Submarine Design and the Development of the Astute Class Presented - - PowerPoint PPT Presentation

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Submarine Design and the Development of the Astute Class Presented - - PowerPoint PPT Presentation

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Submarine Design and the Development of the Astute Class Presented by Kevin Young BEng(Hons) CEng MIMechE Head of Engineering Design Improvement BAE Systems Submarines Solutions 4 th December 2007 Date/reference/classification 1 Contents

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Submarine Design and the Development of the Astute Class

Presented by Kevin Young BEng(Hons) CEng MIMechE

Head of Engineering – Design Improvement BAE Systems Submarines Solutions

4th December 2007

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Contents

  • BAE Systems & the Barrow Shipyard
  • Why Submarines?
  • The Requirement
  • The Astute Design
  • The Product
  • Build Strategy
  • Construction
  • Major Modules
  • Roll out and Naming Ceremony
  • Trim Dive
  • Questions
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BAE Systems & The Barrow Shipyard

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BAE Systems Submarine Solutions

Barrow-in-Furness (3400) Farnborough (107) Weymouth (34) Filton (5) Ash Vale (30)

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What we currently do…

  • Design, build and preliminary in-service

support for 4 Astute class submarines for the Royal Navy. Bidding for boat 5.

  • The delivery of the Swiftsure and Trafalgar

class update programme for the Royal Navy

  • Industry lead for successor SSBN

programme

  • CVF Engineering and Block build
  • Export contract with Spain for build strategy

and manufacture of dome pieces for Spanish submarine programme

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First of Class Pedigree

Vanguard (4) Astute (3+) Upholder/ Victoria (4) Swiftsure (6) Trafalgar (7) Upholder (4) Invincible (3) T42 (7) Sheffield T42 (Stretch) (4) Manchester Ocean (1) Albion (2) Wave (2)

2000 1995 1990 1985 1980

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Brief History - Submaries

  • First Royal Navy Submarine was Holland 1 built in Barrow in 1901
  • Early Naval submarines were designed to operate predominantly on the surface,
  • nly diving to remain concealed (normally during the day). The submarines

would submerge to attack a target and then remain submerged to make their escape.

  • Early submarines were powered in two ways – diesel powered on the surface,

electrically powered whilst submerged. Limited running time underwater

  • The German Navy are said to have been the first to use diesel engines (1906)

and to deploy a snorkel (1940’).

  • The first nuclear submarine – USS Nautilus (1954)
  • First Royal Navy Submarine was HMS Dreadnought, built in Barrow
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Why Submarines?

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Why Submarines?

  • The ultimate stealth vessels - can fulfil roles no other vessel

can:

  • Go anywhere underwater
  • Anti submarine and anti surface ship capability
  • Deny enemies the use of an area
  • Gather data (both electronically and visually)
  • Undertake precise strike / land attack
  • (Virtually) invulnerable nuclear deterrent
  • Assymetric force
  • Stealth
  • you don’t know it’s there, AND you don’t know it’s not there !
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Why Nuclear?

  • Can stay underwater for very long periods
  • doesn’t need refuelling,
  • produce their own oxygen/water supplies,
  • Can completely circumnavigate the world underwater
  • the only limit on time underwater is food and crew endurance.
  • Can deploy rapidly and covertly to any area of the globe
  • Much higher sustained speeds than diesel electric boats
  • No need to surface or snort
  • Greater Stored Energy
  • Boat can be larger with more capability and greater crew comfort
  • Able to support more weapons/sensors
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The Requirement

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The Requirement

  • The Royal Navy operates two different types of

submarine SSN, SSBN

  • SSBN provide the nuclear deterrent
  • The Royal Navy have 4 Vanguard class SSBNs 150m

long, 16000 T

  • SSNs are ‘Hunter/Killer’ Submarines
  • Anti submarine/ship warfare
  • Surveillance
  • Reconnaissance
  • Land attack using missiles.
  • The RN currently has 9 SSNs, each about 85m long,

weighing about 4600Te

  • Swiftsure & Trafalgar Classes
  • Astute is SSN20
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The Astute Design

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SSN 20 - 24/5

Trafalgar Astute

SSBN 05 - 08 SSN 13 - 19

S&T Update Vanguard Upholder

Design

  • The Reality: Greater weapons/sensors capacity, enhanced Reactor safety,

enhanced boat safety and modular build means:

