Ultimate magic smoke (UMS) story: The summer prior to my senior year in college I was in a salaried position as Student Engineer at Inland Steel in the No.1 Electric Arc Furnace and Billet Caster (a continuous caster). The prior summer, the 1F cap story, worked in the No. 3 Basic Oxygen Furnace and Slab Caster, the number 1 steel making shop in the world, not just then but also now.
Do a web search on continuous casters and find some YouTube videos if you can. They are fascinating....and potentially dangerous as you're about to find out when a 21 year old has control system schematics and a pencil.
The continuous caster control system was in a room perhaps 15m by 10m with most walls covered by enclosed racks of equipment including a bajillion relays. The schematics are a mess, outdated and staff members were concerned about using them and erroneously "fixing" something resulting in a disaster. My job was to red-line the schematics to bring them up to date. So, I have schematics, a pencil, and a multimeter and I'm in the caster control room. There's a door at both ends of the room with the caster, in operation, only about 2 to 3m beyond one of them. I get to work.....with the caster in operation. What could possibly go wrong here?
I'm frustrated, but need to make progress. I think one circuit could be validated if I close this one relay and I'd see just this one other relay flop in an adjacent panel (can anyone guess where this is going?). So I have both panel doors open and find both relays. Using my pencil eraser I close the target relay while keeping an eye on the other.. Then it seemed like there were several hundred relay closures in the room all around me....and it kept on happening!!!! Then a siren alarm sounded....then I looked at the door at the caster end where a red light was flashing.....then I saw molten steel bouncing off of everything.....then I saw two guy run by the door apparently trying to save their lives....then I saw more molten steel fly around all over the place. Oh...my....I just caused a breakout....a phenomenon created when the caster is sped up such that the steel can't form a cooled shell before leaving the mold, so the internal molten contents started spilling onto the floor. Damn! My 21 year old frustration almost got people killed!!!
So, I didn't let the magic smoke out, but I made a very, very big error! There was some water around and some oil & grease, so there was some smoke and a whole bunch of steam. I'll never forget that and it was in 1980!!
Here's the punch line, and it is crazy. After a few weeks I admitted to my boss that I thought I caused the breakout and explained to him in graphic detail. His response to me? "You know what, Bill? We consider you a virgin until you destroy at least $50,000 worth of equipment." Feel free to jump on-line and find one of those inflation calculation tools to see what 1980's $50,000 USD is worth today. You will be stunned!
There's my best magic smoke story, and I was still a student at the time.
take care all!
Bill