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
Power Plant Safety is Job Number One
Originally posted September 14, 2012:
I found out soon after I arrived at the Coal-fired power plant in Oklahoma the first summer I worked as a summer help that Safety was Job Number One. I was given a hard hat and safety glasses the first day I was there, and I watched a safety film on how to lift with my legs and not with my back. I thought the hard hat made me look really cool. Especially with the safety glasses that looked like someone wore as a scientist during the 1950s. Dark and square.
The first safety glasses we had didn’t have side shields
I used to keep a pair with me when I went back to school. When I was a senior at the University of Missouri, Columbia, while working at the Bakery on Broadway, I kept a pair with me at all times, along with a hat that I had stol…um…. borrowed from my dad and always forgot to return. (In fact, I still have that hat to this day).
A hat just like this. An Inspector Clouseau hat.
That way, whenever someone suspected who I was, I would put on my glasses and hat and people would think I was Clark Kent. Anyway…. I diverse. I never thought about it being an Inspector Clouseau hat until one winter morning in the parking lot at the plant Louise Gates (later Louise Kalicki) called me Inspector Clouseau.
The yellow hard hat made me confident that I was part of the blue collar working class. Hard hats have a suspension system in them that make them look like it is riding too high on your head. You soon get used to it, but for the first couple of weeks I kept bumping into things because my hardhat made me taller than I was used to being.
See? The hardhat looks like it is floating above this man’s head
This is this because of this great suspension system that causes the hat to ride so high on someone’s head. I learned about this not long after I arrived and Marlin McDaniel the A Foreman at the time told me to sort out of bunch of large steel chokers (or slings) in a wooden shack just inside the Maintenance shop by the door to the office elevator.
Ok. Not this big, but pretty large
While I was bending over picking up the chokers (I mean…. While I was lifting with my legs and not my back…) and hanging them on pegs I suddenly found myself laying on the ground. At first I wasn’t sure what had happened because I hadn’t felt anything and it happened so fast. It seemed that my legs had just buckled under me.
I soon realized that one of the large chokers that I had just hung on a peg a couple of feet above my head had fallen off and struck me square in the middle of the hard hat. I was surprised by the force of the cable and how little I had felt. I became a true believer in wearing my hardhat whenever I was working. The steel rope had left a small gash across the hardhat that remained as a reminder to me of the importance of wearing my hardhat at all times.
Larry Riley used to comment to me that I didn’t need to wear it when we were in the truck driving somewhere. Especially when I was sitting in the middle in the back seat of the crew cab and it made it hard for him to see anything through the rear view mirror other than a yellow hard hat sticking up to the top of the cab.
During my first summer at the plant (1979), I did witness how easy it was for someone to hurt their back. I mean… really hurt their back. I was helping to carry a very large 30 foot long section of a wooden extension ladder. There were four of us. Each on one corner. I know that Tom Dean was behind me carrying one side of the back end. I believe that Ben Hutchinson and Aubrey Cargill were on the other side of the ladder.
As we were walking through the shop, Tom stepped on the floor drain just outside of the A Foreman’s office. The drain cover was missing and a wooden piece of plywood had been put in its place to cover the hole.
A Cast Iron Floor drain cover similar to this was missing
Large equipment had driven over the plywood and it was smashed down into the drain making a slight indention in the middle of the floor.
When Tom stepped on the piece of wood, he lost his balance, and ended up spinning himself around as he tried to remain holding onto the ladder. By doing this, he became slightly twisted, and at once he was in terrible pain. Back pain. I didn’t realize it at the time, but this one event was a critical turning point in Tom Dean’s career at the power plant. He was pretty well out the rest of the summer recuperating from the back injury.
The next summer when I returned to the plant, Tom was working in the tool room. Obviously a step down from being a mechanic. He was also very unhappy. You could tell by looking at him that he had lost the proud expression that he had wore the summer before.
