Rules for Movement by Train Orders

201. For movements requiring their use, train orders will be issued by authority and over the signature of the superintendent or designated train dispatchers and only contain information or instructions essential to such movements.

They must be brief and clear; in the prescribed forms when applicable; and without alteration, erasure, or interlineation.

Words or figures in train orders must not be surrounded by brackets, circles, or other marks.

The different forms of train orders may be combined in one, provided that every movement in such combination directly affects the train first named in the order.

202. Each train order must be given in the same words to all employees or trains addressed.

203. Train orders, except those relating to track or other conditions, must be numbered consecutively each day, starting at midnight.

Train orders relating to track or other conditions must be numbered consecutively, using a separate series of numbers, and re-issued if continuing in effect for a period of two weeks.

204. Train orders must be addressed to those who will execute or observe them, naming the place at which each is to receive his copy. Those for a train must be regarded as addressed to conductors, enginemen, and also to pilots or snow plow foremen, if any. Those addressed to yardmasters may used only by crews within yard limits. A copy for each employee addressed must be provided by the operator.

Train orders addressed to operators restricting the movement of trains must be respected by conductors and enginemen the same as if addressed to them.

205. Each train order must be written in full in a book provided for the purpose in the office of the train dispatcher; and with it recorded the signals and responses transmitted, the offices from which the order is repeated and the time, the names of those who sign for the order, the times at which the order is made complete, and the train dispatcher’s initials. These records must be made at once and never from memory or memoranda.

Additions to train orders must not be made after they have been repeated.

206. In train orders, regular trains will be designated by numbers as “No. 10 Eng. 756”, sections as “Second 10 Eng. 756” and those handling a snow plow as “No. 86 Eng. 756 snow plow”. If the number of the engine cannot be ascertained the word “unknown” will be used.

Extra trains, except work extras, will be designated by engine numbers and the direction, as “Extra 234 East”, “Psgr. Extra 234 East”, “Mixed Extra 234 East”, “Plow Extra 234 East”, etc.

Work extras will be designated as “Work Extra 234”.

Engines of other railways will be designated by their initials and numbers, as “Eng. ABC 234”, “Extra ABC 234 East”, or “No. 76 Eng. ABC 234”.

When two or more engines are coupled, or when a combination of units are operated in multiple service, the number of the leading engine or unit will be used in train orders, except when an engine or unit is placed on the head end of a train to operate over a portion of a subdivision only, the number of the engine operating through may be used.

To express even hours in train orders the word “oclock” will be used as “nine oclock 900 am (or pm)” and the words “noon” or “night” will be used instead of “am” or “pm” where midday or midnight is involved as “twelve oclock 1200 noon (or night)”.

In transmitting and repeating train orders by telephone, train order numbers, and the numbers of trains and engines in the address, will be pronounced and then spelled letter by letter. All stations and numerals in the body of an order must be first plainly pronounced and then spelled letter by letter, this: Aurora A-u-r-o-r-a, and one nought five o-n-e n-o-u-g-h-t f-i-v-e.

When train orders are transmitted by telephone, train dispatcher must write the order as he transmits it, and check and underscore each word and figure each time it is repeated. When transmitted by telegraph he must write it as it is being repeated the first time and check and underscore each word and figure each time it is repeated thereafter.

207. Before transmitting a train order, the train dispatcher must give the signal 19R or 19Y followed by the direction to each office addressed, the number of copies being stated, if more or less than three, as: “19R east copy 2”, or “19Y west copy 7”, and receive the proper response from the operator as prescribed by Rule 221.

208. A train order to be sent to two or more offices must be transmitted simultaneously to as many of them as practicable. When not sent simultaneously to all, the order must be sent first to the trains being restricted.

OUTSIDE ABS TERRITORY: The operator at the first restricting point (except initial stations) and at all meeting points must, when practicable, be made a party to the order on 19R, and must deliver copies to all trains affected until all have arrived from one direction.

In transmitting a train order of a previous date, the operator must be advised of the date of issue and when such order is repeated, operator will record the date repeated following the repeated order.

208A. OUTSIDE ABS TERRITORY: A train order must not be sent for delivery to a train at the point at which its right or schedule is being restricted by the order if the train order signal is located beyond the point where such train would be required to stop to permit an opposing train to clear, and at other points, except the initial station, such order should not be sent if it can be avoided. When a train order is so sent to a train, except at its initial station, the operator must be made a party to the order and the words “This order to ____ at ____” must be added, which is notice to an opposing train to approach that point at restricted speed. When Form A train order is used, provision must be made for the restricted train to hold the main track under conditions where such train would otherwise be required to take the siding.

