Posts in Steam Locomotive Repair
Converting Coal Fired Steam Locomotives to Oil

FMW SOLUTIONS TO CONVERT STORIED U.K. STEAM LOCOMOTIVE TO OIL IN AN EFFORT TO FUTURE-PROOF NORTH YORKSHIRE MOORS RAILWAY

G R O S M O N T, U. K. | U.S.-based railroad engineering and mechanical contractor FMW Solutions (“FMW”) is excited to announce that it will be working alongside the talented shop forces of the North Yorkshire Moors Railway (“NYMR”) to convert historic steam locomotive “Dame Vera Lynn” from coal to oil. This will be the first full-size steam locomotive oil conversion in the U.K. since the end of steam, and it is a crucial step forward in “future-proofing” the busiest heritage railway in the country.

“We are thrilled to work alongside the NYMR Engineering Department at Grosmont to convert War Department (“WD”) 2-10-0 No. 3672 as part of its upcoming overhaul,” explained FMW President Davidson Ward. “This work will be a trans-Atlantic effort, with key firing components being manufactured both at our workshop in Tennessee and by the NYMR forces at Grosmont. The final installation is anticipated to take place on the NYMR.”

In recent years, domestic sources for high-quality steam coal have dried up in the U.K., and changing climate patterns have caused the NYMR to stop running steam locomotives during the height of summer due to the acute risk of lighting lineside fires. The conversion of Dame Vera Lynn from coal to oil is a key step in the “future-proofing” of steam heritage in the U.K.

“We had a chance to join FMW leadership on the Sugar Express steam operation in Florida and experience enhanced oil firing firsthand,” said NYMR Director of Engineer Paul “Piglet” Middleton. “There is no doubt in my mind that the proposed conversion will enable our railroad to adapt to a changing environment and preserve our ability to run steam in the coming decades.”

Ward was a headline speaker at the U.K. Heritage Railway Association conference last November in Newcastle. The presentation before a sold-out room was well received, and FMW is working with various preserved railways in the U.K. to discuss additional opportunities for oil conversion.

Also during his visit, Ward worked alongside engine crews to get a sense of the NYMR operation, firing and driving steam locomotives on their rugged line. With ruling grades over 2% and an 18-mile mainline, the NYMR is among the steepest and longest heritage railways in the U.K., boasting more than 300,000 passengers per year.

FMW and NYMR inked the deal at the close of 2023 and preliminary engineering work is expected to begin in early 2024. Fundraising for the restoration project is underway, and the timeline to see the locomotive returned to operation largely depends on public donations. To learn more about the opportunity, visit the NYMR website.


North Yorkshire Moors Railway has served as a living museum since 1973, playing a vital role in helping preserve the past and protect the legacy of steam travel for future generations in the UK. Its mission is to engage with wider communities, encourage learning for all, and ensure our future environmental and financial sustainability by being an adaptable, dynamic, and innovative charity that inspires all generations.  To learn more, visit www.nymr.co.uk.

FMW Solutions and its subsidiary National Rail Consulting Group offer professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment. For more on FMW Solutions, to request a quote, proposal, or to explore opportunities for your railroad operation, visit fmwsolutions.com, email info@fwmsolutions.com, or call (423) 425-9753.

Steam Locomotive Assessment | Restoration Roundtable with Pennsylvania Raliroad No. 1361

Join the Railroaders Memorial Museum and FMW Solutions to recap the colorful history of Pennsylvania Railroad steam locomotive No. 1361 and explore the engineering and restoration challenges in taking on the rebuild of the Spirit of Altoona. You can support the project by making a donation here.

The restoration of K4 1361 is a thirty-year undertaking that has seen multiple project managers, with considerable work completed. However, there is still much to be done. The latest boiler studies revealed some of the following:

(1) Some of the rivets used in the boiler were of the incorrect steel.
(2) The repair and subsequent re-repair of the main dome course needed further inspection.
(3) Some firebox repairs were completed with improperly sized materials. FMW Solutions has undertaken ultrasonic testing to further assess the boiler’s integrity. It was determined that the firebox area would require some of the project's most substantial repairs.