I don’t remember how long Tom worked at the plant after that. I just know that it really made me sad to see someone’s life deteriorate during the snapshots that I had in my mind from the summer before to when I returned to see a man tortured not only by back pain, but by a feeling of inadequate self worth. Hurting your back is one of the most common and most serious injuries in an industrial setting. It is definitely a life changing event.
There were other tragedies during my time as a summer help and they didn’t necessarily have to do with something dangerous at work. One summer there was a young man working in the warehouse and tool room. His name was Bill Engleking (thanks Fred. I didn’t remember his name in the original post). The next summer I asked where he had gone, and I learned that one morning he had woke up and found that he had become completely blind. It turned out that he had a very serious case of diabetes. The sugar levels in his blood had reached such dangerous levels that it destroyed his optic nerves overnight.
Then there was one of the Electricians, Bill Ennis. He would say that he was “Blind in one eye and couldn’t see out of the other one.” He was actually blind in one eye completely, and the other eye he was color blind. So, what he said was actually true.
It happened on occasion that people visiting the plant would be seriously hurt. Everyone at the plant was trained in first aid, and Power Plant Men, being the way that they are, are always willing to do whatever it takes to help someone out in time of trouble.
One day during lunch, a man came to the plant to fill the unleaded gas tank on the side of the garage in front of the warehouse. While he was reaching over the PTO (Power Take Off), His shirt sleeve caught in the spinning PTO shaft and broke his arm.
An example of a PTO shaft on a brush hog
I remember Mickey Postman explaining what happened. His crew was eating lunch in the garage when they heard someone yelling for help. When they ran out to see what had happened, they found the man tied up in the PTO with one bone from his arm sticking straight out in the air. They quickly took care of him and treated him for shock as they waited for the Ambulance from Ponca City to arrive.
It is times like this that you wish would never happen, but you are glad that you had first aid training and you know what to do. This person could easily have died from this injury if not for the quick action of Mickey Postman and the rest of his crew. I believe other Power Plant Men that were there to help was Dale Mitchell, George Alley, Don Timmons and Preston Jenkins. Mickey would know for sure. I’ll leave it up to him to remind me.
Mickey Postman
I have illustrated these tragic events to demonstrate the importance of making Safety Job Number One. The Power Plant Men didn’t have to be told by a safety video to know how important it was. They all knew examples of tragedies such as these.
Each month the plant would have the Monthly Safety Meeting, and every Monday morning each crew would have their own safety meeting. Safety pamphlets would be read, safety videos would be watched. Campaigns would be waged to re-emphasize the importance of proper lifting techniques. Everyone in the plant had to take the Defensive Driving course.
The last summer I worked as a summer help in 1982 was the first summer that everyone was required to take the Defensive Driving course. The course was being given by Nancy Brien, Nick Gleason and Ken Couri. We learned a lot of defensive driving slogans like, “Is the Pass really necessary?” “Slow down, ride to the right, ride off the road” (when an emergency vehicle is approaching), “Use the Two Second Rule” (Only, I think it was 3 seconds at that time). “Do a Circle For Safety” etc….
The Defensive Driving Course we took when I was a summer help
My friend Tim Flowers and another summer help were carpooling during that time and we made signs with those slogans on them. Then when we were driving home in my little Honda Civic, we would hold one of those signs up in the back window so that the Power Plant person that was following us home (Usually Dick Dale and Mike Gibbs) would wonder what it said, and would pull up closer to read the sign, and it would say, “Use the 3 second rule”, or “If you can read this, you are too close”.
That was when I began wearing my seat belt all the time. Before that, it was not common for people to wear seat belts. They only had the lap belt before that, and those weren’t the safest things in the world. Especially since they would get lost inside the seat. I attribute the Defensive Driving Course that I took while I was a summer help at the plant for my safe record as a driver. There were a number of tips that I learned then, that I still use all the time today.
There is one advantage to wearing a hardhat that I didn’t realize until I left the power plant in 2001. It is that you never have to worry about hair loss on the top of your head. Whenever you are outside at the plant, you always wear your hardhat and safety glasses. When I changed jobs to become a software developer at Dell, I would find that just by walking down the street in the neighborhood in Texas, I would quickly develop a sunburn on the top of my head.
