DOCSLIB.ORG

Flying Scotsman Report October

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
Flying Scotsman Report October A report for the Trustees of the Science Museum Group into the restoration of A3 Class Pacific Flying Scotsman and associated engineering project management. Researched and written by Robert Meanley Assisted by Roger Kemp 26 October 2012 Page 1 of 29 1. Executive summary Locomotive 4472 Flying Scotsman was purchased for the nation in April 2004 at a cost of £2.3m by the National Railway Museum (NRM) a, through a sealed-bid auction process. It ran intermittently until December 2005 at which point it was withdrawn from traffic to undergo a major overhaul. The original objective was for the repair to last 1 year and cost about £750k. This proved to be over-optimistic with the work still unfinished 6 years later and the cost likely to exceed £2.6m. The overhaul and renewal of Flying Scotsman has turned out to be one of the most extensive restoration projects ever undertaken in the heritage railways sector. This investigation was set up to discover why it is so late and so much over budget. The reasons for the delays and cost escalation can be summarised as follows: 1. The condition of the locomotive when purchased was poor. In almost 50 years of post- BR ownership, it had a large number of owners, several of which failed financially. It had been heavily used and maintenance standards had been neglected. 2. The pre-purchase inspection was rushed and painted an overly positive picture . 3. NRM failed to undertake an adequate investigation of the condition of the locomotive, either when it first took ownership or at the start of the refurbishment. Consequently the original budget and timescale for the refurbishment were not based on engineering reality. 4. For much of the time, project management was ineffectual or non-existent. Since the project started, half a dozen different people have been in charge, few of whom had experience of managing a £2m engineering project. It has not been possible to find proper scope or planning documentation for the project. 5. NRM’s supply chain was largely restricted to the heritage railways sector. This is a cottage industry that had difficulty in working within the formal contract management procedures expected of a publically-funded organisation. Several suppliers failed to meet their contractual targets but NRM’s contract management system was ineffective in resolving the problems. 6. The NRM engineering organisation was inadequate for the scale of the work or for supporting the formal contract management structure. Staff losses and illnesses and delays in recruitment exacerbated the situation. 7. There were conflicts between the curatorial desire to retain as many original components and assemblies as possible and the need to produce a locomotive meeting the stringent demands of Network Rail for main line operation. 8. There were also conflicts between the desire of senior management for the locomotive to be seen at public events (the public having funded the purchase) and the need to pursue a structured engineering refurbishment programme. These issues are discussed in more detail in the body of the report, which also recommends actions to reduce the likelihood of other projects suffering similar problems. a The National Railway Museum is part of the Science Museum Group (SMG) formerly know as the National Museum of Science and Industry (NMSI). Page 2 of 29 Contents 1. Executive summary.........................................................................................................................2 2. Objective of report..........................................................................................................................4 3. Brief history of Flying Scotsman prior to NRM ownership .............................................................4 4. Timeline for NRM refurbishment....................................................................................................6 5. Assessment of the condition of the locomotive before purchase..................................................8 5.1. The AEA Technology pre-purchase report...........................................................................8 5.2. The valuation report........................................................................................................111 6. Condition of the locomotive on purchase ....................................................................................13 7. Maintenance and operation of the locomotive in the first 12 months........................................14 8. Viability of the initial restoration plan..........................................................................................15 8.1. Refurbishing the A3 boiler.................................................................................................15 8.2. Frames and running gear................................................................................................177 9. NRM Engineering capability and organisation to undertake the restoration ..............................19 9.1. NRM engineering management........................................................................................20 9.2. Professional engineering skills ........................................................................................211 9.3. Managing subcontractors.................................................................................................22 9.4. Using non-railway subcontractors ....................................................................................22 10. Project management and project ‘drift’ .................................................................................233 