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The Communication Cord

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The Communication Cord THE COMMUNI C A T ION CORD No. 19 August 2010 Record Breaker! A1 60163 Tornado tackles Shap with ‘The Border Raider’, 24 June 2010. Roy Mears Under repair at Hither Green. Alan Weaver Alan IN THE WORKS By David Elliott and Graham Nicholas The first indication of what has become for the end of June). undertake the full repairs a little earlier our on-going boiler issue occurred on However, following trouble-free trips than planned. 20th May whilst preparing the locomotive to Norwich (28th May) and Bristol (29th Representatives of DB Meiningen for its 22nd May (Chester) train. Peter May), at Canterbury (on 31st May) further travelled to the UK and, after a meeting Neesam discovered a damp patch in the firebox leaks were detected and the with other interested parties (VAB, DB ash, with water coming out of a ‘tell tale’ immediate decision was taken to remove Schenker, insurance company and HMRI), a stay hole in the rear corner of the Tornado from her train. repair process was agreed which involved firebox. Consultation with our colleagues Back at Hither Green depot, with the replacing the defective stays and those at DB Meiningen allowed an approved loco fully cooled down, it was discovered adjacent. Due to the fantastic response of repair to be applied to an isolated stay that there were further defects with two DB Meiningen and grateful co-operation fault such as this, pending a full repair (for other stays in the rear of the firebox. of Balfour Beatty who made their shed which arrangements were put in hand Events had therefore forced us to facilities instantly available, by the following ➤ 1 Thursday evening (11th June), the repairs back corners, welds and adjacent plates. Editorial by Mark Allatt were complete, hydraulic and steam tests This has shown the platework to be in undertaken and engine re-assembled. DB good condition. Not only is this a relief, but he lead news Meiningen meanwhile took the broken it provides further pointers to this being item in the stays back to Germany for metallurgical exclusively a stay problem. T July edition examination. William Cook has also been providing of The Tornado The locomotive then resumed its invaluable support in cleaning up and Telegraph was booked programme, with the run to examining the removed stays to allow a entitled ‘Triumph Swanage on 16th June. This and subsequent detailed picture of the overall condition to & Tragedy’ and I trains culminating in the Trust’s own train, be built up. would say that this ‘The Border Raider’, on the 24th June were At about the same time, the results still sums up the Trust’s position undertaken without incident. However of the metallurgical examination of the over the past few weeks. As you will following the engine and coach run back original failed stays was received back from read elsewhere in this edition of TCC to Stewarts Lane, two further leaking stays Meiningen. This has concluded that the we have the triumph of our record were discovered, once again in the rear of stays have been failing after a prolonged breaking run northbound over Shap the firebox. period of fatigue and stress caused by and the sad news of Tornado’s second It was now clear that we were dealing expansion and thermal cycling. Several withdrawal from service in as many with a wider spread problem than first of the subsequently removed stays have months with boiler stay issues. thought and following further consultation evidence of fatigue damage building up in We have done our utmost during with industry renowned boiler inspector much the same manner. this time to keep our covenantors, John Glaze and DB Meiningen, a more Ultimately, 184 stays were removed customers and other supporters comprehensive stay replacement before all were happy that the affected informed as the current situation, programme was agreed. area had been dealt with and then the primarily through TTT and our Since then, the engine has been at process of replacement could begin. Once website, and I would like to take this Hither Green once more, where a again, we called in the DB Meiningen and opportunity to thank you all for your systematic programme of stay removal and over a concentrated three day period support and understanding. examination has been undertaken. There Monday 26th – Wednesday 28th July the I would also like to put on record is no reliable Non Destructive Test (NDT) new stays were welded in, concluding our thanks to a number of people procedure to identify stays with incipient with a successful hydraulic test. All the and organisations who have gone cracks so the method used involved new welds were proved watertight at first way beyond the call of duty in removing fixed stays up to where the time of asking, which is a pretty impressive helping us to get Tornado back onto flexible stays start, progressively working