During the years of wearing a hardhat, I may have been losing my hair, but it never occurred to me. Not until I had a sunburn on the top of my head. I wondered at times if people would look at me funny if I showed up for work in my cubicle at Dell (when we had cubicles) wearing a yellow hardhat. Oh, and a pair of super stylish safety glasses like those shown at the top of this post.
You know when you are young, and I’m sure this has happened to all of you at one point in your life, you dream that you get off of the school bus at your school in the morning only to find that you are still wearing your pajamas. — Yeah. I thought you would remember that one. Well. I still have dreams of showing up at my desk job wearing a hardhat and safety glasses. I don’t realize it until I lift my hardhat up to wipe the sweat off of my brow, then I quickly look around to see if anyone noticed as I stuff the hardhat under the desk.
Comment from previous post:
Jack Curtis January 22, 2014:
The safety meetings, Defensive Driving, safety glasses… it was the same way for telephone men, too. And they jumped in whenever there were problems as well. It is striking to me, to see the differences in attitudes from one generation to another…
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
Power Plant Safety is Job Number One
Originally posted September 14, 2012:
I found out soon after I arrived at the Coal-fired power plant in Oklahoma the first summer I worked as a summer help that Safety was Job Number One. I was given a hard hat and safety glasses the first day I was there, and I watched a safety film on how to lift with my legs and not with my back. I thought the hard hat made me look really cool. Especially with the safety glasses that looked like someone wore as a scientist during the 1950s. Dark and square.
The first safety glasses we had didn’t have side shields
I used to keep a pair with me when I went back to school. When I was a senior at the University of Missouri, Columbia, while working at the Bakery on Broadway, I kept a pair with me at all times, along with a hat that I had stol…um…. borrowed from my dad and always forgot to return. (In fact, I still have that hat to this day).
A hat just like this. An Inspector Clouseau hat.
That way, whenever someone suspected who I was, I would put on my glasses and hat and people would think I was Clark Kent. Anyway…. I diverse. I never thought about it being an Inspector Clouseau hat until one winter morning in the parking lot at the plant Louise Gates (later Louise Kalicki) called me Inspector Clouseau.
The yellow hard hat made me confident that I was part of the blue collar working class. Hard hats have a suspension system in them that make them look like it is riding too high on your head. You soon get used to it, but for the first couple of weeks I kept bumping into things because my hardhat made me taller than I was used to being.
See? The hardhat looks like it is floating above this man’s head
This is this because of this great suspension system that causes the hat to ride so high on someone’s head. I learned about this not long after I arrived and Marlin McDaniel the A Foreman at the time told me to sort out of bunch of large steel chokers (or slings) in a wooden shack just inside the Maintenance shop by the door to the office elevator.
Ok. Not this big, but pretty large
While I was bending over picking up the chokers (I mean…. While I was lifting with my legs and not my back…) and hanging them on pegs I suddenly found myself laying on the ground. At first I wasn’t sure what had happened because I hadn’t felt anything and it happened so fast. It seemed that my legs had just buckled under me.
I soon realized that one of the large chokers that I had just hung on a peg a couple of feet above my head had fallen off and struck me square in the middle of the hard hat. I was surprised by the force of the cable and how little I had felt. I became a true believer in wearing my hardhat whenever I was working. The steel rope had left a small gash across the hardhat that remained as a reminder to me of the importance of wearing my hardhat at all times.
Larry Riley used to comment to me that I didn’t need to wear it when we were in the truck driving somewhere. Especially when I was sitting in the middle in the back seat of the crew cab and it made it hard for him to see anything through the rear view mirror other than a yellow hard hat sticking up to the top of the cab.