The square, Belpaire-style firebox with which K4 1361 was built was a key feature of PRR steam locomotives. The Pennsy designed the K4s with the ability to swap components between 400 different locomotive designs. FMW undertook both traditional and computational engineering analysis of the boiler in addition to building a 3D CAD model. Through modifying material thickness and staybolt size, FMW has engineered a solution that will preserve the original Belpaire boiler and return the locomotive to operation. Much of the firebox will be replaced with new steel—resulting in a safer and sturdier locomotive to last.

For a summary of our initial inspection and engineering report for the locomotive, click here.

Rail professionals with expertise in finance, management, and operations join industry consulting firm

CHATTANOOGA, TN – FMW Solutions, a railroad mechanical, engineering, contracting, and consulting firm, has hired railroad veterans Katie Slider as Senior Operations Manager and Roy Wullich as Manager of Operations and Finance.

“Our firm has over 60 active projects between our machine shop, engineering department, heritage work, and diesel locomotive repair efforts,” explained Davidson Ward, President of FMW Solutions. “Katie and Roy will bring valuable organizational support to not only our 30-plus employees around the country but our diverse group of clients as well. We’re humbled to have these accomplished rail industry professionals aboard.”

An award-winning Norfolk Southern employee, Katie Slider’s 24-year career saw her administer equipment planning, operating best practices, end-of-train devices, and car maintenance with senior leadership, mechanical departments, business analysts, and fleet managers. Katie also helped lead Norfolk Southern’s 21st Century Steam Program between 2011 and 2015. Her role at FMW will oversee client onboarding, project management, internal procedures, and the firm’s expanding machine shop in Soddy-Daisy, Tennessee.

With over 40 years in accounting and finance, including 20 years in rail operations, passenger car management, and historic preservation, Roy has held various senior management positions at several international companies including Intel, KPMG, and Price Waterhouse. Roy’s service in rail preservation includes leadership and advisory positions with Canadian Pacific, Railroad Passenger Car Alliance, Tom E. Dailey Foundation, Nashville Steam Preservation Society, and service with the New Kent County Sheriff’s Department.


ABOUT FMW SOLUTIONS

FMW Solutions and its subsidiary National Rail Consulting Group offer a suite of professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment. For more on FMW Solutions, to request a quote, or proposal, or to explore opportunities for your railroad operation, email us, or call (423) 425-9753.

FMW Solutions earns ASME "S Stamp" and NBIC "R Stamp" Certifications for Boiler Repair
 

CHATTANOOGA, TN (March 27th, 2023) – Railroad contracting, engineering, and mechanical services firm FMW Solutions has received its ASME “S Stamp” and NBIC “R Stamp” Certifications. These two certifications enable the firm to complete the new fabrication and repair to “Code” regulated pressure vessels, including steam locomotives operating at theme parks and historic traction engines. FMW is now under contract to assist a steam heritage railroad and a steam traction engine owner with code work, utilizing these new certifications to aid those clients in operating and restoring their historic boilers.

“FMW’s earning of the R and S Stamp certifications allows us to expand our quality boiler repair work beyond just FRA-regulated locomotives,” explained Shane Meador, FMW Vice President – Mechanical. “This development allows our firm to continue providing one-stop, in-house solutions to our heritage customers, utilizing our team of mechanical engineers, welders, fabricators, and machinists to champion craftsmanship in the 21st Century.”

First on the list of “Code” work for FMW is the provision of on-call steam locomotive mechanical, inspection, and repair work to a steam heritage operation in New England. The state-regulated railroad is home to three operational steam locomotives that it operates throughout the tourist season.

In addition to our work in New England, FMW is also assisting with the overhaul of a Nichols & Shepard steam traction engine. While the engineering survey is underway for the boiler, it is envisioned that a new boiler will need to be fabricated for the vintage traction engine. FMW will complete the fabrication of this new boiler at its Soddy-Daisy, Tennessee, machine and fabrication shop.

FMW Solutions and its subsidiary National Rail Consulting Group offer a suite of professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment. For more on FMW Solutions, to request a quote, proposal, or to explore opportunities for your railroad operation, email us, or call (423) 425-9753.

 
Rebuilding a Michigan Icon | Steam Locomotive Running Gear Overhaul

Pere Marquette steam locomotive No. 1225 is undergoing some of the most extensive mechanical restoration work in over 70 years. Visit with leadership from the Steam Railroading Institute and FMW Solutions - Railroad Contractor Services to learn about the in-depth process of renewing the running gear of one of Central Michigan's beloved railroad attractions.

