.
Like this
Anyway. That wasn’t the day that someone wished they could take back, but I thought I would throw that one in anyway so that now Reggie will wish that he could take back that day.
When I was on Labor Crew, and we were waiting on the boiler for the dynamiters to blast all the large clinkers, the engineer in charge, Ed Hutchins decided that things would go a lot quicker if all the laborers would go into the boiler and shake tubes while the dynamiters were setting their charges. Then we would climb out when they were ready to blast, and then go back in. So, we did that. All 10 or so of us climbed into the boiler, and went to work rattling boiler tubes until we heard someone yell, “Fire In The Hole!!!” Then we would all head for the one entrance and climb out and wait for the blast.
The extra time it took to get all of us in the boiler and back out again actually slowed everything down. We weren’t able to get much work done each time, and everyone spent most of their time climbing in and out instead of working, including the dynamiters. So Ed had another brilliant idea. What if we stayed in the boiler while the dynamite exploded? Then we wouldn’t be wasting valuable time climbing in and out and really wouldn’t have to stop working at all.
Of course, common sense was telling us that we didn’t want to be in an enclosed boiler while several sticks worth of dynamite all exploded nearby, so the engineer decided to prove to us how safe it was by standing just inside the entrance of the boiler with his ear plugs in his ears while the dynamite exploded. The dynamiters at first refused to set off the charges, but after Ed and the labor crew convinced them (some members on the labor crew were anxious for Ed to try out his “brilliant idea) that there really wouldn’t be much lost if the worst happened, they went ahead and set off the dynamite.
Needless to say…. Ed came wobbling his way out of the boiler like a cracked boiled egg and said in a shaky voice, “I don’t think that would be such a good idea.” All of us on the Labor Crew said to each other, “..As if we needed him to tell us that.” I think that may be a day that Ed Hutchins would like to take back. The day he learned the real meaning of “Concussion”. I think he was promoted shortly after that and went to work in Oklahoma City at Corporate Headquarters.
Comments from Original Post:
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eideard April 21, 2012
When you have pallets double-stacked, you should only move them about with a pallet jack. The bottom pallet – and whatever is stacked on it – is thoroughly supported. And even if the pallet jack is powered, you aren’t likely to get in trouble with rapid acceleration.
As you would with a fork lift truck.
And the double stacked pallets are truck mirrors boxed for shipment to retailers. A couple hundred mirrors. And I dumped both pallets when I went to back up and turn into the warehouse aisle.
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jackcurtis May 5, 2012
Modern parables like these are much too good to waste! They should be included in every freshman Congressman’s Washington Welcome Kit when he first takes office and new ‘reminder’ versions again every time he wins an election. These are wonderful essays on unintended consequences, at which our Congress is among the best!
Comments from Previous repost:
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I worked with Ed on the Precipitator control replacement project (84 controls X 2) in 2006 I think. He was getting ready to retire at the time. He was a good engineer and a tough customer. I was working for the control supplier and those 168 controls were the first installation of a brand new control design. I had lead the design team for the controls and this was the culmination of our work. I spend more days and nights than I can remember going up and down the aisles of controls loading software fixes into the processors! Anyway, great people at the plant and great memories… including a rapper control cabinet that took the express route to the ground elevation from the precip roof! (ouch, it really is the sudden stop that gets you!)
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Thanks for the comment John! It’s good to hear about improvements to the Precipitate and the control rooms I used to call home.
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OMG – The very thought of a group staying in the boiler when the dynamite went off! Thank goodness THAT didn’t happen. I felt the tension just reading that bit. I’m glad Ed came out of it all right.
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In Memory of Sonny Karcher – Power Plant Man
this was originally posted on January 7, 2012. Added a picture of Sonny Karcher:
When I heard the sad news of the death of Sonny Karcher on 11/11/11, I wished I had been able to attend his funeral. I did observe some amount of time that night when I heard about his death to remember the times I have spent with Sonny. All of them good, as Sonny was always pleasant to be with even when he was mad about something. Here are some of the first and last things I remember:
When I first worked at the Sooner power plant the summer of 1979, Sonny and Larry Riley were the first two mechanics I was assigned to work with. They taught me how things were at the plant at that time. Both of the units were still under construction, so there was no electricity being generated.
The first job we were to work on (my second day at the plant, since the first day was taking a safety class, and getting my hard hat and safety glasses and getting fitted for ear plugs) was a stuck check valve in the dumper sump pump pit (Not only did I not know what a check valve was, I wasn’t too sure what was meant by a dumper sump, though I did know “pump”). It took us about an hour to take the truck to the coal yard, as a coal yard foreman Richard Nix had the key and wasn’t going to give it to us until one of his hands was ready to go with us. So we sat in the truck parked in the north entrance of the maintenance shop for almost an hour. When the guy was finally ready, and he had climbed in the back of the pickup, it turned out that he only needed to go as far as the parking lot… about 200 yards away (as the parking lot was at the Engineer’s shack at the time). We dropped him off and drove up to the coal yard, and made our way down belt 2 to the sump pump pit at the tail end of the belt.
