Steam Department Update May 2015

It looked precarious but the acid test (large volunteer jumps up and down on the projecting end!) proved that it was solid.  This way only the thin tips of the forks had to fit above the axle.  With this set up the fitting went relatively smoothly and the tender was again complete with a coupler and ready to push forward onto the locomotive.  Once it is back in place, it is difficult to visualize all the effort that has gone into making it look so normal!.  JD then completed the operation over the next few days with a couple of heavy contacts when coupling to break the wood blocks in the draft gear and release the spring mechanism to its normal operation.

Back in place

In the second week the footplate welding as completed, the tender pushed forward to the locomotive and the drawbars fitted to make her a single unit again.  With this done, she was moved to allow the fitting of the coupling rod on the fireman’s side and she was again mechanically complete.

Around these major activities, a lot of other people were working to:

Rebuild the reverser air cylinder;

Reassembling the reverser

Make and fit the new steam feed line to the air compressor;

Load and fit the brick arch;

Clean and refit the injector starter valves;

Refit all the connections between locomotive and tender;

… and numerous other little tasks.

However, by Wednesday she was ready to switch out to the steam service lead and load with coal and water.  During this came the “ceremonial last task”.  With the assistance of Dave Diamond operating the boom truck, the dome cover was lifted into place.

The last step

On Thursday came the acid test.  The fire was lit and steam raised.  All the essential tests of critical equipment such as safety valves, injectors and air compressor proved very successful.  Once the steam test was completed a number of test runs, first light engine and then with train were completed and we were satisfied that she was again operational.

Having now fired a couple of days it is clear that she is significantly better than last year (after all the Winter work we would be pretty disappointed if this were not the case!!).  A number of nagging steam leaks are gone.  The work on the rear axle has significantly reduced knocking that was apparent last year and the rod bearing that tended to run warm is now cool despite having much less play than last year.  So a very successful outcome to the Winter work program.

It is on Shay #5 that we have the biggest news.  We can now clearly see our way to a second operating steam locomotive in the near future.

She is currently a single unit again and at the North end of the shop. 

One unit again

However the real achievements are not obvious.

Phil’s efforts over the last couple of months have overcome the problem that has sidelined this locomotive for many years.  He successfully cleared the tell-tale holes on all but 20 firebox stays.  So all stays in the boiler are now fully compliant with current FRA requirements and the 20 had all been removed for replacement.

Additional thickness testing was carried out on some parts of the boiler to ensure that we have all the data to complete the form #4 and this indicates that all parts of the boiler and firebox shell are suitable for normal operating pressure.

In the last week, with Brian Davies (who leads this project) up from Florida, all 20 of the stays previously removed were replaced.  (This involves re-tapping the firebox sheets and machining stays to fit each location).  Good progress was also made on peening the ends of a number of the new stays.

New stays in the backhead

Work has also been progressing on exact measurement of the tube sheet and tubes to identify exactly what ferrules are required to fit around the tubes in both front and rear tube sheets.

The remaining work on this locomotive is clearly defined and not as big as it might appear.  So when will we see her in steam?.  A lot of thought is going into this question at present.

The steam department at IRM has traditionally worked almost entirely on a volunteer basis.  Near miracles have been achieved this way but it is slow.  In practical terms a job that would take 2 men 10 days to complete in a traditional back shop would take us 2 months, probably more once you consider that both guys may not be available every weekend and there are inefficiencies in putting a job down and picking it up again a week later.

In the last few months we have, to a limited extent, used donated money to employ people on a part time basis to concentrate several days a week on major jobs and this has allowed us to complete some tasks that had previously been stalled.

So this is the big question being considered now.  The work required to get #5 into steam is now clearly defined:

Re-tube the boiler and hydro test;

Fit (weld and rivet) the new smokebox bottom sheets (inner and outer) and then fit the exhaust assembly into the new steelwork;

Lag the boiler and fit the sheet steel cladding;

Produce and fit a new front beam and walkways;

…………. Plus the various minor tasks to fit accessories and reconnect the drive mechanism.

Several aspects of this work are of the type that would take months to do entirely with volunteer effort but a matter of weeks if we “bite the bullet” and pay people to work full time on them.

On a purely volunteer basis, we should probably be able to get her into service sometime next year.  If we have the funds to accelerate the key tasks, it could be a lot quicker.

So a lot rests on the level of interest.  If you are in favor of accelerating the steaming of Shay#5 by paying to get key work done quickly, consider a donation to the Shay #5 fund.  My own view is clear!.  I will offer to match donations received during June up to a total of $2,000.

Now we go into a few months of very different activity.  There is a lot of work required each week to address any minor maintenance on #1630 then fuel her and prepare for the next operating session.  In parallel with this we hope to progress work on #5, the painting of #938 and various shop improvement projects.  But there is always the contending attraction of taking time out to see #1630 running ……. and you can hardly deny us that pleasure!.

Nigel