Steam locomotive fuel oil conversion aided by FMW Solutions
FMW Solutions engineers steam locomotive for oil fuel conversion.

Hollidaysburg, PA (March 15th) - The Everett Railroad Company has successfully converted its historic 1920s steam locomotive No. 11 back to fuel oil with help from rail preservation contractor FMW Solutions, allowing the popular tourist railroad operation to improve the locomotive’s performance and simplify its operation.

“With our increased ridership and popularity, the 11 has been operating on our tourist trains now more than ever. It’s become a challenge to get the right coal at a reasonable price, and the quality of coal can greatly affect how a locomotive operates. Combined with our desire to be a good neighbor through reducing smoke, we’ll also be able to simplify our fueling logistics and free up more space for parking,” said Alan Maples, President of the Everett Railroad Company.                       

CAD drawing by FMW Solutions shows a cross section of a steam locomotive smokebox with improvements made to aid the conversion to oil firing.

In addition to designing an improved exhaust nozzle, the engineering work extended the petticoat by 12-inches, reducing the gap between the bellmouth and the nozzle itself to improve draft. This application was largely inspired by L.D. Porta’s Lempor Exhaust system.

The conversion to oil meant more than just changing the fuel. FMW Solutions performed the engineering and design work for the required drafting changes in the locomotive smokebox, which included a new exhaust nozzle, and petticoat extension to optimize draft production without needing to alter the original smokestack. FMW also provided guidance for the firebox and firepan modifications, which Everett Railroad performed in-house.

“There are some major differences in how coal and oil combust, which means that the steam locomotive needs to generate more of a draft on the fire to evenly distribute the heat and draw the fire forward,” explained Wolf Fengler, Vice President of Engineering for FMW Solutions. “Our approach was informed by historic railroad mechanical practices, modern fluid mechanics, and our background in installing similar systems on other locomotives.”       

“Working with FMW Solutions made this an economical solution in more ways than one. With our upcoming season just around the corner, we had a fairly small window to get this conversion right and ensure the conversion itself was cost-effective. FMW had the skills to ensure that this was the case. Their work went a long way to save us money and the engine’s performance now is the best it's ever been,” explained Zach Hall, Everett Railroad steam shop foreman.               

The Everett Railroad constructed a new oil tank for the 11 and Stockton Locomotive Works provided Everett with a burner, firing valve quadrant, and emergency oil shutoff.                   

Built by the Cooke Works of the American Locomotive Company, the locomotive was originally constructed to burn oil for a railroad in Cuba, but ultimately never delivered for its intended use. It was converted to burn coal and served various short line railroads until the 1980s. The 11 was later acquired by the Everett Railroad Company in 2006 and restored to service in 2015.           

The Everett Railroad Company is a short-line freight and tourist railroad headquartered in Hollidaysburg, PA, operating 22 miles of track and providing rail freight transportation for industrial and agricultural customers. Its tourism program has welcomed over 100,000 passengers to the area since 2015. It is currently restoring Huntingdon & Broad Top Mountain Railroad steam locomotive No. 38, which will also be an oil burner. For more information on the Everett Railroad Company, visit everettrailroad.com.                   

FMW Solutions and its subsidiary National Rail Consulting Group offer a suite of professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment. For more on FMW Solutions, to request a quote, proposal, or to explore opportunities for your railroad operation, visit fmwsolutions.com, email us, or call (423) 425-9753.

Steam Railroading Institute and FMW Solutions Partner for Work on Pere Marquette Locomotive No. 1225

OWOSSO, MI - The Steam Railroading Institute (SRI) has retained FMW Solutions to perform critical wheel and running gear work on Pere Marquette steam locomotive No. 1225. Underwritten by recent grants and generous donations, the work will see 1225 lifted, and its 30-tons of drivers, axles, and wheel assemblies removed and rebuilt by FMW. This will be the most extensive running gear work performed on the locomotive since before it was retired in 1951.

“This project is all about sustainability,” shared Steve Wasiura, Superintendent of Facilities & Railroad Operations for SRI. “1225 has been a reliable performer throughout its excursion career, and this work will keep it running for decades more. At FMW, we found partners who share our passion for preservation while understanding what it takes to keep steam-era railroading alive in 2022 and beyond. We are thrilled to be working with them!”

