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Thales Defense and Security is being awarded with a delivery order for the repair of the airborne low frequency sonar system (ALFS) sonar dome installed on the Navy’s MH-60R helicopters. The undefinitized contract action is priced at $14 million and covers the repair of 58 sonar units. The AN/AQS-22 Airborne Low Frequency Sonar (ALFS) is the primary undersea warfare (USW) sensor of the MH-60R multi-mission helicopter. This integrated dipping sonar system enables the ‘Romeo’ to perform ASW missions. including submarine detection, tracking, localization and classification. Work will be performed in Clarksburg, Maryland and Brest, France. Performance is expected to be completed by November 2020.

Boeing is being contracted to increase resilience of the Wideband Global Satellite (WGS) communication system. The $14 million contract modification includes mitigation and anti-jam efforts and additional strings. The Wideband Global SATCOM satellite system is the successor to the Defense Satellite Communications System-III, and is the backbone of US military global satellite communications. The WGS constellation provides flexible, high-capacity high-data-rate and long-haul communications for the nation’s warfighters. Boeing’s experts will provide an X-Band anti-jam upgrade for the satellite constellation that increases resilience to unintentional and hostile electronic threats. Work will be performed at Boeing’s facilities in El Segundo, California and Colorado Springs, Colorado, and is expected to be completed by February 28, 2021.

Embraer is one step closer in achieving the Final Operation Capability (FOC) for its KC-390 transport aircraft. During recently held tests at Brasília Air Force Base, Embraer was able to successfully complete troop unloading, evacuation by hatch and evacuation tests through the front and rear doors of the multi-mission medium airlift. About 370 Brazilian Air Force and Brazilian Army participated in the tests. “By completing this important stage of the testing campaign toward final military certification with excellence, the KC-390 demonstrates compliance with the industry’s most stringent operating and safety standards,” said Walter Pinto Junior, vice-president of the KC-390 Program. The Brazilian Air Force currently has 28 multi-role tankers on order, with the first expected to be delivered in the first half of 2019. Embraer hopes that its new aircraft will rival Lockheed Martin’s C-130.

One of the Air Force’s F-35 Joint Strike Fighters dropped for the first time a GBU-49 precision bomb. The converted “dumb” bomb was dropped during a combat training exercise at Eglin Air Force Base, Florida. The GBU-49 Enhanced Paveway II is a dual-mode GPS and laser-guided 500 pound bomb designed for attacking both stationary and moving targets. It is an improved derivative of the laser-guided GB-10 Paveway II. “It’s a really flexible weapon,” Lt. Col. Matthew Johnston said in a press release. “It was reliable, accurate, and effective.” The GBU-49 can be used in a variety of weather conditions.

Middle East & Africa

Israel Aerospace Industries can now offer a next-generation version of its Drone Guard counter-UAV system. Drone guard is able to detect, track and disrupt hostile UAVs. Developed by IAI subsidiary Elta, Drone Guard is comprised of 3-Dimensional (3D) radars and Electro-Optical (EO) sensors for detection and identification, as well as dedicated Electronic Attack (EA) jamming systems for disrupting drone flight. The radar setup includes the ELM-218M, ELM-2026B and ELM-2026 for short (3km), medium (5km) and long (6 km) ranges, respectively. The newly developed next-generation system adds a communication intelligence (COMINT) suite for more precise detection, classification and identification based on broadcast frequencies. The jamming disrupts the drone’s flight and can either cause it to return to its point-of-origin (‘Return Home’ function) or to shut down and make a crash landing.

Europe

The Belgium government is advancing in its MQ-9B acquisition program. The Belgian MoD will now start negotiations with the US Government to acquire the SkyGuardian UAS. The SkyGuardian is a NATO-standard variant of the B-model Predator. The Sky Guardian has a 13-foot longer wingspan than the Predator-B, a more damage tolerant composite airframe with double the service life, nearly twice the operational endurance and a greater payload capacity. “We look forward to providing our unmanned aircraft systems to meet Belgium’s mission requirements, while also supporting the NATO Alliance,” said Linden Blue, CEO of GA-ASI. “We are also eager to work with our industrial partners in Belgium on a host of activities ranging from manufacturing to maintenance.” The MQ-9B also flys for the UK Royal Air Force, where it is the main platform of the country’s Protector program.

Asia-Pacific

Russian firm Rosoboronexport is being contracted to supply the Indian Army with a Very-Short-Range Air Defence, or VSHORAD system. The decision about the $1.5 billion delay comes after months of delays over complaints made by other competitors in the competition. The Russian company reportedly undercut offers by Sweden’s SAAB RBS-70 NG and France’s MBDA Mistral. Both Saab and MBDA have complained to the Indian army that the Russian firm was even allowed to be a finalist, as it had failed two initial technical tests. It is latest model of Russian MANPADS (Man-portable air-defense system) technology. It offers superior performance over earlier supplied SA-18 missiles to India. The Igla-S can be used to engage a variety of targets including tactical aircraft, helicopters and unmanned aerial vehicles. The new systems will replace India’s ageing inventory of Igla-M air defense systems.

Today’s Video

Watch: Watch the Su-57 operating in Syria

The US military needs a bigger data firehose. In an era of streaming data from proliferating UAVs and other persistent surveillance platforms, and the need for control of those systems anywhere in the world, bandwidth is almost as important as fuel. Commercial satellite communications (SATCOM) can fill some of the gaps, but it’s expensive, and may not be available when needed. The Wideband Gapfiller SATCOM (now Wideband Global SATCOM) program began as a way to ease these problems in the near term, but went on to become one of the twin pillars of US military communications, alongside the hardened AEHF constellation. Both satellite types expanded their roles after the super-high bandwidth T-SAT program was canceled. Instead, the USA is adding WGS and AEHF satellites in space, even as it makes both programs multi-national efforts here on earth.

WGS is a set of 13-kilowatt spacecraft based on Boeing’s model 702 commercial satellite. These satellites will handle a significant portion of the USA’s warfighting bandwidth requirements, supporting tactical C4ISR(command, control, communications, and computers; intelligence, surveillance, and reconnaissance); battle management; and combat support needs. Upon its 2007 launch into geosynchronous orbit, WGS Flight 1 became the U.S. Department of Defense’s highest capacity communication satellite. WGS F4, launched in January 2012, offers further improvements, as do satellites from WGS F8. The constellation is set to grow to 10, including international participation.

This is DID’s FOCUS Article covering the WGS program’s specifications, budgets, travails, international partnerships, and contracts, with links to additional research materials.