10.1. Contract management....................................................................................................233 10.2. Conflicts between conservation and standards for main-line operation........................244 10.3. Marketing vs. Restoration.................................................................................................25 10.4. Project drift .......................................................................................................................25 11. Engineering capacity to maintain and operate the locomotive .............................................255 12. Future NRM engineering core competences............................................................................26 12.1. Systems engineering .........................................................................................................27 13. Conclusions and key findings ..................................................................................................277 14. Appendix: List of people interviewed .......................................................................................29 Page 3 of 29 2. Objective of report Locomotive 4472 Flying Scotsman was purchased for the nation in 2004 at a cost of £2.3 million. It ran in preservation for a further year at which point it was withdrawn from traffic to undergo a major overhaul. The original objective was for the repair to last 1 year and cost £750k. This has proved to be an over optimistic outcome with the repairs still unfinished and with a new budget likely to be in the region of £2.6 million. Following the discovery of additional problems, completion is now anticipated in late 2013. The objective of this inquiry 1 is “to conduct full research into the origins of the [restoration] project and its subsequent management from the engineering perspective. The report is not to focus on individuals but is to draw general lessons and conclusions, including recommendations. The following are areas to be covered: ◊ Engineering history of the locomotive pre-purchase. ◊ Steps taken to assess the engineering condition of the locomotive before purchase. ◊ Condition of the locomotive on purchase. ◊ Maintenance history of the locomotive for the first 12-18 months of ownership and operation, and nature of problems discovered at that time. ◊ Viability of the initial restoration plan. ◊ The extent to which NRM Engineering capability and organisation was capable of conducting the restoration. ◊ Project management and project ‘drift’. ◊ Engineering support and capacity required both to maintain and operate the locomotive once complete. ◊ Recommend future NRM engineering requirements and core competences both to restore/maintain operational locomotives and to maintain the static fleet in the National Collection. Access was provided to relevant documents and interviews were held with NRM staff associated with the project and other parties involved (listed in the Appendix). 3. Brief history of Flying Scotsman prior to NRM ownership The locomotive was originally built by LNER as a Class A1 in 1923. On 30 November 1934, it was the first steam locomotive to be officially recorded at 100 mph. Flying Scotsman was rebuilt in 1946-7 as a Class A3, with its boiler pressure increased from 180 psi to 220 psi and carried out a variety of roles under BR ownership until it was withdrawn from service in 1963 when it was sold for preservation and restored at Darlington Works as closely as possible to its LNER condition. Following another overhaul in 1968-9 by the Hunslet Engine Company, Flying Scotsman went on a tour to the USA, for which it was fitted with cowcatcher, buckeye couplings, and other American equipment. This ended in bankruptcy and a change of ownership. The locomotive was returned to Britain in 1973 and was overhauled in Derby Works. It was subsequently based in Carnforth Steamtown, where it was used for rail
Load more

Recommended publications
  • Fall New Items 2017
    Korrektur an Märklin Freigabe Märklin Fall New Items 2017 E Gelesen Korrektur an Märklin Freigabe Märklin Daten an Marieni The last S 3/6 in active service qd%!SW\ A classic that is a must on any layout: The elegant 16185 Express Train Locomotive with a Tender, The locomotive and tender are close coupled. 3 axles Digital Functions DCC SX2 SX class 18.5, a member of the S 3/6 family, generally con- Road Number 18 505 powered through side rods. Traction tires. Triple headlights Headlight(s) • • • sidered by many railroaders as one of the most beautiful Prototype: German Federal Railroad (LVA Minden) road consisting of warm white LEDs. Locomotive whistle • • • steam locomotives. The class 18 505 can still be admired number 18 505 (class S 3/6, series k, Maffei 1924) with a Length over the buffers 142 mm / 5-5/8“. Steam locomotive op. sounds • • at the DGEG Railroad Museum in Neustadt/Weinstraße, type 2´3 T38 tender. The locomotive looks as it did around Conductor‘s Whistle • • Germany. 1967. • Tooling variation. Direct control • • Model: The locomotive is a tooling variation (examples: • Digital sound with many functions. Sound of squealing brakes off • • sound dampers for the Riggenbach counter-pressure Replenishing fuel • • brake, air intake valves). The locomotive and tender are Whistle for switching maneuver • • constructed of die-cast metal. The locomotive has a motor A passenger train to go with this locomotive is Station Announcements • • with a bell-shaped armature and a flywheel, mounted in available under item number 15680. Letting off Steam • • the boiler. It also has a built-in digital decoder and sound Sound of coal being shoveled • • Replenishing fuel generator with the formats DCC, Selectrix, and Selectrix 2.