We tested the pump and saw that the water would run back into the sump once the pump stopped running. So, it was determined that the check valve was stuck. We drove back to the plant and took the morning break.
About an hour later, Sonny told me to go to the tool room and get the following items (which I thought was a joke, because he gave me such a strange list of tools that I didn’t recognize): Two ¾ box ends, One four foot soft choker, a ¾ come-along, a ¾ shackle, a two foot steel choker a flat bastard file, a large channel lock, and two pry bars (I did recognize Pry Bars and shackle, which I believed was thrown in there just to make it sound legitimate). – I wrote down the list, because I recognized right away that a joke was being played on me and I was going to play right along. So, I went to the tool room and I asked Bud Schoonover (a very large tall and easy going man at the time), “I need a ¾ come-along (I thought I would choose the most ridiculous item on the list first, just to get it over with…). Well. Bud turned around, walked to the back wall, took a come-along off the top of a pallet full of what appeared to be a bunch of junk, and laid it across the tool room gate window (The tool room was still being “organized” at the time). So, I asked for two ¾ box ends (this was before anyone had been issued toolboxes by the way, that’s why we had to go to the tool room for these things). Well, you know the rest of this part of the story. These are all legitimate items, and I learned a lot that day and the next few weeks about the names of various tools. I kept that list in my wallet for over 10 years as a reminder to myself of when I first came to the plant, and how much I didn’t know then.
So, Larry, Sonny and I went up to the coal yard, and went down to the tail end of #2 belt and removed the check valve from the discharge pipe and brought it back to the maintenance shop to repair. When we returned, we went to lunch. During lunch Sonny told me about how he was hired at Sooner plant. He said he lived a few miles down the road and had heard that someone was building a lake up on top of the hill he could see from his property. So, he went on over to see who was dumb enough to build a lake on top of a hill, and while he was looking around Orville Ferguson came up to him and asked him if he was looking for a job. Sonny said that he liked to mow grass, and Orville said that he would hire him to mow grass then. Sonny said, if I remember correctly, that he was hired at the same time that Linda Shiever, the timekeeper, was hired and that they were the first two new hires at the plant. The rest were already company employees that had transferred there.
After lunch we went down to the shop and took the check valve apart and what do you know…. There was a piece of coal stuck in the check valve keeping it open. We cleaned it up and put it back together. When we were finished, we took our afternoon break. After break we drove back up to the coal yard and went down to the tail end of #2 Conveyor belt and put the check valve back in the discharge pipe. When we returned to the maintenance shop, we returned the tools to the tool room and filled out our time cards. A day’s worth of work cleaning a check valve.
I did many other things that first summer, since Sooner Plant didn’t have a yard crew yet, I worked most of the time in the maintenance shop bouncing around from crew to crew helping out. I also did a lot of coal cleanup (especially on weekends), since the conveyor system didn’t work correctly when they started it up when they were starting to fire up unit 1. But the second day before I left at the end of the summer to go back to school, I worked again with Larry Riley and Sonny Karcher to fix the exact same check valve. This time we jumped in a truck (we had a lot more trucks now…. Which is another story), went to the coal yard, went down #2 tunnel to the tail end of #2 Conveyor, pulled out the check valve, removed the piece of coal, put the check valve back in, went back up to the truck and back to the maintenance shop just in time for morning break. Sooner Plant had improved a lot in the short time three months I worked that summer.
I worked many years with Sonny Karcher in the garage, and fixing coal handling equipment, and just about anything else. He finally left the plant to go mow grass, when after a battle to move to the garage from coal yard maintenance to mow grass, he was told that he was going to have to go back to the coal yard to be a coal yard mechanic, because he was real good at that and they just needed him up there. So he left. He talked to me about it before he went, that’s how I know what was on his mind. He said, “Kev, you remember when you first came here and I told you how they hired me to mow grass? Well, that’s what I want to do. Mow grass. So I’m going to have to go back home and do just that.”
After that, the only times I remember seeing Sonny was when he was mowing grass down at Bill’s corner, with a smile on his face waving at the Sooner plant employees on their way home from work.
I can see Sonny talking to St. Peter at the gates of heaven now….. The only words I can hear Sonny saying is, “I like to mow grass”… and St. Peter nodding with approval.
Sonny Karcher
Cracking a Boiled Egg in the Boiler and Other Days You Wish You Could Take Back — Repost
Originally Posted on April 13, 2012:
There are some days you wish you could take back after making a grand decision that turns out to look really dumb when your decision fails. It is important to think outside the box to break new ground as long as you bring common sense along for the ride. It seemed that during the days when I was a summer help, and even when I was a laborer on Labor Crew that in order to be promoted you had to come up with one grand idea that set you apart from the others and that also failed miserably.