performance! the main line, in particular Steve out from the bottom back corners column The next step was to conduct a steam Ayton, Graeme Bunker, David Elliott, by column until an area of ‘good’ stays was test and so Tornado was lit up and the Tony Lord, Peter Neesam, Graham established. boiler was allowed to warm through gently Pearce, Jon Pridmore, Mick Robinson, Thanks to a kind offer from Andrew for 60 hours with no pressure raised. and Chris Walker as well as Balfour Cook (of William Cook Cast Products), In the following 12 hours pressure was Beatty (especially Chris McNaughton, Chris Hoyland from William Cook NDT brought around and on Sunday 1st August manager at Hither Green depot, for visited the locomotive on Thursday 8th July the boiler successful passed its steam test. the use of covered facilities at short and carried out state-of-the-art Magnetic This was followed by a successful FTR notice), William Cook Cast Products Particle Inspection (MPI) and Ultrasonic on Sunday 8th August and test run the (David Baxter and Chris Hoyland scanning of the inner and outer firebox following day. David Elliott/A1SLT for the NDT of stay materials and David Elliott/A1SLT of course Andrew Cook for his unstinting support for Tornado) and DB Meiningen (for coming over to the UK so quickly). It’s not all good news with our new support coach either. The vehicle has proved to be in a much worse condition than originally thought and therefore a lot more work is required to bring it up to the requisite standard. Getting Tornado back onto the main line is our Left: Plain Stay number one priority at the moment Right: Flexible Stay and so work on the coach has been de-prioritised whilst we focus on our locomotive and reassess the support coach project plan and cash-flow. Finally, I would like to thanks Stephen Slack, who has had to step down for personal reasons, for his time as editor of Top Link and The Communication Cord. TCC Notes 2 Neil Whitaker Neil Peter Neesam and Trust volunteers re-assemble Tornado after her boiler repairs. So where does this leave us? The nature of time, positively affecting wear patterns. FTR on Sunday 8th August and test run of the defects and the extent of the repairs There is a significant difference between the following day. might sound alarming at first but in fact operational patterns today as compared to It should be stressed that we have not periodic stay replacement is nothing out the 1950s. suffered a single broken stay – modern of the ordinary and is to be expected with Therefore the most likely scenario boiler design using tell-tale holes in the steam locomotive boilers. A quick glance at therefore is that we are simply using stays means that the problem has been the locomotive’s usage records shows that the locomotive at a rate significantly detected at the stage where a small crack the boiler has been taken through over 60 greater than comparable locomotives has worked its way through from the cold-hot-cold cycles since its first steaming in preservation – and like all mechanical surface of the stay to the hole allowing a in 2008. And, as we all know, metal expands things, the more you use it, the quicker visible leak of water. when it is heated up, with the inner firebox it wears out and consequently the more But clearly we don’t want to be faced metal in particular getting very hot when frequent repair work required. A typical with another out-of-course significant the locomotive is in steam with a good 10 year overhaul of a boiler would see repair in 12-18 months time. Therefore fire established - so the source of thermal a significant number of stays replaced by minds are currently focused on an expansion and contraction is obvious. In way of routine; it’s just that in our case, the engineering study to help us predict the some respects, this amount of use puts usage/wear rate is more akin to service areas of the firebox where future stay Tornado ahead of A1s in service days, days where locomotives visited main problems may occur and see if minor when of course locomotives were kept in works every 12-18 months for remedial changes could be made to improve fatigue constant steam for much greater periods attention. This was followed by a successful life. TCC FINANCIAL IMPLICATIONS It was all going so well until we experienced our first boiler stay repairs. Although the Trust has sufficient immediate financial problem at Canterbury on 31st May. The subsequent repairs reserves to deal with such a situation thanks to our prudent resulted in the loss of seven days of main line operations and financial management and the generosity of our supporters, 14 days of operations on heritage railways (the West Somerset those reserves are now significantly depleted and we now Railway and the Bluebell Railway) in addition to the two tours need to re-double our efforts to rebuild them – all donations already cancelled by Torbay Express Limited.
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