  • A longer, wider and heavier boat than originally planned
  • over 70% of components are new or re-qualified
  • The Original Theory (Batch 2 Trafalgar):
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The Product

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Astute Class

  • 97m long
  • 10m draught
  • 11.3 beam
  • Displaces 7,400 tonnes submerged
  • Depth >300m
  • >25 knots
  • 6 Torpedo tubes
  • Stowage for 1.5 x T class weapons
  • Spearfish
  • Tomahawks
  • PWR2 Pressurised Water Reactor –

fuelled for life

  • Astute’s sonar suite has the

processing power of c1,000 Pentium IV computers

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A Complex Design

  • The Astute Boat 1 plan comprises:
  • 3000 requirements
  • 7,100 drawings
  • 29,000 build activities
  • 96,000 installable items
  • 10,000 devices
  • A Nuclear Submarine built today by BAE Systems is comparable in engineering

complexity with current space programmes (as recognised in US research programmes).

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A Complex Design

Space Shuttle Astute Length, Diameter 38m, 7m 97m, 10.7m Weight 78 T.e. 7400 T.e. Components 3 main engines 368 km of cable 1,060 valves 27,000 tiles Nuclear reactor, 2 diesel generators, weapons 148 km of cable 23,000 pipes, 5,000 valves 50,000 tiles Crew 5 - 7 97 Mission Duration, Design Life 5 – 16 days, 100 missions > 90 days, 25 years Environment 190 – 350 miles above sea level, vacuum Below sea level, very high pressure, corrosive Speed 17500 m.p.h. > 25 knots

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General Layout

Engine Room Weapons Stowage Compartment Bow Array Accommodation Diesel Generators Reactor Compartment Command Deck

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Build Strategy

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Build Strategy

  • Construction Elephant
  • Modular Construction
  • Pre-outfit
  • Modularisation
  • Maximise Construction Facilities
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HMS Astute - Boat 1122 Build Definition

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Construction

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Explaining Build Stages

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Units that make up the Astute Submarine

DDH Build Line Prior to Combination of Boat

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Vertical Outfit

  • Parallel / concurrent working fronts
  • 360 degree working internal / external of unit
  • More efficient equipment installation (improves access to pressure hull outfitting)
  • Allows a greater number of tradesmen to work at one time
  • Allows the use of cranes rather than fleeting / end loading
  • Staging is lifted in and out with crane in levels, hence no building taking part inside

unit

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Horizontal Outfit Units Ready for Combination

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Structural Welding

  • Materials
  • HY80 derivative and HSLA 80
  • Weld techniques
  • Submerged Arc automated for pressure hull (virtually defect free on Astute)
  • Flux Core for remainder
  • NDE techniques
  • Radiography largely replaced by Time of Flight Tip Diffraction Ultrasonics

allied to phased array sensing of near surface crack tip detection.

  • Increasingly fabrications (often weld clad) are replacing castings
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Other Welding

  • Pipe Materials
  • 316L Stainless Steel (thick and thin wall)
  • 254 SMO Super Duplex Stainless Steel
  • 3602 Carbon Steel
  • 70/30 Copper/Nickel
  • 90/10 Copper Nickel
  • Monel K500
  • Overall there are 57,000 pipe welds
  • Many are high integrity welds with strict QA controls
  • NDE
  • Radiography still dominant
  • 18,000 pipe welds demand radiography
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Accuracy & Dimensional Control

Accuracy Control

  • Necessary survey points established in plan
  • Key to modularisation
  • Interfaces are defined and maintained throughout

evolving design Advantages:

  • Minimise rework
  • Build under control and confidence

Dimensional Control

  • As-built information collected for further analysis
  • Interfaces managed in CAD before join up
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Major Modules

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Submarine Assembly – Major Modules

UNIT 8 / F.E.C UNIT 6 / 7 UNIT 5 UNIT 4 UNIT 3 A.E.C / UNIT 1 / UNIT 2 DG MODULE AMM BLK 74 MRM MPMP Reactor Compartment FERM Bridge-Fin & Casing CDM AEC FEC

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Submarine Assembly – Major Modules