It was said that the electrical supervisor there before Leroy Godfrey (I can see his face, but his name escapes me), was promoted to that position after he caused the destruction of one of the Intake pump motors (a very large pump that can pump 189,000 gallons of water per minute).
To name a couple of minor “Faux Pas” (how do you pluralize that word? I don’t know), let me start out with the least embarrassing and less dangerous and work my way to the most embarrassing and most dangerous of three different stories of someone thinking out of the box while leaving common sense somewhere behind and maybe wishing they could take back that day.
The first two stories both involve the Electrical Supervisors of two different Power Plants.
Tom Gibson, the Electrical Supervisor from our plant was trying to find a way to keep moisture out of the Bottom Ash Overflow Sump Pumps. This was a reoccurring problem that required a lot of man hours to repair. The bell shaped pump would have to be pulled, the motor would have to be disassembled and dried, and new seals would have to be put in the pump to keep it from leaking.
A Bottom Ash Overflow Sump Pump or BAOSP for Short
So, Tom Gibson decided that he was going to fill the motor and pump cavity with turbine oil. All electricians knew that oil used in turbines is an insulator so electrically it wouldn’t short anything out. But something in the back of your mind automatically says that this isn’t going to work. I remember helping to fill the motor up with oil in the Maintenance shop and hooking up some motor leads from the nearby Maintenance shop 480 volt switchgear. Needless to say, as soon as the pump was turned on, it tripped the breaker and oil began leaking from the cable grommet. That’s when common sense tells you that the all the oil causes too much drag on the rotor which will cause a 480 motor to trip very quickly. After removing some of the oil and trying it again with a larger breaker and still having the same result Tom was satisfied that this just wasn’t going to work. The pump and motor was sent away to a nearby electric shop to be rewound and other ways were developed by the help of our top notch machinist genius Randy Dailey who came up with a positive air pressure way to keep water out of the Bottom Ash Overflow Sump Pump and motor (also known as the BAOSP). Not much harm done and Tom Gibson didn’t feel too bad for trying something that the rest of us sort of thought was mildly insane.
The next story was told to me by my dear friend Bob Kennedy when I was working at a Gas Powered Plant in Midwest City and he was my acting foreman. So I didn’t witness this myself. This one was a little more dangerous, but still thankfully, no one was hurt. Ellis Rooks, the Electrical Supervisor needed to bump test a 4200 Volt motor and wanted to do it in place. For some reason he was not able to use the existing cables, maybe because that was the reason the motor was offline. Because one of the cables had gone to ground. So, he decided that since the motor only pulled 5 to 10 amps he could use #10 wire and string three of them (for the three phases of the motor) from the main High Voltage switchgear across the turbine room floor over to the motor. Now, most electricians know how many amps different size wires can generally handle. It goes like this: #14 – 15 amps, #12 – 20 amps, #10 – 30 amps, #8 – 50 amps and on down (smaller numbers mean bigger wires). So, Ellis thought that since the motor only pulls around 5 amps, and he only wanted to bump the motor (that is, turn it on and off quickly) to watch it rotate, he thought that even though there was normally a 3 – 0 cable (pronounced three aught for 3 zeroes, very large wire), this would be ok because he was only going to bump it.
This works when you are using is 120 or 220 volts
Needless to say, but I will anyway, when the motor was bumped, all that was left were three black streaks of carbon across the turbine room floor where the wire used to exist before it immediately vaporized. You see, common sense tells you that 4200 volts times 5 amps = 21,000 watts of power. However, the starting amps on a motor like this may be around 50 to 100 amps, which would equal 210 to 420 Kilowatts of power (or about 1/5 to 2/5 of a Megawatt). Thus vaporizing the small size 10 wire that is used to wire your house.
All right. I have given you two relatively harmless stories and now the one about cracking the boiled egg in the boiler. This happened when I was still a janitor but was loaned to the Labor Crew during outages. When the boiler would come offline for an outage, the labor crew would go in the boiler and knock down clinkers and shake tubes to clean out clinkers that had built up around the boiler tubes in the intermediate pressure area of the boiler. Clinkers are a hard buildup of ash that can become like large rocks, and when they fall and hit you on the head, depending on the size, can knock you to the floor, which makes wearing your hardhat a must. Your hardhat doesn’t help much when the clinkers falling from some 30 feet above hits you on your shoulder, so I always tried to suck my shoulders up under my hardhat (like a turtle pulling in his arms and legs) so that only my arms were left unprotected. It wasn’t easy looking like a pole with no shoulders, but I tried my best. I think Fred Crocker the tallest and thinnest person on Labor Crew was the best at this.