209. Operators receiving train orders must write or typewrite them in manifold on the prescribed form during transmission. They must retain a copy of each train order. The word “complete”, the time, and the signature of the operator must be in his handwriting.

If for any reason a train order is to be rewritten, the operator must make additional copies from one previously repeated, and repeat to the train dispatcher from the new copy each time additional copies are made. The date of issue, repeated time, “complete”, and time must not be changed and the name of the operator who first copied the order will be shown with the initials of the operator who made the additional copies.

The train dispatcher must make record in train order book of each repetition.

When an error is made in transmitting a train order and before it has been repeated, all copies of that order must be immediately destroyed, the order marked “void” in the train order book, and if re-issued, given another number.

210. When a train order is transmitted, each operator receiving the order must, unless otherwise directed, repeat it at once from the manifold copy in the succession in which the several offices may have been addressed. Each operator receiving the order must, unless relieved of the duty by the train dispatcher, check the other repeats for correctness. If an operator is so relieved, the train dispatcher must make record in the train order book. An operator must not be relieved of this duty unless one or more operators who have received the order are required to check each repeat.

When an order cannot be simultaneously transmitted to all, or if the repeat from any office is delayed, or is again required, train dispatcher must, when practicable, require an operator from an office from which repeat has already been made to check the correctness of each subsequent repeat. The office checking such repeats must be recorded in the train order book.

210A. In issuing train order, 19Y may be used to restrict right or schedule of trains, except 19R must be used:

When a train carrying passengers is affected outside ABS territory unless the operator has been made party to the order as prescribed by Rule 208;

When an order is sent for delivery to a train at the point at which its right or schedule is being restricted;

When signatures are required as prescribed by Rules 217, 218 and 219.

210B.

210C.

211.

211A.

213.

214.

215.

216.

217.

218.

219.

219A.

220.

221.

222.

223.

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Falconbridge Nickel Mines Railway

While INCO (now Vale) was always the dominant player in the nickel mining and processing scene in Sudbury, Falconbridge (now Glencore) was the major independent competitor to INCO. This post will look at Falconbridge and how it relates to CPR’s railway operations.

Map showing location of Falconbridge smelter (top right) and rail lines. Red lines are Canadian Pacific, blue lines are Canadian National.

Falconbridge Mine and Smelter

Falconbridge Nickel Mines Ltd. was incorporated in 1928 to develop mining claims near the village of Falconbridge to the north-east of Sudbury. The first mine on the site was brought into operation in 1930. At the same time, development of a mill and smelter adjacent to the mine site was begun, with the smelter beginning operation in 1930 and the concentrating mill in 1933. A second mine at Falconbridge opened in 1935.

Due to patent restrictions in North America on nickel refining processes, Falconbridge purchased the Nikkelverk Refinery in Kristiansands, Norway in 1929 to acquire access to the refining processes they required. The smelter in Ontario produced a semi-refined nickel product known as “matte”, which would be refined to cathodes in the Norway facility.

FNM Railway map - Onaping-Levack

Rail map of the Onaping-Levack area. Red line at bottom left is the CPR main line. The (now-abandoned) FNM railway is in purple. Yellow is the INCO line to Levack Mine.

 

Hardy Mine/Mill

In the early 1950s, Falconbridge expanded their mining operations from their original mines on the east side of Sudbury and developed some mines on the north west rim of the Sudbury crater in the Onaping-Levack area. By 1955 these operations included a pair of nickel-copper mines, Hardy Mine and Mount Nickel Mine, and a processing mill (Hardy Mill) located alongside Hardy Mine on the south-west edge of the town of Levack, capable of processing 1,500 tons of ore per day into concentrate which would be shipped to the smelter at Falconbridge east of Sudbury in open cars (hoppers and gondolas). This dry concentrate has been described as “pyrophoric”, meaning it can spontaneously undergo oxidation reactions (combustion) in contact with air and/or moisture, and could arrive at the smelter in a clumped or “burning” state.