WGS: Capabilities & Role

WGS
(click for video)

The WGS constellation has limitations, as its wideband communications are “unprotected” against jamming and nuclear effects. This makes them less secure than programs like AEHF or the canceled T-SAT. On the other hand, WGS excels in 3 areas: bandwidth, coverage, and flexibility.

The WGS payload can filter and route 4.875 GHz of instantaneous bandwidth. Depending on the exact ground equipment and network settings, each satellite can support data transmission rates ranging from 2.1 to 3.6 Gbps – more than 10 times the communications capacity of the predecessor DSCS III satellite’s 0.25 Gbps. Indeed, just 1 WGS satellite provides more throughput than the entire Defense Service Communications Satellite (DSCS) constellation did before WGS F1 was launched.

Reconfigurable antennas and a digital channelizer allow WGS to tailor its coverage areas, and to connect X-band and Ka-band users anywhere within the satellite’s field of view. The WGS design includes 19 independent coverage areas that can be positioned throughout the field of view of each satellite. To accomplish this, it uses 8 steerable and shapeable X-band beams formed by separate transmit and receive phased arrays; 10 Ka-band beams served by independently steerable, diplexed antennas, including 3 with selectable RF polarization; and transmit/receive X-band Earth coverage beams. Within those limits, WGS’ digital channelizer divides the uplink bandwidth into nearly 1,900 independently routable 2.6 MHz subchannels, providing connectivity from any uplink coverage area to any downlink coverage area (including X and Ka band crossbanding). The channelizer supports multicast and broadcast services, and provides uplink spectrum monitoring to support network control.

A new channelizer in WGS F8-F10 looks set to increase that throughput, by removing the bottleneck in the satellite’s architecture and letting the birds take full advantage of their antennas. Instantaneously filtered and routed bandwidth rises to 190% vs. the 100% baseline for previous Block II satellites (about 9.25 GHz). Data capacity rises to 130% (up to 4.68 Gbps transmission rates) depending on loading, but exact system throughput is dependent on how the satellite is used. The number of independently routable 2.6MHz subchannels, including crossbanding, is expected to increase from 1,900 to approximately 3,200.

Boeing adds that:

“Despite all of its military features, WGS is substantially more cost-effective than leased commercial SATCOM bandwidth.”

It’s also more flexible. Unlike commercial services, WGS satellites can be repositioned in orbit to adapt to changing mission requirements.

WGS-4 and the Block II set will be similar to the 3 Block I satellites, but will include a switchable radio frequency bypass capability designed to support airborne intelligence, surveillance and reconnaissance platforms requiring additional bandwidth. The RF bypass will support data rates of up to 311 megabits per second, which is about 3x the rate of Block I birds, allowing platforms like the US Navy’s RQ-4N BAMS UAVs to rely on the WGS constellation for satellite control.

The U.S. MILSATCOM Joint Program Office (MJPO), Space and Missile Systems Center (SMC), is responsible for development, acquisition and sustainment of the WGS Program, which is a joint-service program funded by the US Air Force and Army. A total of 8 satellites are currently planned, augmenting X-band communications now provided by the Defense Satellite Communications System (DSCS) and one-way Ka-band service provided by the Global Broadcast Service (GBS). Additionally, WGS will provide a new 2-way Ka-band service.

Operation of WGS is a shared responsibility. Spacecraft platform control is accomplished by the 3rd Space Operations Squadron (3 SOPS) at Schriever AFB in Colorado Springs, CO, using WGS mission unique software and databases provided by Boeing, and hosted on the Command and Control Segment Consolidated (CCS-C) system fielded by Integral Systems, Inc. The satellite is designed for compatibility with current S-band capabilities, as well as the planned Unified S-band (USB) formats and frequencies. The Army controls the communications payloads and warfighter transmissions from 4 Wideband SATCOM Operations Centers (WSOCs) around the world, using ground equipment hardware and software developed by Boeing, ITT Industries, and Raytheon. Each Gapfiller Satellite Configuration and Control Element (GSCCE) has the capability to control up to 3 satellites at a time, via “in-band” (X-band or Ka-band) telemetry and command links.

The WGS Program & Schedule

Thermal vacuum testing
(click to view full)

The T-SAT Transformational Satellite Network that was originally intended to replace WGS, has been canceled. To address that gap, the US Department of Defense is buying AEHF-4 and 5 for secure communications, and will field a total of 10 WGS satellites, instead of just 3. The program has also become international. Australia bought WGS F6, and an international consortium led by Canada funded WGS F9, leaving 8 satellites to be funded by the USAF. Full members now include the USA, Australia, Canada, Denmark, the Netherlands, and New Zealand, all of whom have seats on a WGS partnership steering committee.

The program even received the Air Force’s John J. Welch Award for acquisition management in 2001 for its use of commercial approaches. On the whole, the end results mark WGS as an unquestioned success.

That doesn’t mean the program has been problem free. Far from it.

For starters, total program cost rose well beyond $1.8 billion, and the initial launch was pushed back almost 3 years.

Wideband Global SATCOM F1 was originally scheduled to be launched in 2004, to be followed by 2 more satellites launched on Delta IV and Atlas V Evolved Expendable Launch Vehicle (EELV) rockets. That schedule was pushed back to F1 launch in 2007, with F2 also intended to go aloft in 2007, and F3 scheduled for 2008.

WGS F1 actually launched in October 2007, and was placed into service over the Pacific Ocean region, but wasn’t declared operational until April 2008.

WGS F2 launched in April 2009. It’s in service over the Middle East.

WGS F3 had its schedule moved back several times; it was eventually launched in December 2009, and was declared operational in March 2010. Its operations cover Europe and Africa.

The WGS program’s design, integration and manufacturing issues stemmed from a number of causes. One was less-than-anticipated commercial demand for the base 702 satellite, which reduced the program’s expected ability to leverage commercial expertise and orders. A second problem arose after a launch date in December 2005 was scratched, in favor of a higher priority satellite. The delay was actually very fortunate, as subsequent checks found a widespread problem with fasteners in WGS F1. That manufacturing issue caused heavy slippage in the satellite’s launch date, and created an expensive production gap between satellites F3 and F4 until the USAF was satisfied that future satellites wouldn’t need all that rework.

The Block II contract called for the launch of F4 by the first quarter of 2011, and subsequent launches of F5 and F6 in 2012 and 2013 (moving the launch schedules back by about a year).

In reality, WGS F4 didn’t launch until January 2012. It was declared operational in August 2012, and covers the Indian Ocean Region.

WGS F5 lifted off in May 2013, and will cover the Americas once it’s operational.

WGS F6 lifted off in August 2013.