    [Show full text]
  • RAILTOURS by Sophie Bunker-James
    3403 ANON Recreating Gresley’s last design THE COMMUNICATION ORD No. 56 Winter 2020 C Daniela Filová No. 2007’s tender tank nears completion at North View Engineering. THE P2 PROGRESSES! This edition of The Communication Cord works. At Darlington Locomotive Works boiler parts are beginning to appear for focuses on the volume of work that has great strides continue to be made with the two new diagram 118a boilers, the first been completed on No. 2007 Prince of dozens of sub-assemblies and parts are of which should be assembled later this Wales. Construction of the locomotive now being produced for the fabrication of year. The accelerating rate of construction has moved forward on many fronts but the pony truck in parallel with the on-going means that we must re-double our efforts none more so than the tender, the tank manufacture of the complex electrical to finance all this work if No. 2007 is to be of which is nearly finished at North View system at both DLW and in deepest completed in 2022 – you all know what to Engineering as are the frames at Ian Howitt’s Cambridgeshire (see page 22). In Meiningen do! TCC 1 CONTENTS editorial by Graham Langer PAGE 1 We live in changing and challenging times! With the The P2 progresses! PAGE 2 confirmation that HS2 is going ahead it is becoming clear that Contents there will be massive changes in the way in which the West Editorial Coast route evolves and subsequent benefits for many of the PAGE 3 secondary lines that feed into it.
    [Show full text]
  • The Mikado Messenger | Issue No. 66| April 2020 Ian Matthews Sanding the Filler, on the Tender Tank, Before It Is Painted
    The Mikado Messenger | Issue No. 66| April 2020 Ian Matthews sanding the filler, on the tender tank, before it is painted - A1SLT Welcome to edition No. 66 of The Mikado Messenger, our monthly eNewsletter which aims to provide a regular progress update on the construction of new Gresley class No. 2007 Prince of Wales. Thanks to our supporters’ continued generosity, over £3.5m has now been donated or pledged – this equates to over 70% of the required £5m. This month see the launch of a brand new club - The Pony (Truck) Club - please see below for more information. Stephenson Engineering Ltd have sent us a fabulous video of the CNC machining programme that will be carried out on the coupling rods - it can be found in the Motion Update section, below. We are following Government guidelines with regards to the coronavirus, and whilst our office-based staff are now working from home, our workshop staff are continuing to work at Darlington Locomotive Works where they are taking all necessary precautions. However, as many of our supporters and volunteers are from vulnerable groups, the Works is currently closed to non-essential staff. In addition, Nene Valley Railway have cancelled all their events until the end of May 2020 so this means we can no longer hold the P2 Roadshow on Saturday 23rd May 2020 and the Supporters’ and Tornado Team day on Sunday 24th May 2020. We are sorry to have to make these changes. We hope you understand that the circumstances are beyond our control and the restrictions are very necessary at this challenging time.
    [Show full text]
  • The Economics of Coal As a Locomotive Fuel on US Class I Railroads
    The Economics of Coal as a Locomotive Fuel on US Class I Railroads By John Rhodes Overview • Coal‐Burning Steam Locomotive: 73% Fuel Savings US Class I RR’s • $8.9 Billion 2007 Class I Diesel Fuel Bill • $2.5 Billion Coal Bill Instead • $6.4 Billion Cost Saving • 2007 Operating Ratio Could Have Been 67% Instead Of 78% Presentation Outline • Mechanical Engineers of Modern Steam • The Modern Steam Locomotive • Important Technologies Of Modern Steam • American Class I Railroad: Needs • Maintenance: Modern Steam and Diesel • Comparisons: Modern Steam and Diesel • Infrastructure and Servicing: Modern Steam • Next Steps • Other Locomotive Alternatives The Mechanical Engineers of Modern Steam Pioneers (Deceased): • Andre Chapelon • Livio Dante Porta Current: • David Wardale • Phil Girdlestone • Shaun McMahon • Roger Waller • Nigel Day Andre Chapelon • French Mechanical Engineer 1892‐1978 • SNCF, Steam Locomotive Design Division • Grandfather Of Modern Steam • Applied Thermodynamics And Fluid Dynamics To The Steam Locomotive • Chapelon’s Former Boss, George Chan, From The SNCF Described Him As “The Man Who Gave New Life To The Steam Locomotive” Andre Chapelon cont. • 1946 Design And Construction Of The 3- Cylinder Compound: SNCF 242A.1 – Rebuilt From A 3-Cylinder Simple Locomotive – Raised IHP From 2,800 To 5,500; 96% Increase – Twice The Thermal Efficiency Of American Steam Livio Dante Porta • Argentinean Mechanical Engineer 1922‐2003 • Father Of Modern Steam • Developed 3 Most Important Parts Of Modern Steam: • Clean High Efficiency Combustion • High Efficiency Exhaust • Heavy‐Duty Boiler Water Treatment Livio Dante Porta Cont. • 1949 Built “Argentina” From A 4-6-2 – 2,100 DBHP – High Power-to-Weight Ratio: 65 lb.