To serve the new mines and mill, a new private rail line was built between Hardy Mine/Mill to the CPR Levack siding where several interchange transfer tracks were built. FNM locomotives would haul loads from the mill to the CPR and bring back empties delivered by CP. Hardy Mill was FNM’s rail base of operations, with a single stall engine shop, repair track, and a turning wye located next to the mill loading tracks.

Hardy Mine aerial photo

1975 aerial photo of Hardy mine and mill. City of Greater Subdury aerial imagery. (Click on image to open larger size)

The Hardy Mill operated until 1977 when it was closed, with the older mines in the area reaching end of life near the end of the 1970s, and newer replacement mines having their ore processed at the newer Strathcona Mill (see below).

Fecunis Mine/Mill

In 1956 a new pair of mines, the Fecunis and Longvack Mines were in development on the north-east side of Levack. The odd name of “Fecunis” is based on the chemical symbols of the primary minerals found in the rocks here – iron (Fe), copper (Cu), nickel (Ni), and sulphur (S). By 1957 these mines and a new mill at Fecunis to handle the production were on line capable of processing 2,400 tons per day of ore into concentrate, which like Hardy Mill was shipped in a partially dry concentrate in open cars. The FNM private rail line was extended past Hardy Mill to serve the new mill. Additionally another large mine, the Onaping Mine, was opened by the end of the 1950s.

Fecunis Mine Aerial 1975

Fecunis mine and mill aerial photo from 1975. City of Greater Sudbury aerial imagery. (Click on image to open larger size)

The Fecunis Mill closed operations in 1979.

Strathcona Mill

Also in 1956 the Strathcona Mine was discovered, though it would be 1967 before this mine went into full production along with a brand new mill which would serve as the basis for all further Falconbridge expansions in the Levack/Onaping area.

Strathcona Mill Aerial 1975

Strathcona mill Aerial 1975. City of Greater Sudbury aerial imagery. (Click on image to open larger size)

The new Strathcona mill opened in 1967 with a 6,000 tons per day capacity, but was upgraded quickly to 7,500 tons per day capacity to support increased production from various new mines in the area.

In contrast to the Hardy and Fecunis Mills, the concentrate produced at Strathcona Mill was shipped to the smelter in a slurry form, with the concentrate mixed with water. To handle this traffic, CP provided a small fleet of specially designed short cylindrical hoppers to carry the slurry from Strathcona to Falconbridge. The first 20 of these cars were built in 1967, with another 40 cars added in 1969. These cars operated to the late 1980s or early 1990s, as the cars were starting to wear out due to the rough effects of the concentrate slurry on the interiors of the cars. At this point, rail service to Falconbridge’s Levack operations came to an end, as Falconbridge elected to ship their product by truck rather than agree to CPR freight rates that would have covered replacement costs for the rail cars.

CP 381930 ore slurry car

CP 381930 represents the special hoppers that were constructed for the slurry concentrate service from Strathcona Mill to Falconbridge. Bill Grandin Collection photo.

While no longer rail served, Strathcona Mill remains an important and active processing site for nickel ores from Glencore’s (Falconbridge’s current successor) mines in the area to this day.

Nickel-Iron Refinery

In 1970 Falconbridge opened a large new facility on their property on the south-east side of their main smelter to recover the trace amounts of iron from the processed nickel ores in order to directly market it to the steel industry. Unfortunately this operation was short-lived and closed in 1972.

Aerial photos from 1975 show a rather significant set of railway yard tracks and loading (and/or unloading) structures at this (then shuttered) facility, and CN (which also accessed the Falconbridge smelter via the north side) also built a spur crossing the CPR spur to directly access the iron plant. However given the short lived nature of this operation we have very little other information on its operation from a railway perspective; what went in and out by which railway and what kind of cars used.

Falconbridge Smelter Upgrades

Another major project at Falconbridge was the construction during the 1970s of an upgraded smelter using new modern technology. This modernization project opened in 1978. The project included new fluidized bed roasters which removed iron sulphide from the ore, and electric furnaces to smelt the roasted ore. The upgrade also included an acid plant which captured sulphur compounds from the off-gas of the roasters and produced large quantities of sulphuric acid. Some of the tracks leading to the shuttered iron plant (which was itself demolished) were reused to built large tank car loading racks for the sulphuric acid.