Satellite F7 is scheduled to launch in FY 2016, and F8 is scheduled for FY 2017.

Budgets & Participants

WGS satellite, closeup
(click to view full)

As one might guess, the program’s budget has grown in tandem with the constellation. WGS was originally envisaged as a US-only program, with an upper limit of $1.3 billion for 6 satellites. As of the FY 2014 budget, the American WGS program will involve about $3.35 billion in American procurement costs alone, for a constellation of 10 satellites: 8 paid for by the USA, and the other 2 paid for by international customers. Contributing countries can use any satellite in the constellation, within pre-arranged terms for bandwidth, access, etc.

That growth took place over time, but most of it came early. By December 2009, program costs in $FY01 had grown to $2.971 billion for 7 American satellites, owing in part to the costs and manufacturing delays mentioned above. New expenses included associated ground-based payload command and control systems, mission unique software and databases, satellite simulators, logistics support and operator training. When the 2012 budget added a 10th satellite to the constellation, the USA was committed to 8 birds.

According to US DoD documents, recent budget allocations to the program have included:

WGS Industrial Team

As the prime contractor and overall systems integrator, Boeing supplies the satellites, and also performs final satellite processing and preparations for launch, as well as initial orbital operations and on-orbit testing. Listed members of Boeing’s WGS team have included:

The internationalization of WGS is likely to add suppliers from those countries as well, in accordance with local industrial offset agreements.

WGS Program: Contracts & Key Events FY 2018

F5 and 6.

WGS-5 mission
click for video

November 23/18: Resilience Boeing is being contracted to increase resilience of the Wideband Global Satellite (WGS) communication system. The $14 million contract modification includes mitigation and anti-jam efforts and additional strings. The Wideband Global SATCOM satellite system is the successor to the Defense Satellite Communications System-III, and is the backbone of US military global satellite communications. The WGS constellation provides flexible, high-capacity high-data-rate and long-haul communications for the nation’s warfighters. Boeing’s experts will provide an X-Band anti-jam upgrade for the satellite constellation that increases resilience to unintentional and hostile electronic threats. Work will be performed at Boeing’s facilities in El Segundo, California and Colorado Springs, Colorado, and is expected to be completed by February 28, 2021.

FY 2013

Aug 7/13: F6 Launch. Australia’s WGS-6 successfully lifts off aboard a Delta IV medium+ (5,4) configuration rocket, which means a 5m diameter payload fairing, and 4 strap-on boosters. All 3 WGS Block II satellites have been launched using this configuration, and WGS payloads make up all 4 of the configuration’s launches to date. Unlike past launches, this one was funded entirely by Australia.

About an hour later, controllers confirmed that WGS-6 was functioning as expected. As usual, it’s going to be a few months before the satellite is in its final orbit, handed over, tested by both Boeing and the USAF, and declared operational. Current estimates are for full operational status in early 2014.

USAF SMC MILSATCOM director Dave Madden is quoted as saying that the satellite’s final coverage area isn’t finalized yet, but any area it picks will overlap one or more of the other satellites. It doesn’t really matter, since Australia has bought into service from the whole constellation, and Australia’s areas of interest are already covered by existing birds. Australia DoD | ULA | ATK | Boeing | Spaceflight Now.

WGS-6 launch

May 24/13: F5 launch. WGS-5 lifts off aboard a Delta IV heavy rocket. Subsequent reports reveal that this satellite will cover the Americas, completing the constellation’s initial global service.

This launch involved more work than usual, following the successful but low-performing GPS IIF-3 launch in October 2012. The United Launch Alliance, Pratt & Whitney Rocketdyne (PWR), and USAF had been working on their investigations, and they made a number of changes before ULA and the USAF would issue flight clearances. Engine testing replicated fuel leaks in the upper-stage RL10 engine, similar to those observed in the GPS IIF-3 launch. That led to a regime of extensive engine and launch-vehicle inspections. Launch vehicle hardware modifications include in-flight helium purges to critical areas. Operational changes include changes to how the engine is thermally conditioned in-flight post-boost, to prepare for the first engine start. They all seemed to work for this launch, but it will take a few launches to really be sure.

The satellite is fully launched, but it isn’t in its operational orbit yet. That process will take over a month of controlled burns, monitoring, and testing. ULA pre-launch | ULA post-launch | ATK | Boeing.

WGS-5 launch

April 10/13: FY 2014 Budget. The President releases a proposed budget at last, the latest in modern memory. The Senate and House were already working on budgets in his absence, but the Pentagon’s submission is actually important to proceedings going forward. See ongoing DID coverage.

For FY 2014, PE 0303600F (Wideband Global SATCOM (Space)) seems to disappear, but even a comparison of the corresponding 3020F line shows a sizeable drop of around $82.1 million in WGS procurement funding from FY 2013-2017. Launch costs fall under the EELV budget line, and the associated pre-launch delivery, post-launch checkout, and satellite sustainment costs don’t seem like a very flexible outlay. We asked USAF SMC for clarification, and they offered a reasonable explanation – but wow, $80 million over 4 years, in savings, from ONE program:

“The cost savings are a result of reduced level of Government Program Management and Administration effort required to manage and execute the Firm-Fixed Price contract for the acquisition of WGS satellites 7-10.”

FY 2012

Program goes multi-national; WGS-4 launched; WGS-8-10 contracts; WGS-10 lead items.

WGS-4, pre-launch
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July 27/12: WGS F10. Boeing Satellite Systems Inc. in El Segundo, CA received a $317.7 million contract modification to a previously awarded firm-fixed-price contract for WGS Satellite Vehicle 10 (SV10) production, processing, launch, and on-orbit activation.

This modification adds an additional satellite to the $1.1 billion WGS 7-9 contract (vid. Sept 1/11), but only 3 of those satellites were American, so from the Pentagon’s point of view, its terms didn’t change. Work will be performed in El Segundo, CA by March 31/18. As usual, the contract is managed by US Space & Missile Command at Los Angeles AFB, in El Segundo, CA (FA8808-10-C-0001, PZ0026). See also USAF | Boeing.

WGS-10

July 6/12: USAF Space Command announces a $111 million contract modification to Boeing Space and Intelligence Systems, to develop a better bandwidth channelizer for WGS F8 and F9. USAF officials say that it will improve overall bandwidth on each satellite by 90%, and add that its development was funded by savings from the WGS 7-9 block-buy contract.

A satellite bandwidth increase is an odd effect from a channelizer, which normally apportions satellite bandwidth among different channels. Some interesting channelizer development has been done in recent years by firms like RF Engines Ltd. and others, and the USAF saw an opportunity to remove the bandwidth bottleneck in WGS’ architecture. Which wasn’t the antenna, but the channelizer.