    [Show full text]
  • Steam Locomotive Firebox Explosion on the Gettysburg Railroad Near Gardners, Pennsylvania June 16, 1995
    PB96-917008 NTSB/SIR-96/05 NATIONAL TRANSPORTATION SAFETY BOARD WASHINGTON, DC 20594 SPECIAL INVESTIGATION REPORT STEAM LOCOMOTIVE FIREBOX EXPLOSION ON THE GETTYSBURG RAILROAD NEAR GARDNERS, PENNSYLVANIA JUNE 16, 1995 . Illlr 6768 Abstract: On June 16, 1995, the firebox crownsheet of Gettysburg Passenger Services, Inc., steam locomotive 1278 failed while the locomotive was pulling a six-car excursion train about 15 mph near Gardners, Pennsylvania. The failure resulted in an instantaneous release (explosion) of steam through the firebox door and into the locomotive cab, seriously burning the engineer and the two firemen. This accident illustrates the hazards that are always present in the operation of steam locomotives. The Safety Board is concerned that these hazards may be becoming more significant because Federal regulatory controls are outdated and because expertise in operating and maintaining steam locomotives is diminishing steadily. As a result of its investigation, the National Transportation Safety Board issued safety recommendations to the Federal Railroad Administration, the National Board of Boiler and Pressure Vessel Inspectors, and the Tourist Railway Association, Inc. The National Transportation Safety Board is an independent Federal agency dedicated to promoting aviation, railroad, highway, marine, pipeline, and hazardous materials safety. Established in 1967, the agency is mandated by Congress through the Independent Safety Board Act of 1974 to investigate transportation accidents, determine the probable causes of the accidents, issue safety recommendations, study transportation safety issues, and evaluate the safety effectiveness of government agencies involved in transportation. The Safety Board makes public its actions and decisions through accident reports, safety studies, special investigation reports, safety recommendations, and statistical reviews.
    [Show full text]
  • The Communication Cord Is Rather “P2 from Acorns Grow”
    60163 TORNADO 2007 PRINCE OF WALES 3403 ANON New Steam for the Main Line Building Britain’s Most Powerful Steam Locomotive Recreating Gresley’s last design THE COMMUNICATION CORD No. 61 Spring 2021 Simon Apsley/Frewer & Co. Engineers A superb rendering by Simon Apsley of the 3D CAD of Prince of Wales's front end, cut away to show the Lentz gearbox and the double Kylchap exhaust in the smokebox. POETRY IN MOTION? by Graham Langer Despite the difficulties of the past year has involved Frewer and Co. Engineers of No. 2007 – in consequence he has the P2 project continues to forge ahead undertaking the Computational Fluid been sending us the most impressive and we have reached the stage of fine- Dynamics [CFD] analysis of the cylinder renderings of parts and sections of tuning the design for the cylinders and block steam passageways and one of the new P2, some of which we are valve gear so that construction can be their team, Simon Apsley, has got a delighted to feature in this edition of The put out to tender. Part of the process bit carried away with the 3D CADs Communication Cord. TCC 1 CONTENTS EDITORIAL by Graham Langer FROM THE CHAIR by Steve Davies PAGE 1 Poetry in motion? As I write this towards the use of coal. However, the n recent weeks time, from Leicester to Carlisle via the physically meeting. Video conferencing is PAGE 2 editorial Tornado sector produces a tiny percentage of we have all felt spectacular Settle & Carlisle Railway. It probably here to stay but punctuated by Contents is still “confined to the country’s greenhouse gasses and Idrawn even might seem premature to say this, but I periodic ‘actual’ meetings.