Before we could get into the boiler to start shaking tubes, the dynamiters would go in there first and blow up the bigger clinkers. So, for a couple of days some times, at the beginning of an overhaul, you would hear someone come over the PA system about every 20 minutes saying, “Stand Clear of Number One Boiler, We’re Gonna Blast!!!” This became so common to hear over the years that unless you were up on the boiler helping out, you didn’t pay any attention to it.
This is something that is only done at a Coal-fired Power Plant because Gas Plants don’t create Ash that turns into Clinkers. Maybe some Soot, I don’t know, but not Ash. Which brings to mind a minor joke we played on Reginald Deloney one day when he came from a gas plant to work on overhaul. We were going to work on a Bowl Mill motor first thing, which is down next to the boiler structure in an enclosed area. We brought our large toolbox and other equipment over to the motor. Andy Tubbs and Diana Brien were there with Reggie and I. I think Gary Wehunt was there with us also. When someone came over the PA system saying, “Stand Clear of Number Two Boiler, We’re Gonna Blast”, all of us dropped everything and ran for the door as if it was an emergency. Reggie, not knowing what was going on ran like the dickens to get out in time only to find us outside laughing at the surprised look on his face.
Anyway. That wasn’t the day that someone wished they could take back, but I thought I would throw that one in anyway so that now Reggie will wish that he could take back that day.
When I was on Labor Crew, and we were waiting on the boiler for the dynamiters to blast all the large clinkers, the engineer in charge, Ed Hutchins decided that things would go a lot quicker if all the laborers would go into the boiler and shake tubes while the dynamiters were setting their charges. Then we would climb out when they were ready to blast, and then go back in. So, we did that. All 10 or so of us climbed into the boiler, and went to work rattling boiler tubes until we heard someone yell, “Fire In The Hole!!!” Then we would all head for the one entrance and climb out and wait for the blast.
The extra time it took to get all of us in the boiler and back out again actually slowed everything down. We weren’t able to get much work done each time, and everyone spent most of their time climbing in and out instead of working, including the dynamiters. So Ed had another brilliant idea. What if we stayed in the boiler while the dynamite exploded? Then we wouldn’t be wasting valuable time climbing in and out and really wouldn’t have to stop working at all.
Of course, common sense was telling us that we didn’t want to be in an enclosed boiler while several sticks worth of dynamite all exploded nearby, so the engineer decided to prove to us how safe it was by standing just inside the entrance of the boiler with his ear plugs in his ears while the dynamite exploded. The dynamiters at first refused to set off the charges, but after Ed and the labor crew convinced them that there really wouldn’t be much lost if the worst happened, they went ahead and set off the dynamite.
Needless to say…. Ed came wobbling his way out of the boiler like a cracked boiled egg and said in a shaky voice, “I don’t think that would be such a good idea.” All of us on the Labor Crew said to each other, “..As if we needed him to tell us that.” I think that may be a day that Ed Hutchins would like to take back. The day he learned the real meaning of “Concussion”. I think he was promoted shortly after that and went to work in Oklahoma City at Corporate Headquarters.
Comments from the original Post:
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When you have pallets double-stacked, you should only move them about with a pallet jack. The bottom pallet – and whatever is stacked on it – is thoroughly supported. And even if the pallet jack is powered, you aren’t likely to get in trouble with rapid acceleration.
As you would with a fork lift truck.
And the double stacked pallets are truck mirrors boxed for shipment to retailers. A couple hundred mirrors. And I dumped both pallets when I went to back up and turn into the warehouse aisle.
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Thanks for that. I have a few of those days myself that I will probably share in later posts.
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Modern parables like these are much too good to waste! They should be included in every freshman Congressman’s Washington Welcome Kit when he first takes office and new ‘reminder’ versions again every time he wins an election. These are wonderful essays on unintended consequences, at which our Congress is among the best!
Power Plant Men 
I worked with Ed on the Precipitator control replacement project (84 controls X 2) in 2006 I think. He was getting ready to retire at the time. He was a good engineer and a tough customer. I was working for the control supplier and those 168 controls were the first installation of a brand new control design. I had lead the design team for the controls and this was the culmination of our work. I spend more days and nights than I can remember going up and down the aisles of controls loading software fixes into the processors! Anyway, great people at the plant and great memories… including a rapper control cabinet that took the express route to the ground elevation from the precip roof! (ouch, it really is the sudden stop that gets you!)
Thanks for the comment John! It’s good to hear about improvements to the Precipitator and the control rooms I used to call home. I spend many weekends walking back and forth through those control rooms.
OMG – The very thought of a group staying in the boiler when the dynamite went off! Thank goodness THAT didn’t happen. I felt the tension just reading that bit. I’m glad Ed came out of it all right.