During my first summer at the plant (1979), I did witness how easy it was for someone to hurt their back. I mean… really hurt their back. I was helping to carry a very large 30 foot long section of a wooden extension ladder. There were four of us. Each on one corner. I know that Tom Dean was behind me carrying one side of the back end. I believe that Ben Hutchinson and Aubrey Cargill were on the other side of the ladder.
As we were walking through the shop, Tom stepped on the floor drain just outside of the A Foreman’s office. The drain cover was missing and a wooden piece of plywood had been put in its place to cover the hole.
A Cast Iron Floor drain cover similar to this was missing
Large equipment had driven over the plywood and it was smashed down into the drain making a slight indention in the middle of the floor.
When Tom stepped on the piece of wood, he lost his balance, and ended up spinning himself around as he tried to remain holding onto the ladder. By doing this, he became slightly twisted, and at once he was in terrible pain. Back pain. I didn’t realize it at the time, but this one event was a critical turning point in Tom Dean’s career at the power plant. He was pretty well out the rest of the summer recuperating from the back injury.
The next summer when I returned to the plant, Tom was working in the tool room. Obviously a step down from being a mechanic. He was also very unhappy. You could tell by looking at him that he had lost the proud expression that he had wore the summer before.
I don’t remember how long Tom worked at the plant after that. I just know that it really made me sad to see someone’s life deteriorate during the snapshots that I had in my mind from the summer before to when I returned to see a man tortured not only by back pain, but by a feeling of inadequate self worth. Hurting your back is one of the most common and most serious injuries in an industrial setting. It is definitely a life changing event.
There were other tragedies during my time as a summer help and they didn’t necessarily have to do with something dangerous at work. One summer there was a young man working in the warehouse and tool room. His name was Bill Engleking (thanks Fred. I didn’t remember his name in the original post). The next summer I asked where he had gone, and I learned that one morning he had woke up and found that he had become completely blind. It turned out that he had a very serious case of diabetes. The sugar levels in his blood had reached such dangerous levels that it destroyed his optic nerves overnight.
Then there was one of the Electricians, Bill Ennis. He would say that he was “Blind in one eye and couldn’t see out of the other one.” He was actually blind in one eye completely, and the other eye he was color blind. So, what he said was actually true.
It happened on occasion that people visiting the plant would be seriously hurt. Everyone at the plant was trained in first aid, and Power Plant Men, being the way that they are, are always willing to do whatever it takes to help someone out in time of trouble.
One day during lunch, a man came to the plant to fill the unleaded gas tank on the side of the garage in front of the warehouse. While he was reaching over the PTO (Power Take Off), His shirt sleeve caught in the spinning PTO shaft and broke his arm.
An example of a PTO shaft on a brush hog
I remember Mickey Postman explaining what happened. His crew was eating lunch in the garage when they heard someone yelling for help. When they ran out to see what had happened, they found the man tied up in the PTO with one bone from his arm sticking straight out in the air. They quickly took care of him and treated him for shock as they waited for the Ambulance from Ponca City to arrive.
It is times like this that you wish would never happen, but you are glad that you had first aid training and you know what to do. This person could easily have died from this injury if not for the quick action of Mickey Postman and the rest of his crew. I believe other Power Plant Men that were there to help was Dale Mitchell, George Alley, Don Timmons and Preston Jenkins. Mickey would know for sure. I’ll leave it up to him to remind me.
Mickey Postman
I have illustrated these tragic events to demonstrate the importance of making Safety Job Number One. The Power Plant Men didn’t have to be told by a safety video to know how important it was. They all knew examples of tragedies such as these.
Each month the plant would have the Monthly Safety Meeting, and every Monday morning each crew would have their own safety meeting. Safety pamphlets would be read, safety videos would be watched. Campaigns would be waged to re-emphasize the importance of proper lifting techniques. Everyone in the plant had to take the Defensive Driving course.
The last summer I worked as a summer help in 1982 was the first summer that everyone was required to take the Defensive Driving course. The course was being given by Nancy Brien, Nick Gleason and Ken Couri. We learned a lot of defensive driving slogans like, “Is the Pass really necessary?” “Slow down, ride to the right, ride off the road” (when an emergency vehicle is approaching), “Use the Two Second Rule” (Only, I think it was 3 seconds at that time). “Do a Circle For Safety” etc….