    [Show full text]
  • The Niagara Story Thomas R
    The Making Of A Legend- The Niagara Story Thomas R. Get:bracht Part I diameter from 25" on the J1, to 22.5", and they in­ Introduction creased the stroke from 28" to 29" to take maximum In 1945, the Equipment Engineering Department of advantage of the expansive properties of higher pressure the New York Central Railroad developed and Alco exe­ steam. This reduction of 16 percent in cylinder swept cuted a locomotive design which had a marked impact volume was offset by a 22 percent increase in boiler pres­ on the steam locomotives to follow, and on the tradi­ sure, to 275 psi. Main engine starting tractive effort was tional measurements by which motive power would be about the same, at 43,440 lbs. for the J3, but at the same evaluated. This locomotive was so significant that its cutoffs the J3 would be more economical in the use of performance is still discussed by the men who design steam than the Jl. Weight per driving axle increased, and run locomotives. The locomotive was the New York due in part to the use of one piece engine beds and roller Central class S1 4-8-4 Niagara. bearing axles on the J3's. (Later J1's also were provided There have been a number of articles pertaining to by Alco with one piece engine beds.) The weight per this locomotive in the technical and railfan press. The driving axle of the J3 Hudsons was 65,300 lbs. compared purpose of this series is to supplement these various ar­ with the 60,670 lbs.
    [Show full text]
  • New Items 2013 Trix
    New Items 2013 Trix. The Fascination of the Original. New Items 2013 E E Dear Trix Fans, The year 2013 is a very special year for Trix, Another highlight awaits you as a Swiss new because we are bringing old treasures back item. The cultivation of sugar beets is an to life. We are very pleased that Trix Fine Art important part of the economy. Long trains and Trix Express are part of our new items transport beets from Switzerland to Southern for 2013. Germany. A freight car set with a laser-cut kit of a sugar beet loading facility and a tractor What makes the products of the Fine Art with a trailer complete this interesting set. brand so unique? They are produced exten- sively by hand for the particularly demanding Of course, the H0 program has not been model railroaders and collectors. Close- ignored! You can look forward to many excit- ness to the prototype is always up front and ing new items. A heavy class Dm3 ore loco- center with the extraordinary, highly detailed motive used on the Swedish State Railways 2 – 3 New Items for Trix H0 2013 76 –103 brass models for the Fine Art brand. (SJ) runs on the line Lulea – Kiruna – Narvik. New Items for Minitrix 2013 15 – 75 78 – 79 Trix Express is next to Märklin the pioneering Appropriate ore cars can be added to the Starter Sets 16 – 18 Starter Set 80 system for H0 model trains and is back in the locomotive for a long ore train. Gateway to the World 45 – 53 Accessories 106 –107 Trix program for 2013 with four models.
    [Show full text]
  • A Brief History of Front-End Research and Latest Developments
    A Brief History of Front-End Research and Latest Developments Ir. J.J.G. Koopmans Ph.D. Paper presented during the conference on “Developments in modern Steam Traction” in the National Railway Museum in York, 11th of December 2006. 1 Introduction This paper will cover some of the historic highlights of the development of front-ends during the last 200 years. It is also intended to give a phenomenal description of the functioning of a front-end. Illustration and proof of the examples is provided by some of the results of the tests with the RTM 54 steam locomotive. Notion The discussion is about the use of exhausted steam to create artificial draught in the boiler of steam locomotives. Figure 1 Terence Cuneo's painting of the first steam locomotive The history of the front-end started with Richard Trevithick, who mounted a blast pipe from the cylinders to the chimney, and turned its orifice upwards. The 20th century painting by Terence Cuneo, present in the Welsh National Museum, shows this detail together with the feedwater heater around the blast pipe. The picture shows the joyous moment it represents, but this author has some reservations about the way Trevithick is represented, walking with a spanner in his hand. Locomotive owners and engineers have a common and lasting tendency to be on the locomotive themselves! Some 60- years later the first serious research on the subject was started by Prof. Zeuner1. He used a simplified model of a front-end. During the tests he found that certain dimensional ratios in the front-end gave an asymptotic limit to its performance.
