Posts tagged Steam Locomotive Rebuild Contractor
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.

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 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.

FMW Solutions Enlisted as Strategic Partner for Historic Pennsylvania Railroad Locomotive Restoration
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ALTOONA PA (June 25th)  - The Railroaders Memorial Museum (RMM) announced this week that it has named FMW Solutions LLC as its strategic partner in the restoration of Pennsylvania Railroad K4s-class steam locomotive No. 1361. Working with the board and staff at RMM, and a team of qualified volunteers, FMW Solutions will oversee the day-to-day restoration efforts of the museum’s national icon and assist in strategic planning for the eventual operation of the attraction.

“FMW Solutions brings a remarkable set of skills and talents to this project,” said Joseph DeFrancesco, Executive Director of the RMM. "Their portfolio and professional approach is exactly what we need for this endeavor and their highly credentialed team has a successful track record that speaks for itself.”

“The legacy of the Pennsylvania Railroad, the K4, and the industrious identity of Altoona makes this extremely special to us,” said Davidson Ward, President of FMW Solutions. "Our team is prepared to assist RMM turn a new page in this project. Our hope is to make the locomotive a viable ambassador for Altoona and the Commonwealth for years to come.”

For the past 30 years, the K4 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.

FMW Solutions undertook both traditional computational engineering analyses of the boiler as well as built a 3D CAD model of the boiler. The 3D studies also employed finite element analysis of key boiler components.

FMW Solutions undertook both traditional computational engineering analyses of the boiler as well as built a 3D CAD model of the boiler. The 3D studies also employed finite element analysis of key boiler components.

“Paired with our board of directors, staff, skilled volunteers, government agencies, and donors, this partnership will return The Spirit of Altoona to the high iron once again and create educational and economic development opportunities while fulfilling the museum’s goal to preserve America’s rail heritage through the Altoona railroading experience,” DeFrancesco added.

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. To learn more about the project or to support the museum with donations or memberships, visit railroadcity.org/1361.

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, email info@fwmsolutions.com, or call (423) 425-9753.

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

Steam Locomotive Restoration Passes Major Milestone
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Since 2016, the United States Sugar Corporation (U.S. Sugar) has worked diligently to complete the restoration to operation of historic steam locomotive No. 148, a 1920s-era steam locomotive the company employed decades ago to haul sugarcane from the fields to its mill. In Spring 2019, U.S. Sugar retained FMW Solutions LLC (FMW) to complete the restoration to operation of the historic locomotive, and the locomotive passed a substantial milestone this week: successful completion of its official hydrostatic test of the boiler and witnessed and inspected by Federal Railroad Administration officials.

“This steam locomotive is part of our history, and we wanted to bring it home,’’ said Judy Sanchez, Senior Director of Corporate Communications and Public Affairs for U.S. Sugar, during a welcoming home celebration in Clewiston. “Engine No. 148’s restoration is making great progress, and it is only a matter of time before it is restored to its former glory.”

Locomotive No. 148 was built in 1920 by the American Locomotive Company for use on the Florida East Coast Railway. In 1952, the locomotive was sold to U.S. Sugar for use in hauling sugar cane trains from field-to-plant for processing into refined sugar. After being sold by U.S. Sugar into private ownership in the 1960s, it spent a few years operating, then was moved across the country, finally landing in Monte Vista, Colorado. Thanks to the vision of U.S. Sugar CEO Robert Buker, the locomotive was re-purchased in 2016, kick starting this most recent restoration.

FMW VP-Mechanical Shane Meador inspects the front tube sheet of No. 148 earlier in 2019.

FMW VP-Mechanical Shane Meador inspects the front tube sheet of No. 148 earlier in 2019.

 “The amount of pride U.S. Sugar has in its heritage, and this artifact in particular, is something truly exceptional in this day-and-age,” said Shane Meador, FMW VP-Mechanical. “We are honored that U.S. Sugar approached our firm to complete the restoration to operation of No. 148, and we are pleased with the amount of progress our team has made to-date in finalizing key portions of the project.”

Since assuming its role in managing the project, FMW has overseen substantial boiler, mechanical, and engineering work, including removing the boiler from the frame of the locomotive, driving new rivets into the boiler, reuniting the boiler with the frame, rolling boiler tubes and flues, and additional mechanical and engineering work.

“The Code of Federal Regulations dictates that the boiler be tested hydrostatically, with water of a prescribed temperature range, to 25% above maximum allowable working pressure, or ‘MAWP,’” explained FMW VP-Engineering Wolf Fengler, MSME. “For this test, we pressurized the boiler of No. 148 to 225 PSI in the presence of an FRA Regional Motive Power & Equipment inspector, demonstrating that repairs made to the pressure vessel were completed appropriately.”

Today, U.S. Sugar is the only sugarcane farming company in the continental United States that transports all its cane to a sugar factory by railroad, which saves on fuel and reduces truck traffic and fossil fuel emissions.  Its dozen modern locomotives and 850 specially modified railcars serve more than 300 miles of track, including the South Central Florida Express, which transports sugar, citrus products, fertilizer, farm equipment and other agricultural freight year-round, and the Sugarcane Train, which hauls sugarcane from the fields to the mills during the October-May harvest season.

 With the “hydro” test of No. 148 successfully completed, work will focus on the hundreds of detailed mechanical tasks required to finalize the restoration. With the help of dozens of expert mechanics (including many U.S. Sugar employees), U.S. Sugar is nearing the return the 99-year-old steam engine back to fully operational condition. A date for completion of the project has not yet been set, but as additional milestones are met, updates will be made available. Keep track of the project online via the U.S. SUGAR 148 Facebook Page: https://www.facebook.com/SugarExpressFL/