“1225 has emerged as an icon in our industry and one of the few large mainline steam engines with a regular operating schedule, which puts a unique kind of demand on a machine that’s 80 years old,” stated Shane Meador, Vice President of Mechanical for FMW Solutions. “We’re looking forward to assisting SRI in getting thousands of miles more out of this machine.”

1225 joins the lineup of over a half dozen steam locomotives in the United States for which FMW has performed work or is currently under contract, including the restoration of United States Sugar Corporation No. 148; Former Atlantic Coast Line No. 1504 for the United States Sugar Corporation, Pennsylvania Railroad No. 1361 at the Altoona Railroaders Memorial Museum; Nashville, Chattanooga, & St. Louis No. 576; Western Maryland Scenic Railroad No. 1309, among others. FMW is also responsible for the marketing, operations, and passenger car restoration for Sugar Express.

The Steam Railroading Institute is a non-profit, volunteer-driven educational organization dedicated to preserving steam era equipment and the skills needed to maintain and operate it. In addition to Pere Marquette 1225, SRI also operates a growing fleet of historic passenger equipment and is restoring another steam locomotive, Chicago & Northwestern 175, to operation. Visit michigansteamtrain.com for more information on how you can help keep steam railroading alive for future generations.

FMW Solutions and its subsidiary National Rail Consulting Group offer a suite of professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment. For more on FMW Solutions, to request a quote, proposal, or to explore opportunities for your railroad operation, visit fmwsolutions.com, email info@fwmsolutions.com, or call (423) 425-9753.

Steam Locomotive Frame Inspection on Pennsylvania Railroad K4 No. 1361

Vice President of Mechanical Shane Meador walks us through the condition of Pennsylvania Railroad steam locomotive no. 1361's frame at the Railroaders Memorial Museum in Altoona, Pennsylvania. Learn what we've discovered about the frame’s current condition and our expectations for future work on the Spirit of Altoona.

To learn more about the project or to support the museum with donations or memberships, visit www.railroadcity.org/1361. Vintage and historic footage courtesy of the Railroaders Memorial Museum.

To learn more about our work on the K4, click here.

HISTORY

For the past 30 years, the K4-type locomotive has been disassembled, partially restored, but unfinished. In 2019, FMW Solutions performed a comprehensive inspection of No. 1361, including a full review of all past work performed, and a full engineering study of the integrity and repairability of the locomotive boiler. This six-month process included engineering calculations and reporting, 3D modeling, non-destructive spectrometer, radiograph, and ultrasonic thickness tests, rivet material review, visual inspections, and consultation with the Federal Railroad Administration (FRA).

FMW has determined that much of the boiler’s firebox will need to be replaced with new steel. FMW’s findings and repair procedures have been reviewed and accepted by the FRA. The repairs will allow the original Belpaire boiler design to be preserved while being brought up to contemporary safety standards. Projections indicate the restoration, which will include repair of the boiler, appliances, frame, spring and brake rigging, drivers and running gear, and test runs will cost in excess of $2 million dollars.

Initial fundraising efforts are being led by railroad preservation advocates Bennett Levin and former Norfolk Southern and Amtrak CEO Wick Moorman. Among other rail preservation efforts, FMW is currently assisting with the rebuilding of Nashville, Chattanooga, & St. Louis steam locomotive No. 576; recently completed the restoration of U.S. Sugar No. 148, and is undertaking the relocation and eventual rebuilding of Atlantic Coast Line No. 1504. For more on FMW Solutions, to request a quote, or to explore opportunities for your railroad operation, visit fmwsolutions.com.

Former Lucey Boiler Company Site to Host Historic Steam Locomotive Restoration
Atlantic Coast Line steam locomotive no. 1504 has arrived at Lucey Quarter for restoration. Southern steam locomotive no. 4501 was originally restored at Lucey Boiler in the late 1960s and now operates at the nearby Tennessee Valley Railroad Museum.

Atlantic Coast Line steam locomotive no. 1504 has arrived at Lucey Quarter for restoration. Southern steam locomotive no. 4501 was originally restored at Lucey Boiler in the late 1960s and now operates at the nearby Tennessee Valley Railroad Museum.