WGS 8-10, with the new channelizer, are still officially Block II satellites. Bandwidth rises to 190% of previous Block II satellites, data capacity rises to 130% (vs. the 100% baseline of previous Block IIs) depending on loading, but exact system throughput is dependent on how the satellite is used. The number of independently routable 2.6MHz sub-channels, including crossbanding, is expected to increase from 1,900 to approximately 3,200.

June 15/12: Lockheed Martin Integrated Systems, Inc. in Bethesda, MD receives a $10.7 million firm-fixed-price/ cost-plus-fixed-fee contract to operate, maintain, and sustain the Camp Parks Communication Annex site equipment. Camp Parks is 1 of 5 Automated Remote Tracking Stations (ARTS), with the mission control center located at nearby Onizuka Air Force Station in Sunnyvale, CA. The Camp Parks ARTS is used to test and analyze signals form communications and navigation satellites. It supports WGS satellite performance in orbit testing, payload characterization testing, and other satellite on-orbit ancillary tests as needed.

Work will be performed in Bethesda, MD. Work is to be completed by Nov 30/12. The SMC/PKJW at Los Angeles AFB, CA manages the contract (GSA-00-Q-09BGD0039/ FA8808-12-F-0001).

May 10/12: F10 lead in. Boeing Satellite Systems, Inc. in El Segundo, CA receives a $21 million firm-fixed-price contract to purchase parts for SV10, under the “Wideband Global SATCOM 7 & Beyond” contract. The life size Buzz Lightyear action figure is presumably thrown in for free, though it may be interesting to see who gets it; WGS-10 was paid for by a consortium of countries (vid. Jan 17/12).

Work will be performed Palm Bay, FL and El Segundo, CA,and is to be complete by June 2012. USAF SMC HQ / PKJW in El Segundo, CA manages the contract (FA8808-10-C-0001, PO 0031).

April 12/12: Boeing announces that the USAF has accepted control of WGS F4, after several weeks of rigorous on-orbit tests from Boeing’s Mission Control Center in El Segundo, CA, and from “government facilities in central California.” Air Force operations personnel at Schriever AFB, CO are conducting additional tests, and preparing to move WGS-4 into its operational position so it can go into service this summer.

Jan 19/12: F4 launch. The 1st Block II satellite, WGS-4, successfully blasts off from Cape Canaveral aboard a Delta IV Medium-plus. It then sends signals from space, indicating readiness for on-orbit testing. So far, WGS 1 & 2 have launched on Atlas V EELV rockets, while 3 & 4 launched on Delta IVs.

WGS-4 used a ULA single common booster core powered by a Pratt & Whitney Rocketdyne RS-68 main engine, along with 4 ATK GEM 60 solid rocket motors. The 5m diameter upper stage was powered by a PWR RL10B-2 engine, with the satellite encapsulated in a 5m diameter composite payload fairing. ULA | Boeing | Boeing post-launch | ATK | America Space.

WGS-4 launch

Jan 17/12: WGS International. At the Canadian Embassy press conference in Washington, USAF deputy undersecretary for international affairs Heidi Grant announces that Canada won’t be alone. All together, Canada, Denmark, Luxembourg, the Netherlands and New Zealand have agreed to contribute $620 million toward development and launch of a 9th WGS satellite, in return for access to the system.

As noted below, Canada is investing the lion’s share, at $333 million. New Zealand is investing NZ$ 83.2 million [$66.5 million] over 20 years, which compares favorably to the current model of $NZ 4.3m per year, growing at about 10% per year, for 1/20th of the bandwidth. Australia’s experience has shown (vid. Aug 30/11 entry) that participation in WGS also entails changes to ground and receiving infrastructure. The Canadian Forces are defining requirements and preparing a separate tender for that, and the other countries involved will be doing likewise.

American officials said that they are open to negotiating the entry of new members, but said there were no specific expansion plans at the moment. USAF | New Zealand government | NextGov | Reuters | TMCNet.

WGS-9 international

Jan 17/12: Canada joins. Canada announces that it’s joining the WGS program, which will be known to DND as the Mercury Global project. DND currently pays about C$ 25 million per year to commercial providers, and was expecting those costs to rise over the next 20 years. As battlefield bandwidth demands continue to grow, it remains to be seen whether WGS will be able to serve as a full substitute for commercial providers.

“By signing the WGS Memorandum of Understanding, Canada joins allies such as Australia, Denmark, Luxembourg, the Netherlands, New Zealand, and the United States. In exchange for a contribution of [C$] 337.3 million [DID: about $333 million], the CF will obtain approximately 20 years of access to reserved frequencies for military communications systems in theatres of operation across the globe. This cost is approximately [C$] 140 million less than what was approved by the Order in Council in October 2011… The signing of the MOU will provide funding for the construction of a ninth satellite.”

Canada’s IRB industrial offsets policy applies to this buy, but it’s a bit more complicated than usual. Boeing, Canada’s largest aerospace firm, must place activities in Canada equal to the standard 100% of Boeing’s C$ 240 million share. Since the WGS agreement was a direct government-to-government MoU, the Boeing agreement is a separate document. That document also commits Boeing to provide 20% of that C$ 240 million in “direct and/or global value chain business activities” involving Canada’s space sector, and a possibly-overlapping 10% with Canadian small and medium-sized businesses. Canada DND.

Canada joins

Jan 12/12: F9 contract. Boeing Satellite Systems, Inc. in El Segundo, CA receives a $376.5 million firm-fixed-price contract modification of the Wideband Global SATCOM (WGS) Block II follow-on contract, “exercising the option to produce, process, launch, and activate on-orbit WGS F9.” Per the pattern for WGS F8 (vid. Dec 16/11), it’s part of the $1.1 billion maximum contract announced on Sept 1/11, rather than being extra monies on top of that figure. Later events reveal that most of the satellite’s cost is paid for by Canada.

Boeing’s own release describes it as a production option to make WGS F8, and authorization to produce F9 through a cooperative agreement with Canada, Denmark, the Netherlands, Luxembourg and New Zealand. They value the WGS-9 authorization and the WGS-8 production option at a combined $673 million, as part of the $1.09 billion umbrella contract announced in September 2011.

Work will be performed in Fort Worth, TX, and is expected to be complete by May 2013. The USAF SMC/PKJW in El Segundo, CA manages the contract (FA8808-10-C-001, PO 0020).