The Defensive Driving Course we took when I was a summer help
My friend Tim Flowers and another summer help were carpooling during that time and we made signs with those slogans on them. Then when we were driving home in my little Honda Civic, we would hold one of those signs up in the back window so that the Power Plant person that was following us home (Usually Dick Dale and Mike Gibbs) would wonder what it said, and would pull up closer to read the sign, and it would say, “Use the 3 second rule”, or “If you can read this, you are too close”.
That was when I began wearing my seat belt all the time. Before that, it was not common for people to wear seat belts. They only had the lap belt before that, and those weren’t the safest things in the world. Especially since they would get lost inside the seat. I attribute the Defensive Driving Course that I took while I was a summer help at the plant for my safe record as a driver. There were a number of tips that I learned then, that I still use all the time today.
There is one advantage to wearing a hardhat that I didn’t realize until I left the power plant in 2001. It is that you never have to worry about hair loss on the top of your head. Whenever you are outside at the plant, you always wear your hardhat and safety glasses. When I changed jobs to become a software developer at Dell, I would find that just by walking down the street in the neighborhood in Texas, I would quickly develop a sunburn on the top of my head.
During the years of wearing a hardhat, I may have been losing my hair, but it never occurred to me. Not until I had a sunburn on the top of my head. I wondered at times if people would look at me funny if I showed up for work in my cubicle at Dell (when we had cubicles) wearing a yellow hardhat. Oh, and a pair of super stylish safety glasses like those shown at the top of this post.
You know when you are young, and I’m sure this has happened to all of you at one point in your life, you dream that you get off of the school bus at your school in the morning only to find that you are still wearing your pajamas. — Yeah. I thought you would remember that one. Well. I still have dreams of showing up at my desk job wearing a hardhat and safety glasses. I don’t realize it until I lift my hardhat up to wipe the sweat off of my brow, then I quickly look around to see if anyone noticed as I stuff the hardhat under the desk.
Comment from previous post:
Jack Curtis January 22, 2014:
The safety meetings, Defensive Driving, safety glasses… it was the same way for telephone men, too. And they jumped in whenever there were problems as well. It is striking to me, to see the differences in attitudes from one generation to another…
Power Plant Safety is Job Number One
Originally posted September 14, 2012:
I found out soon after I arrived at the Coal-fired power plant in Oklahoma the first summer I worked as a summer help that Safety was Job Number One. I was given a hard hat and safety glasses the first day I was there, and I watched a safety film on how to lift with my legs and not with my back. I thought the hard hat made me look really cool. Especially with the safety glasses that looked like someone wore as a scientist during the 1950s. Dark and square.
The first safety glasses we had didn’t have side shields
I used to keep a pair with me when I went back to school. When I was a senior at the University of Missouri, Columbia, while working at the Bakery on Broadway, I kept a pair with me at all times, along with a hat that I had stol…um…. borrowed from my dad and always forgot to return. (In fact, I still have that hat to this day).
A hat just like this. An Inspector Clouseau hat.
That way, whenever someone suspected who I was, I would put on my glasses and hat and people would think I was Clark Kent. Anyway…. I diverse. I never thought about it being an Inspector Clouseau hat until one winter morning in the parking lot at the plant Louise Gates (later Louise Kalicki) called me Inspector Clouseau.
The yellow hard hat made me confident that I was part of the blue collar working class. Hard hats have a suspension system in them that make them look like it is riding too high on your head. You soon get used to it, but for the first couple of weeks I kept bumping into things because my hardhat made me taller than I was used to being.
See? The hardhat looks like it is floating above this man’s head
This is this because of this great suspension system that causes the hat to ride so high on someone’s head. I learned about this not long after I arrived and Marlin McDaniel the A Foreman at the time told me to sort out of bunch of large steel chokers (or slings) in a wooden shack just inside the Maintenance shop by the door to the office elevator.