UNIT 8 / F.E.C UNIT 6 / 7 UNIT 5 UNIT 4 UNIT 3 A.E.C / UNIT 1 / UNIT 2 DG MODULE AMM BLK 74 MRM MPMP Reactor Compartment FERM Bridge-Fin & Casing CDM AEC FEC

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Main Propulsion Machinery Package (MPMP)

MPMP Pictorial

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Facts about Astute MPMP

  • Astute MPMP took 4 years 8 months to Build, Test & Ship
  • During Trials the Main Shaft turned 1,693,832 revolutions. This would mean the

submarine would have travelled from Barrow to Australia (8671 Miles)

  • There are 1,263 Pipes fitted to the MPMP
  • There are 11,500 meters of cable fitted to the MPMP
  • 3105 Tonnes of fuel oil was used (683,920 gallons)
  • 10.9 Billion litres of sea water was pumped; enough to fill 4,034 Olympic-size swimming

pools

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Main Propulsion Machinery Package – Planned shipping date 20th July 2005

Main Machinery Propulsion Package (MPMP)

Shipped 10th June 2005 into Unit 2

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Submarine Assembly – Modules

UNIT 8 / F.E.C UNIT 6 / 7 UNIT 5 UNIT 4 UNIT 3 A.E.C / UNIT 1 / UNIT 2 DG MODULE AMM BLK 74 MRM MPMP Reactor Compartment FERM Bridge-Fin & Casing CDM AEC FEC

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Command Deck Module (CDM)

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  • All electronics masts
  • Visual, communications, radar etc.
  • Navigation - inertial sensors
  • Combat management system
  • Decoys, various sensors, intelligence

and SF, Tomahawk Launch

Command and Control Underwater Sensors Above Water Sensors Tomahawk Land Attack Missile Spearfish Torpedo

Combat System

Communications

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Warspite Facility

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Transporting CDM from Warspite to DDH

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Command Deck Module

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DDFOC – Shipping of Command Deck Module

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DDFOC – Shipping of Command Deck Module

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Submarine Assembly – Modules

UNIT 8 / F.E.C UNIT 6 / 7 UNIT 5 UNIT 4 UNIT 3 A.E.C / UNIT 1 / UNIT 2 DG MODULE AMM BLK 74 MRM MPMP Reactor Compartment FERM Bridge-Fin & Casing CDM AEC FEC

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Submarine Assembly – Major Modules

UNIT 8 / F.E.C UNIT 6 / 7 UNIT 5 UNIT 4 UNIT 3 A.E.C / UNIT 1 / UNIT 2 DG MODULE AMM BLK 74 MRM MPMP Reactor Compartment FERM Bridge-Fin & Casing CDM AEC FEC

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Submarine Assembly – Major Modules

UNIT 8 / F.E.C UNIT 6 / 7 UNIT 5 UNIT 4 UNIT 3 A.E.C / UNIT 1 / UNIT 2 DG MODULE AMM BLK 74 MRM MPMP Reactor Compartment FERM Bridge-Fin & Casing CDM AEC FEC

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The Finished Article

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  • Complex Engineering, Manufacturing and Test programme
  • Highly skilled Resource
  • Teamwork Essential
  • Design process is iterative
  • Structured Design approach
  • Design above anything must be SAFE
  • Improved working environments and methods
  • There’s always more we can do to improve……………………

Summary

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Astute Boat 4 and beyond

  • Boat 4 based on boat 1-3 but…
  • At least 15% lower purchase cost (real terms)
  • Same capability.
  • Overcome obsolescence issues.
  • Same or lower in service costs.
  • At least as safe (preferably safer).
  • Boats 5-7 are based on boat 4 but…
  • At least 5% lower purchase cost (real terms).
  • Same capability.
  • Lower in service costs.
  • Improved safety.
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Sales Pitch!

  • If you think your company has a product or technology that you think

would be of benefit to design or construction of a nuclear submarine then let me know. We welcome alternative thinking and products.

  • Our workload going forward means that we have numerous
  • pportunities for design engineers in all disciplines.
  • We also take on around 40 graduates across a wide range of areas

each year for a structured training programme

  • So let me know if you or someone you know are interested.

kevin.young@baesystems.com