WGS-9 option

Dec 30/11: Boeing Satellite Systems in El Segundo, CA, is being awarded a $9.5 million cost-plus-fixed-fee contract modification. It pays for a study around upgrading the Wideband Global SATCOM Block II’s digital channelizer, as part of ongoing modernizations. This is normal for very expensive platforms that take a long time to build. Just because 2 satellites are “Block II” doesn’t always mean they’re the same, just as 2 Nimitz Class aircraft carriers can be very different under the skin.

Work will be performed in El Segundo, CA, and is expected to be complete on Jan 1/12 – which implies that the study is already done. The USAF SMC/PKJW in El Segundo, CA manages the contract (FA8808-10-C-0001, PO 0021).

Dec 16/11: F8 contract. Boeing Satellite Systems in El Segundo, CA receives a $296.1 million firm-fixed-price contract modification for WGS F8, as part of the Block II satellite follow-on. “The contract exercises the option to produce, process, launch, and activate on-orbit Satellite Vehicle Eight as previously negotiated.” Work will be performed in El Segundo, CA, and is expected to be complete by July 31/16. This was a sole-source acquisition by SMC/PKJW in El Segundo, CA (FA8808-10-C-001, PO 0018). See also USAF.

When queried, Boeing spokespeople explained that:

“Today’s authorization is one of those options on the [Sept 1/11] contract [clarified: and is part of that announced $1.1 billion rather than an addition to it]… The Block II satellites feature a switchable radio frequency bypass that enables the transmission of airborne intelligence, surveillance and reconnaissance imagery at data rates approximately three times greater than the rates available on Block I satellites.”

WGS-8 option

Dec 15/11: Engineers complete the Delta IV rocket encapsulation procedure for WGS F4, at the Astrotech Space Operations facility in Titusville, FL. The event marks completion of Air Force Satellite Control Network compatibility testing, payload and bus functional testing and propellant load. The launch is scheduled for Jan 19/12, which is about a year after the original plan. USAF.

Dec 7/11: ITT Systems Corp. in Colorado Springs, CO won a $121.3 million multi-year, cost-plus-fixed-fee contract “for the services in support of the [WGS] missions identified in the Operational Management System.”

Work will be performed in Colorado Springs, CO; Fort Meade, MD; Fort Detrick, MD; Wahiawa, Hawaii; Landstuhl, Germany; Okinawa, Japan; Fort Gordon, GA; MacDill Air Force Base, FL; and Canberra, Australia, and will run until Jan 31/19. The bid was solicited through the Internet, with 3 bids received by the US Army Space and Missile Defense Command at Peterson AFB, CO (W91260-12-C-0001).

Nov 28/11: F5 launch contract. United Launch Services, LLC in Littleton, CO receives a $150 million unfinalized firm-fixed-price contract, for launch services in support of WGS F5, using their roster of EELV rockets. WGS uses the medium-heavy lift Delta IV or Atlas V. The USAF Space and Missile Systems Center in El Segundo, CA manages the contract (FA8811-11-C-0001).

Nov 17/11: Boeing begins shipping WGS-4 to Cape Canaveral, FL, in preparation for a January 2012 launch. The first Block II WGS satellite flew to Florida aboard a C-5 transport plane.

Oct 28/11: Canada, eh? Canada could also be set to join WGS, and may spend as much as $477 million to participate. The Conservative majority government has given Cabinet approval up to that sum, which means it’s a done deal if it stays within those costs. DND spokesman Daniel Bouin:

“After Afghanistan and Libya, our efforts in those two countries have proven that the exchange of information between headquarters and deployed elements is critical to modern military operations and their success. So, in order to meet that intent while ensuring good value for taxpayer money, we’re seeking out an agreement with international allies that will provide Canadian forces with access to an international constellation of satellites.”

U.S. deputy assistant secretary of defense for space policy, Gregory Schulte, reportedly said on Oct 4/11 that the USAF was in the final phases of developing similar WGS arrangements with several other allies. Canada is also looking to field a 2-satellite “Polar Communications and Weather Mission” constellation of their own, to cover the High Arctic where WGS doesn’t reach. Canada’s Postmedia | Satellite Today.

Oct 11/11: More countries in? Reports surface that The Netherlands is one of several US allies getting ready to join the WGS program, in order to provide more bandwidth for their military forces. By 2018, the WGS program could have 9 satellites in orbit to provide global coverage, serving the USA, Australia, Canada, Denmark, Luxembourg and New Zealand. Aviation Week | Defense Systems.

FY 2011

WGS 7-9 umbrella contract; Australian ancillaries.

WGS satellite, entire
(click to view full)

Sept 1/11: F7-F9 umbrella. Boeing Satellite Systems, Inc. of El Segundo, CA receives a maximum $1.1 billion firm-fixed-price contract modification to allow production of WGS Satellite Vehicle F7 (See also Aug 19/10 entry), as well as advance procurement for Satellite Vehicle F8, per the program changes announced in the April 1/10 Selected Acquisitions Report. Finally, this contract includes options to produce, process, and launch and activate F8 and F9 on-orbit.

The SMC/PKJW in El Segundo, CA issued the contract (FA8808-10-C-0001, PO 0006). See also USAF | Boeing.

Contract, incl. WGS-7 option

Aug 30/11: Australian ancillaries. The Australian Government agrees to first pass approval for Joint Project 2008 Phase 5B, which will buy transportable land terminals to equip the Army, upgrades of the satellite communications fit on Royal Australian Navy platforms, and the establishment of a satellite communications network management system.

The total cost of Joint Project 2008 Phase 5B is cost capped between A$ 300-500 million (currently $320-535 million) in the Public Defence Capability Plan. Initial funding of A$ 12 million has been approved for project development and risk mitigation studies, which must happen between 1st and 2nd pass approval. Studies will include the potential upgrade of the Geraldton ground station, and construction of a new ground station facility in Eastern Australia. Australian DoD.

Australian ancillaries

April 20/11: The USAF says that WGS is proving very helpful in coordinating post-tsunami Japan relief efforts. Ka-band is reserved for emergency use in Japan, and such satellite signals are not allowed. Instead, they’re using WGS X-band transmissions, and using the satellite’s crosslinking capability to transmit to Ka-band receivers outside the region.

Dec 8/10: Boeing Satellite Systems Inc. in El Segundo, CA receives a $6 million contract modification to purchase a spare battery for WGS Block II satellites 5 & 6, or as a test battery for the Block II follow on contract, depending on things like satellites meeting launch schedules, discovering anomalies that would require a battery swap-out, etc. At this time, the entire amount has been committed by the SMC/PKJ at Los Angeles AFB, CA (FA8808-06-C-0001; P00094).