Ok. Not this big, but pretty large
While I was bending over picking up the chokers (I mean…. While I was lifting with my legs and not my back…) and hanging them on pegs I suddenly found myself laying on the ground. At first I wasn’t sure what had happened because I hadn’t felt anything and it happened so fast. It seemed that my legs had just buckled under me.
I soon realized that one of the large chokers that I had just hung on a peg a couple of feet above my head had fallen off and struck me square in the middle of the hard hat. I was surprised by the force of the cable and how little I had felt. I became a true believer in wearing my hardhat whenever I was working. The steel rope had left a small gash across the hardhat that remained as a reminder to me of the importance of wearing my hardhat at all times.
Larry Riley used to comment to me that I didn’t need to wear it when we were in the truck driving somewhere. Especially when I was sitting in the middle in the back seat of the crew cab and it made it hard for him to see anything through the rear view mirror other than a yellow hard hat sticking up to the top of the cab.
During my first summer at the plant (1979), I did witness how easy it was for someone to hurt their back. I mean… really hurt their back. I was helping to carry a very large 30 foot long section of a wooden extension ladder. There were four of us. Each on one corner. I know that Tom Dean was behind me carrying one side of the back end. I believe that Ben Hutchinson and Aubrey Cargill were on the other side of the ladder.
As we were walking through the shop, Tom stepped on the floor drain just outside of the A Foreman’s office. The drain cover was missing and a wooden piece of plywood had been put in its place to cover the hole.
A Cast Iron Floor drain cover similar to this was missing
Large equipment had driven over the plywood and it was smashed down into the drain making a slight indention in the middle of the floor.
When Tom stepped on the piece of wood, he lost his balance, and ended up spinning himself around as he tried to remain holding onto the ladder. By doing this, he became slightly twisted, and at once he was in terrible pain. Back pain. I didn’t realize it at the time, but this one event was a critical turning point in Tom Dean’s career at the power plant. He was pretty well out the rest of the summer recuperating from the back injury.
The next summer when I returned to the plant, Tom was working in the tool room. Obviously a step down from being a mechanic. He was also very unhappy. You could tell by looking at him that he had lost the proud expression that he had wore the summer before.
I don’t remember how long Tom worked at the plant after that. I just know that it really made me sad to see someone’s life deteriorate during the snapshots that I had in my mind from the summer before to when I returned to see a man tortured not only by back pain, but by a feeling of inadequate self worth. Hurting your back is one of the most common and most serious injuries in an industrial setting. It is definitely a life changing event.
There were other tragedies during my time as a summer help and they didn’t necessarily have to do with something dangerous at work. One summer there was a young man working in the warehouse and tool room. His name was Bill Engleking (thanks Fred. I didn’t remember his name in the original post). The next summer I asked where he had gone, and I learned that one morning he had woke up and found that he had become completely blind. It turned out that he had a very serious case of diabetes. The sugar levels in his blood had reached such dangerous levels that it destroyed his optic nerves overnight.
Then there was one of the Electricians, Bill Ennis. He would say that he was “Blind in one eye and couldn’t see out of the other one.” He was actually blind in one eye completely, and the other eye he was color blind. So, what he said was actually true.
It happened on occasion that people visiting the plant would be seriously hurt. Everyone at the plant was trained in first aid, and Power Plant Men, being the way that they are, are always willing to do whatever it takes to help someone out in time of trouble.
One day during lunch, a man came to the plant to fill the unleaded gas tank on the side of the garage in front of the warehouse. While he was reaching over the PTO (Power Take Off), His shirt sleeve caught in the spinning PTO shaft and broke his arm.
An example of a PTO shaft on a brush hog
I remember Mickey Postman explaining what happened. His crew was eating lunch in the garage when they heard someone yelling for help. When they ran out to see what had happened, they found the man tied up in the PTO with one bone from his arm sticking straight out in the air. They quickly took care of him and treated him for shock as they waited for the Ambulance from Ponca City to arrive.