Railway Operations

Operations at Levack should have been fairly simple. While the exact operations of the FNM railway aren’t really documented, it seems Hardy Mine is their base of operations with a small engine shop and repair track. Operating from this base of operations, FNM switchers would gather up outbound loaded cars from the Hardy, Fecunis, and Strathcona Mills and deliver them to the CPR interchange tracks, pick up empties left by CP and spot them at the mills for loading. As noted in the individual descriptions of the mills above, Hardy and Fecunis mills loaded dry or semi-dry concentrate into open cars and Strathcona loaded a liquid slurry into special cylindrical hoppers. On the CP side, a local operating out of Sudbury yard would run up to Levack siding to deliver the empties and lift the loads left by FNM, which would then operate to the smelter where the loads would be dropped off in interchange tracks for the Falconbridge plant switchers.

After Hardy and Fecunis Mills closed (in 1977 and 1979 respectively), the trains from Levack to Falconbridge became “unit” trains of cylindrical slurry cars from Strathcona Mill. By the 1990s rail transport of concentrate from Strathcona was replaced by trucks ending FNM’s rail operations in Levack.

Falconbridge Yard

CP-FNM interchange tracks at Falconbridge smelter site. Note that a CP track is actively performing an interchange here (locos and caboose visible at left.) This shot gives a good overview of the traffic between Onaping and Falconbridge, showing a mix of open cars of dry concentrate, and the distinctive little short slurry cars from Strathcona. At bottom right the FNM switcher appears to also be lifting or spotting covered hoppers probably for nickel matte. (Click on image to open larger size)

Outbound traffic from the smelter was in the form of powdered nickel matte. Due to patent restrictions on refining processes in North America, the matte was shipped to the Falconbridge owned refinery in Kristiansands, Norway for refining. Originally the matte was shipped out of the smelter in barrels, but changed to bulk shipments in covered hopper cars in 1968. As both CN and CP had rail access to the Falconbridge smelter, it’s a little unclear how much product went out via each railway during the 1970s. By the 1990s, CN had abandoned their spur line to Falconbridge and contracted a switching arrangement with CP, wherein CN would supply cars via the interchange at CN Junction between Sudbury and Copper Cliff and CP would exclusively switch the plant.

Coniston

CP local heading up the spur track to Falconbridge in the late 1990s. The train consists mainly of CN hoppers for nickel matte loading (as CN had abandoned their access to Falconbridge by this time and engaged in a switching agreement with CP) and tank cars for sulphuric acid. By this point rail moves of ore concentrate to the smelter had ended. WRMRC collection.

After the new plant upgrades in 1978, sulphuric acid also became a major outbound commodity; with again CN and CP both having direct access to the acid loading tracks until CN’s abandonment of their line to Falconbridge, making it hard to know how much traffic was split between the two railways.

After the 1978 electric furnace upgrade, coke was used as an input. This was sourced from the US and we have noted the occasional presence of various hoppers from the Eastern Seaboard in Sudbury yard in some late seventies photos. An additional input to the mill was powdered dolomite or limestone, which mostly arrived in Penn Central/Conrail covered hoppers.

After the late 1970s upgrade, separate locals handled the ore concentrate from the Levack region and the acid/coke/dolomite/matte traffic to the smelter.

Equipment

Diesel locomotives operated by Falconbridge consisted of a small collection of ALCO/MLW S-series switchers and GE centre-cab models. The larger ALCO and GE 80-ton units seem to have seen service at either Falconbridge or Levack, while the smaller 45 ton models were probably exclusively used within the Falconbridge smelter complex.

Falconbridge 108

Falconbridge S-4 #108, built new for Falconbridge in 1955, showing its 1970s era paint scheme. At CP’s Sudbury shops for maintenance or transfer between FNM operations.

FNM Railway Diesel Locomotive Roster
No. Builder Date Model Notes
101 ALCO 5/49 S-2 ex-NW 3321, ex-Wabash 321; to FNM 3/71
103 ALCO 12/46 S-1 ex-EL 309, ex-ERIE 309; to FNM ?/66
104 GE 8/26 45 ton New
105 GE 1/48 45 ton New; fire damaged 3/71, sold
106 GE 12/51 80 ton New
107 GE 4/53 80 ton New
108 MLW 7/55 S-4 New
109 MLW 1/50 S-4 ex-Canadian Commercial #1, to FNM /68

In terms of freight equipment, Falconbridge would have operated the usual assortment of hot-metal and slag cars for intra-plant movements within the smelter complex, and other freight equipment for the shipment of ores and concentrates from the Levack operation and shipment of refined products out from the smelter were provided by CN and CP.

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