Dec 8/10: Boeing Satellite Systems Inc. in El Segundo, CA received a $26.4 million contract modification, exercising the option for WGS-6 launch services. This option modification is fully funded by the Australian government, and the entire amount has been committed. The SMC/MC in El Segundo, CA manages the contract (FA8808-06-C-0001; P00109).

FY 2010

WGS-3 launched; WGS Block I (F1-F3) all on station; WGS-7 lead-in; SAR officially grows program to 8.

Aug 19/10: F7 lead-in. Boeing Satellite Systems in El Segundo, CA receives a $182.2 million contract “which will provide the necessary items to begin production of Wideband Global SATCOM Satellite 7.” At this time, $164.4 million has been committed by the MCSW/PK at Los Angeles Air Force Base, CA (FA8808-10-C-0001). See also Reuters.

Aug 2/10: WGS Block I on-station. WGS-3 enters formal service with the U.S. Air Force. The first 2 WGS satellites are operating over the Pacific Ocean and Middle East, respectively, while WGS-3 is located over the Atlantic Ocean. This completes the WGS Block I network. Boeing | SatNews Daily | StrategyPage.

June 25/10: Boeing Satellite Systems, Inc. in El Segundo, CA receives a $6.8 million contract modification, which pays for additional on-ground testing thermal vacuum tests of the first WGS Block II satellite, SV4. At this time, the entire amount has been committed by HQ SMC/MCSW/PK in El Segundo, CA (FA8808-06-C-0001/ P00090).

June 25/10: The USAF announces that U.S. Strategic Command has accepted operational command and control of WGS-3.

WGS-3 is operated by the 3rd Space Operations Squadron at the 50th Space Wing in Schriever Air Force Base, CO. It’s under the operational command of the Joint Forces Component Commander for Space at Vandenberg Air Force Base, CA, where the JFCC SPACE Joint Space Operations Center continuously monitors WGS-3’s orbital safety and operational status.

May 25/10: Northrop Grumman announces the last flight test of the 1st airborne Ka-based satellite terminal for use with the WGS system. The flight test used the communications terminal system installed on a modified business jet aircraft to connect with a WGS via the Ka-band link. The test is the 2nd of 3 phases required to certify the airborne communications system for WGS operations. Northrop Grumman is performing the certification under the Multi-Role Tactical Common Data Link (MR-TCDL) Developmental and Operational Test program contract.

April 1/10: The Pentagon releases its April 2010 Selected Acquisitions Report, covering major program changes up to December 2009. WGS qualifies as a full breach under Nunn-McCurdy Legislation, as the program rises to 8 satellites and deals with its issues:

“WGS (Wideband Global Satellite Communications) – The APUC (Average Procurement Unit Cost) increased 27.2% to the current APB and 39.5% to the original APB. The original WGS acquisition strategy, approved in June 2000, called for a commercial-like Firm Fixed Price (FFP) competitively awarded contract with options for six satellites. The original program was baselined for 3 satellites assuming commercial pricing. At the time of the original WGS 1-6 contract award, a strong commercial market for wideband communication satellites was expected. Production options for WGS 1-3 were exercised, and the first satellite launched on October 10, 2007. Due to limited resources and other priorities, the contract options for satellites 4-6 were not exercised before they expired.

Subsequent decisions resulted in the department deciding to award another contract for WGS 4-6 Advanced Procurement and Production. A production break of approximately three years was introduced between WGS 3 and WGS 4. Further, following the acquisition of WGS 1-3, the commercial communication satellite market took a significant downturn, and the WGS X-band phased array transmit and receive system and digital channelizer capability were no longer available commercially. More recently, the department directed the procurement of additional satellite vehicles to support and maintain an eight satellite constellation. These satellites will follow a second break in production estimated at two years which will require re-establishing the supplier and contractor base and addressing issues with parts obsolescence.”

Officially, the accompanying PDF table lists WGS as having only 7 satellites, even though the test (and US FY 2011 budget documents) says 8. Total cost is now pegged at $2.971 billion in $FY01, or $3.441 billion in “then year” dollars (expected dollars actually paid, including inflation).

WGS expands

March 1/10: The USAF accepts control of the 3rd WGS satellite, after the satellite passed several weeks of on-orbit tests. WGS-3 completes the initial WGS constellation, and will be followed by 3 more WGS satellites under Block II of its USAF contract. Boeing release

Jan 29/10: Boeing Satellite Systems in El Segundo, CA received a $21 million change order to the Wideband Global Satellite Communications (WGS) program to integrate, test, and store the 1.5 ship-sets of xenon-ion propulsion system (XIPS) hardware procured. The XIPS is used to maneuver the satellite into its orbit and to change the satellite’s location if necessary. At this time, $14 million has been obligated. MCSW/PKW in El Segundo, CA manages the contract (FA8808-06-C-0001, P00070).

December 2009: Boeing integrates the WGS-4 payload module with a high-power Boeing 702 platform at the company’s Satellite Development Center in El Segundo, CA. WGS-4 is the first of 3 satellites to be built under the Block II contract, adding features like a radio frequency bypass designed to support airborne intelligence, surveillance and reconnaissance platforms requiring additional bandwidth. Over the next few months, the WGS team will conduct final integration activities followed by rigorous environmental testing, including vibration and thermal-vacuum tests.

WGS-1 and WGS-2, launched in October 2007 and April 2009, are already in service. WGS-3 was launched in December 2009. Boeing release.

Dec 5/09: F3 launch. After a Dec 2/09 launch was canceled for inclement weather and a Dec 3/09 launch was scrubbed due to a ground system fault, a United Launch Alliance Delta IV rocket lifted off from its Cape Canaveral Space Launch Complex-37 launch pad at 8:47 p.m. EST, with WGS-3 on board. It was the 36th successful ULA mission in 36 months. Boeing later reported that the satellite had checked out, and sent the first signals from space. Following a series of orbital maneuvers and on-orbit tests over the West Coast of the United States, WGS-3 will be placed into geosynchronous Earth orbit over the Atlantic Ocean.

The satellite joins WGS-1, which entered service over the Pacific Ocean in April 2008, and WGS-2, which began operations over the Middle East in August 2009. Both had been launched by the ULA’s Atlas V rockets. NASA Spaceflight mission overview | ULA Mission Overview [PDF] | Boeing.

WGS-3 launch

FY 2009

Australia buy WGS-6; WGS-2 launched; WGS-3 stored.