It is times like this that you wish would never happen, but you are glad that you had first aid training and you know what to do. This person could easily have died from this injury if not for the quick action of Mickey Postman and the rest of his crew. I believe other Power Plant Men that were there to help was Dale Mitchell, George Alley, Don Timmons and Preston Jenkins. Mickey would know for sure. I’ll leave it up to him to remind me.
I have illustrated these tragic events to demonstrate the importance of making Safety Job Number One. The Power Plant Men didn’t have to be told by a safety video to know how important it was. They all knew examples of tragedies such as these.
Each month the plant would have the Monthly Safety Meeting, and every Monday morning each crew would have their own safety meeting. Safety pamphlets would be read, safety videos would be watched. Campaigns would be waged to re-emphasize the importance of proper lifting techniques. Everyone in the plant had to take the Defensive Driving course.
The last summer I worked as a summer help in 1982 was the first summer that everyone was required to take the Defensive Driving course. The course was being given by Nancy Brien, Nick Gleason and Ken Couri. We learned a lot of defensive driving slogans like, “Is the Pass really necessary?” “Slow down, ride to the right, ride off the road” (when an emergency vehicle is approaching), “Use the Two Second Rule” (Only, I think it was 3 seconds at that time). “Do a Circle For Safety” etc….
The Defensive Driving Course we took when I was a summer help
My friend Tim Flowers and another summer help were carpooling during that time and we made signs with those slogans on them. Then when we were driving home in my little Honda Civic, we would hold one of those signs up in the back window so that the Power Plant person that was following us home (Usually Dick Dale and Mike Gibbs) would wonder what it said, and would pull up closer to read the sign, and it would say, “Use the 3 second rule”, or “If you can read this, you are too close”.
That was when I began wearing my seat belt all the time. Before that, it was not common for people to wear seat belts. They only had the lap belt before that, and those weren’t the safest things in the world. Especially since they would get lost inside the seat. I attribute the Defensive Driving Course that I took while I was a summer help at the plant for my safe record as a driver. There were a number of tips that I learned then, that I still use all the time today.
There is one advantage to wearing a hardhat that I didn’t realize until I left the power plant in 2001. It is that you never have to worry about hair loss on the top of your head. Whenever you are outside at the plant, you always wear your hardhat and safety glasses. When I changed jobs to become a software developer at Dell, I would find that just by walking down the street in the neighborhood in Texas, I would quickly develop a sunburn on the top of my head.
During the years of wearing a hardhat, I may have been losing my hair, but it never occurred to me. Not until I had a sunburn on the top of my head. I wondered at times if people would look at me funny if I showed up for work in my cubicle at Dell (when we had cubicles) wearing a yellow hardhat. Oh, and a pair of super stylish safety glasses like those shown at the top of this post.
You know when you are young, and I’m sure this has happened to all of you at one point in your life, you dream that you get off of the school bus at your school in the morning only to find that you are still wearing your pajamas. — Yeah. I thought you would remember that one. Well. I still have dreams of showing up at my desk job wearing a hardhat and safety glasses. I don’t realize it until I lift my hardhat up to wipe the sweat off of my brow, then I quickly look around to see if anyone noticed as I stuff the hardhat under the desk.
Comment from previous post:
Jack Curtis January 22, 2014:
The safety meetings, Defensive Driving, safety glasses… it was the same way for telephone men, too. And they jumped in whenever there were problems as well. It is striking to me, to see the differences in attitudes from one generation to another…
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
Power Plant Men 
GLAD that you made it….even if the mallet didn’t!!!
I can dig it. When I was hired for Security at one post…I really looked forward to working with and for that particular Supervisor who’d hired me. No such luck–she was gone in a month or two. THAT hurt! 🙂
If the environment is too hot for a respirator to function properly in, it’s too hot for people to work in (if safety is actually job #1). I saw too many examples of “Get the Unit Back On is Job #1″.