    [Show full text]
  • Theory of the Lempor Ejector As Applied to Produce Draught in Steam Locomotives
    Introductory Note Note added February 1999. This theory refers to the fundamentals defining the main dimensions of the ejector. It requires the calculation (or the obtention by experimental procedures) of the boiler characteristics, a serious matter in itself. It also presupposes that a large number of details coming from a long experience are to be respected. It does not include the swirl of both of the steam jet and the gas intake. Finally, a still pending serious problem is that it assumes that the flow is steady, non-pulsating, a field open to future investigation. It is not a "kitchen recipe" guaranteeing good results without a good tuning up with measurements. However, the reader may try, provided that if success crowns his trial and error, the merit is to be credited to the theory. If not, the Author expects that the failure is not to be credited to the theory, but to the user. THEORY OF THE LEMPOR EJECTOR AS APPLIED TO PRODUCE DRAUGHT IN STEAM LOCOMOTIVES Summary This is a revision of the Porta-Taladiz theory of 1957, incorporating the effect of friction in the mixing chamber and other corrections. The theory is based on the principle of conservation of energy as applied by Strahl in 1913, with due corrections for the case under consideration. It serves for the design of an optimum ejector leaving a minimum correction of the blast pipe to be carried out in practice as usual since Stephenson’s times. It serves also to predict the behavior of a given ejector. As a matter of course, the accuracy of either the calculated or the measured performance of the boiler conditions the optimization of the ejector design.
    [Show full text]
  • Full Page Photo
    THE LIFE AND TIMES OF A DUKE Martyn J. McGinty AuthorHouse™ UK Ltd. 500 Avebury Boulevard Central Milton Keynes, MK9 2BE www.authorhouse.co.uk Phone: 08001974150 © 2011. Martyn J. McGinty. All rights reserved No part of this book may be reproduced, stored in a retrieval system, or transmitted by any means without the written permission of the author. First published by AuthorHouse 04/25/2011 ISBN: 978-1-4567-7794-4 (sc) ISBN: 978-1-4567-7795-1 (hc) ISBN: 978-1-4567-7796-8 (e) Front Cover Photo: Th e Duke at Didcot (Courtesy P. Treloar) Any people depicted in stock imagery provided by Th inkstock are models, and such images are being used for illustrative purposes only. Certain stock imagery © Th inkstock. Th is book is printed on acid-free paper. Because of the dynamic nature of the Internet, any web addresses or links contained in this book may have changed since publication and may no longer be valid. Th e views expressed in this work are solely those of the author and do not necessarily refl ect the views of the publisher, and the publisher hereby disclaims any responsibility for them. Born out of Tragedy and Riddles, his lineage traceable, unerasable, back through the great houses of Chapelon, Giffard, Stephenson, Belpaire and Watt, the Duke was laid to rust by the sea, a few meagre miles from the mills that shaped the steel that formed the frames that bore the machine that Crewe built. Time passed and the Duke was made well again by kindly strangers.
    [Show full text]
  • The Lner Society
    6 0163 TORNADO THE New Steam for the Main Line COMMUNICATION CORD No. 39 Summer 2015 Andrew Southwell Andrew Having taken over from Alycidon in York, Tornado heads the return leg at Great Heck. AN A1 JUBILEE! by Graham Langer After a difficult start to the year it feels would be proved wrong and that by 2014 ‘The Silver Jubilee Talisman’ on Saturday like the sun has come out and is now construction would have started on that 26th September and ‘The Peppercorn shining on the Trust during its Silver organisation’s second, massive, steam Phoenix’ on New Year’s Eve, the former Jubilee Year. Yes, it’s been 25 years since locomotive? The A1 Steam Locomotive a celebration of 25 years of Trust activity, a group of visionaries got together and Trust really has something to celebrate the latter a commemoration of the final decided to do something extraordinary, this year. A1 working by No. 60145 Saint Mungo on to build a brand new main line steam As if all this were not enough, The A1 31st December 1965; why not join us and express locomotive! Who would have Steam Locomotive Trust has been able enjoy some exhilarating East Coast Main thought, back in 1990, that the dream to announce not one, but two more of Line running behind a thoroughbred on would become reality, all the doubters its own railtours in the next six months, her ‘home’ track? TCC 1 by Mark Allatt CONTENTS From the chair by Graham Langer PAgE 1 editorial An A1 Jubilee s I write this years.
    [Show full text]