WGS-2 launch
(click to view full)

Sept 14/09: Boeing Satellite Systems, Inc. in El Segundo, CA received a $6.5 million contract to store the 3rd Wideband Global Satellite. Obviously, satellite storage carries very stringent environmental and security requirements, above and beyond normal warehousing. At this time the entire amount has been obligated by the SMC/MCSW/PK at HQ Space and Missile Command in El Segundo, CA (F04601-00-C-0011, P00190).

WGS F3 was originally intended for launch in 2008. Current plans call for a mid-November 2009 launch, on board a Delta IV EELV rocket, from Cape Canaveral, FL.

June 15/09: Following an on-orbit checkout, Boeing successfully transfers control of WGS-2 to the U.S. Air Force, which will monitor and control the new satellite from Schriever Air Force Base, CO. Boeing release.

May 28/09: A $6.3 million contract modification for Boeing Satellite Systems, Inc. of El Segundo, CA, exercising the 3rd 3-month storage option for WGS-3. At this time, the entire amount has been committed by HQ Space and Missile Command in El Segundo, CA (F04701-00-C-0011, P00182).

Spaceflight Now indicates that the Delta 4 launch of WGS-3 has no fixed date, but is expected in late summer or early fall 2009.

April 7/09: Boeing Satellite Systems in El Segundo, CA receives an estimated $8.1 million modification to a fixed price incentive contract to provide sustaining engineering for Post-Initial Operational Capability (IOC) of WGS-2. At this time, the entire amount has been committed by the Space and Missile Systems Center at Los Angeles Air Force Base, CA (FA8808-06C-0001, P00044).

April 3/09: F2 launch. A United Launch Alliance Atlas V rocket carries WGS-2 into orbit from Cape Canaveral Air Force Base. A ground station in Dongara, Australia, receives the satellite’s first signals 44 minutes later, at 9:15 p.m. Eastern time, and Boeing controllers in El Segundo, CA confirmed that the satellite is functioning normally. Boeing.

WGS-2 launch

March 17/09: WGS-2’s launch is scrubbed, when an anomalous leak rate was detected in the Centaur upper stage oxidizer valve. A follow-on review of the time needed to inspect the Atlas V rocket, fix the identified problem and prepare for a rescheduled attempt revealed it could not take place prior to the Delta II launch date on March 24/09, so the schedule will be moved back beyond that. That date was later set for March 31st, but the satellite ended up launching on April 3rd.

Feb 25/09: Boeing Satellite Systems of El Segundo, CA receives a not-to-exceed $8 million change order modification. This contract will purchase Thermal Cycling Testing on the solar panel arrays of the WGS-2 and WGS-3 Block I satellites. At this time, $6 million has been committed. The Military Satellite Communications Systems Wing HQ in El Segundo, CA manages this contract (F04701-00-C-0011, 00172).

Dec 17/08: Australia buys F6. Contract for US/Aussie WGS-6. The USAF modifies a fixed-price incentive contract to Boeing Satellite Systems, Incorporated in El Segundo, CA, adding $233.9 million by exercising the option for WGS satellite #6. At this time, the entire amount has been committed. SMC/MCSW, Los Angeles Air Force Base, CA manages the contract (FA8808-06-C-0001, P00036).

With this authorization, Boeing is now fully funded for the production of all 3 WGS Block II satellites, and is on track to deliver the first in this new series in 2011.

See also Boeing’s release, the Dec 21/07 long lead time materials order below, and the Nov 14/07 agreement regarding this joint US/Australian satellite.

Australia buys WGS-6

FY 2008

WGS-1 operational; Australia joins; WGS-5 bought; WGS-6 lead-in.

WGS-1 launch
(click to view full)

April 16/08: Operational. The first Wideband Global SATCOM Satellite is declared operational. US Army release | Boeing release.

April 11/08: Fast acceptance. Air Force Gen. C. Robert Kehler, commander, Air Force Space Command; and Army Lt. Gen. Kevin T. Campbell, commander of the Army Space and Missile Defense Command/Army Forces Strategic Command at Redstone Arsenal, AL, sign a memorandum at Peterson Air Force Base, CO. It recommends that USSTRATCOM accept of command and control of the first Wideband Global SATCOM satellite ahead of schedule. Source.

Dec 21/07: F5 contract. Boeing Satellite Systems, Inc. of El Segundo, CA received a firm-fixed-price contract for $229.7 million, exercising an option to build WGS satellite #5. This includes the contract requirement to increase the target price due to changes in the foreign currency exchange rate. At this time $510.5 million has been obligated. HQ, Military Satellite Communications Systems Wing at Los Angeles Air Force Base, CA issued the contract (FA8808-06C-0001, P00018).

WGS-5 option

Dec 21/07: F6 lead-in. Boeing Satellite Systems, Inc. of El Segundo, CA receives a firm-fixed-price contract for $51.7 million, exercising an option to begin advance materials procurement for WGS-6 and begin construction. HQ Military Satellite Communications Systems Wing at Los Angeles Air Force Base, CA issued the contract (FA8808-06-C-0001, P00019).

The Commonwealth of Australia is funding the procurement as part of a cooperative agreement between the U.S. and Australian governments. See also Boeing release

Nov 14/07: Australia joins. A memorandum of understanding signed by the US and Australian governments formally adds Australian Defence Force access to WGS services worldwide in exchange for funding the constellation’s 6th satellite.

The 6th WGS satellite, a Block II version, will carry the radio frequency (RF) bypass capability designed to support airborne intelligence, surveillance and reconnaissance platforms requiring additional bandwidth. The RF bypass supports data rates of up to 311 Megabits per second, more than 200 times faster than most cable or DSL connections. WGS-6 is expected to launch in the fourth quarter of 2012.Source.

Australia on board

Oct 10/07: F1 launch. WGS-1 is successfully launched at 8:22 p.m. Eastern (ZULU -0500) by a United Launch Alliance Atlas V vehicle from Cape Canaveral Air Force Base, FL. Following a nominal 45-minute flight, the launch vehicle’s upper stage deployed the spacecraft, and a ground station in Dongara, Australia received the satellite’s first signals 47 minutes later at 9:09 p.m. Eastern. Boeing controllers in El Segundo, CA confirmed that the satellite is healthy, and the firm has acquired signals from the first Wideband Global SATCOM (WGS) satellite. Boeing release.

WGS-1 launch

Oct 3/07: Australia. Australia’s Minister for Defence announces that the Australian Government will enter into an A$ 927 million partnership (about $820 million) with the United States to become part of the new Wideband Global Satellite Communications (WGS) constellation. Dr. Brendan Nelson says that “I expect to finalise the arrangement through the signing of a government-to-government Memorandum of Understanding shortly after the 30 day US Congressional Notification Period.”