CHATTANOOGA,  TN - FMW Solutions has expanded its Tennessee operations through the lease of a portion of the Lucey Boiler Company,  increasing its railroad restoration shop capabilities in the region. Lucey Boiler will host the complete overhaul of historic Atlantic Coast Line steam locomotive No. 1504, which was relocated to the region from Jacksonville, Florida in an effort assisted by the City of Chattanooga and the Tennessee Valley Railway Museum.

“We’re genuinely thrilled to be growing our company’s craft in Chattanooga,” said Shane Meador, VP - Mechanical of FMW Solutions. “In addition to our machine and fabrication shop in Soddy Daisy, Tennessee, our firm is capable of taking on mechanical and restoration projects of any scope, including complete steam and diesel locomotive overhaul, at remote locations across the U.S.”

The 52,000-sq foot Lucey Boiler Company facility is slated for redevelopment into Lucey Quarter by Southern Spear Properties. This investment in the Highland Park Neighborhood aims to transform the century-old industrial complex into a mixed-use community gathering place adjacent to the East Line pathway and the former Belt Railway of Chattanooga. 

“Lucey Quarter will be a historical destination for Chattanooga residents and the southeast,” explained Sean Compton, President of Southern Spear Properties. “The rebuilding of this incredible machine will drive buzz and be the crown jewel in our historical redevelopment. FMW Solutions are incredible in the work they do and pride they apply to their craft. We are thrilled in this partnership and hope to make it a staple of Chattanooga for many years to come.”

Acquired from the City of Jacksonville earlier this year by Sugar Express LLC, locomotive No. 1504 is being returned to operation as a key part of a regional rail tourism and education program in South Central Florida. 

FMW Solutions has worked in collaboration with Sugar Express since 2019, including having successfully completed the restoration of No. 148, the first steam locomotive in the Sugar Express operation. FMW is also underway renovating passenger cars and aiding Sugar Express with strategic planning and operations at its headquarters in Clewiston, Florida. 

“We’ve grown our staff considerably in the last eight months to include 18 full and part-time positions across the United States, and we’ve also grown our services to include experts in safety training and FRA compliance, operations, fabrication, marketing,  grant-writing, and more,” explained Meador. “Our use of the Lucey Boiler facility will also serve as a jumping-off point for our continued growth in alternative fuels research and development; which is another growth sector for our business and signals yet another investment in Chattanooga.”

As part of its network for both rail preservation and modern railroad clients, FMW also maintains a heavy machine shop space and tooling in Watervliet, New York and an engineering and design office in Colorado Springs.

About Atlantic Coast Line No. 1504: Constructed in 1919, locomotive No. 1504 served across the entire Atlantic Coast line engine was retired in 1952 and donated to the City of Jacksonville, where it was later cared for by the North Florida Chapter of the National Railway Historical Society. The locomotive will undergo an extensive three-year rebuilding process at the Lucey Boiler site and current plans call for the finished locomotive to be shipped back and reassembled in Clewiston. 

For more information on Sugar Express, visit sugarexpress.com.

About Lucey Quarter: An urban hub planned for the Highland Park neighborhood, Lucey Quarter is a $20 million, 52,000 square foot development planned for the Lucey Boiler Company site and will include spaces for community, commerce, entertainment and housing. 

For more information in Lucey Quarter, visit luceyquarter.com.

FMW Solutions and its affiliate National Rail Consulting Group offer a suite of professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment. For more on FMW Solutions, to request a quote, or to explore opportunities for your railroad operation email us, or call (423) 425-9753.

Steam Locomotive Boiler and Firebox Inspection on Pennsylvania Railroad K4 No. 1361

How do you begin to rebuild The Spirit of Altoona?

Join Wolf Fengler, Vice President of Engineering for FMW Solutions, on a tour of the boiler and Belpaire firebox of Pennsylvania Railroad steam locomotive no. 1361 at the Railroaders Memorial Museum in Altoona, Pennsylvania. Learn what we've discovered about the locomotive’s current condition and our process to assess past work on this historic machine.

To learn more about the project or to support the museum with donations or memberships, visit www.railroadcity.org/1361. Vintage and historic footage courtesy of the Railroaders Memorial Museum.

To learn more about our work on the K4, click here.