Serioulsy, why did good quality steam coal cause the bars to melt and then fuse?
The coal came from 'outlandish' (Dick Hardy's word!) pits like Ocean Park, Deep Navigations and Penrhiweceiber and was introduced as it was smokeless, and the powers that be declared the suburban locos were producing too much smoke. It was the alien properties of the coal which caused the problem. The usual Notts & Yorks coal broke into pieces when smashed, but the Welsh stuff crumbled and took much longer to fully ignite. Instead it just melted, running molten through the firebars where it was cooled by the draught and set solid deforming the bars beyond use. The fire went dead, steam pressure plummeted and that was that. Even lighting up was a problem the usual oily rags and rolled up newspaper failed to get the fire going.
Two things were supplied to try to help - crystallised firelighters and walnut sized pebbles.
The first are obvious, but a few shovelfuls of pebbles were spread across the firebars prior to adding coal, the idea being that as the fire got hot, so did the pebbles which exploded to keep the molten residue from solidifying between the bars. It worked as well as you might expect, and sheds kept on running out of firebars.
With the intensive service, a method of firing was often used called boxing up - the firebox was filled right up at the start of the journey, and providing the timing was right in that it had burned through sufficiently to maintain steam pressure, it was possible to get the hardest part of the journey (especially the long 1:70 out of Liverpool Street up Bethnal Green Bank) without the fireman half-dying from exhaustion. When Welsh coal was boxed up, not only did it cause the problems noted above, but it actually swelled like a Yorkshire Pudding, causing the brick arch to collapse.
Cue locos stalling in the most inopportune places. Of course the secret was to fire little and often on a white hot firebed to ensure instantaneous combustion, and once this was achieved, the high calorific content of the coal was appreciated as it was easy to maintain a good steam pressure. One by-product also appreciated by the crew was that little ash was left to rake out, just a thin bed of clinker.
In his memoirs, Dick Hardy, then Asst. DMPS at Stratford recalls N7 69620 stalled across the junction at Hackney Downs and after much coaxing, it managed to limp down the bank into Liverpool Street, where, having been attached to a 10 coach train, showed no signs of leaving. When Hardy found them, the crew were mightily fed up and rather hot. Dick gave the fireman a break and set to work with the dart until pressure began to build, then instructed the driver to set off and work the engine as hard as he could. By the time they rounded the curve and had entered the tunnel under Bishopsgate the fire was hitting the roof and cascading along the train, and by Hoe Street the firebed was white hot and the loco blew off.
Typically, just as the crews began to get used to and appreciate the stuff, management stopped buying it in and went back to the original coal supplies.