Under this arrangement, Australia will fund one satellite plus associated ground infrastructure, extending the constellation to 6 satellites. In return, they will receive global coverage from WGS, which will become the backbone of their military satellite communications capability. Minister Nelson’s release states that WGS “will comfortably handle the increase in ADF communications requirements… out to at least 2024.”

Achieving full operational WGS capability by 2013 will coincide with the predicted capability drawdown of the SingTel/Optus C1 satellite. The SingTel/Optus C1 satellite will remain an important element of Australia’s satellite capability until it fails, and will be maintained in parallel with WGS. DoD Ministerial release.

FY 2007

WGS 4-6 umbrella contract; WGS 4 bought.

June 26/07: Integral Systems, Inc. in Lanham, MD received a $5.8 million cost-plus-award-fee contract modification. It modifies the Command and Control System-Consolidated (CCS-C) effort to support the Wideband Gapfiller Satellite (WGS) Program Operations Readiness, add training, and incorporate changes to the system/Subsystem Specification (SSS) to clarify development requirements for the Advanced Extremely High Frequency (AEHF) satellite program.

The CCS-C program provides an upgraded capability to command and control the Air Force’s communication satellites, including the Defense Satellite Communication System, Milstar, Advanced Extremely High Frequency, and Wideband Gapfiller Satellites. At this time, $2 million has been obligated, and work will be complete in June 2010. The Headquarters Military Satellite Communications Systems Wing in Los Angeles Air Force Base, CA issued the contract (F04701-01-C-0012/P00118).

June 5/07: Boeing announces that they have successfully completed end-to-end testing of the Boeing/ITT WGS payload command and control system, paving the way for the launch of the first WGS satellite in the summer of 2007. Three years late, and over budget by more than 33%, but apparently ready at last. The tests also demonstrated a unique design feature of the WGS system, allowing both U.S. Air Force and Army operators to control the payload via separate S-band and in-band (X or Ka-band) radio frequency links for greater operational flexibility and redundancy.

During the tests, the newly-installed WGS ground station equipment at the Camp Roberts Wideband Satellite Communications Operations Center in Paso Robles, CA communicated with a WGS satellite located at Boeing’s El Segundo, CA satellite factory, successfully routing operational commands through the Satellite Operations Center at Schriever Air Force Base, CO and a U.S. Air Force satellite control network connection at Kirtland Air Force Base, NM. Boeing release.

April 24/07: Boeing Satellite Systems Inc. in El Segundo, CA received a $27 million fixed-price-incentive contract modification. This action provides for two priced for Military Satellite Communications Systems Wing WGS Vehicle F4: 1) Launch Services and 2) Astrotech Launch Site Processing Facilities. At this time, no funds have been obligated. Work will be complete in September 2011. The Headquarters Military Satellite Communications Systems Wing, Los Angeles Air Force Base, CA issued the contract (FA8808-06-C-0001/P00009).

Nov 2/06: F4 contract. Boeing Satellite Systems Inc. in El Segundo, CA received a $299.9 million fixed-price-incentive contract modification, exercising an option for the production of Wideband Global SATCOM (WGS) Space Vehicle F4. At this time, total funds have been obligated. Work will be complete March 2011. The Headquarters Military Satellite Communications Systems Wing at Los Angeles Air Force Base, CA issued the contract (FA8808-06-C-0001/P00004). See also Boeing’s press release.

WGS-4 option

Oct 18/06: F4-F6 umbrella. Boeing and the U.S. Air Force MILSATCOM Systems Wing have signed a $1.067 billion contract for up to three more Wideband Global SATCOM satellites (WGS), if all options are exercised. The Block II satellites will be similar to the three Block I satellites already in production, but Boeing will add a radio frequency bypass capability designed to support airborne intelligence, surveillance and reconnaissance platforms requiring ultra-high bandwidth and data rates demanded by unmanned aerial vehicles.

The new Block II contract also gives the USAF the flexibility to independently exercise options for long-lead material, production and launch services for WGS F4 through F6. In February 2006, the Air Force authorized Boeing to begin non-recurring engineering and advanced procurement of parts for the fourth WGS satellite. At the time of this release Boeing anticipates Air Force authorization to proceed with full production of WGS F4 and to begin long-lead work for F5 by the end of 2006. See Boeing press release.

Contract

FY 2006

WGS-4 lead-in; Program delays.

Sept 26/06: Boeing announces the completion of Spacecraft Thermal Vacuum (SCTV) testing for the first of its Wideband Global SATCOM (WGS) satellites. The tests, conducted over two months at the Boeing Satellite Development Center in El Segundo, CA, evaluated the WGS operating systems’ ability to withstand the extreme vacuum and hot and cold temperatures of space. See Boeing release.

July 27/06: The Boeing-led team announces that its WGS program has successfully completed 2 more key space-to-ground compatibility tests with partners Universal Space Network (USN) and ITT Industries. The joint tests were conducted at the Boeing Satellite Development Center in El Segundo, CA, in order to test interoperability between the satellite and two key ground control systems.

Boeing and USN demonstrated the compatibility between the satellite’s telemetry, command and ranging systems and USN’s ground network which controls the satellites. USN’s network of ground stations in Hawaii, Alaska and a collaborative station in Italy will play crucial roles during WGS transfer orbit operations and initial on-orbit testing.

Boeing also verified telemetry and command interface compatibility between the satellite and the Gapfiller Satellite Configuration and Control Element (GSCCE). The GSCCE payload control system, designed by Boeing and ITT Industries, will be fielded at Wideband Satellite Communications Operations Centers around the world. The tests confirmed the system’s ability to properly configure the digital channelizer and the X-band phased array antennas, which are key elements of the WGS communications payload. See Boeing release.

June 1/06: The 1st of 3 Wideband Gapfiller Satellites (WGS) successfully completes key dynamic environmental tests to confirm the spacecraft’s structural design and mechanical integrity. See Boeing release.

Feb 17/06: F4 lead-in. Boeing Satellite Systems Inc. in El Segundo, CA received a $148.2 million firm-fixed incentive with firm-target contract to begin work on the fourth WGS satellite. As part of the non-recurring engineering effort, Boeing Satellite Systems will be addressing spacecraft hardware obsolescence issues through the implementation of alternative components or designs, or selection of new suppliers. They’ll also be handling advance procurement of long-lead-time parts for the manufacture of WGS #4. Solicitations began December 2005, negotiations were complete in February 2006, and work will be complete by July 2007. The Headquarters Space and Missile Systems Center at Los Angeles Air Force Base, CA issued the contract (FA8808-06-C-0001).

Nov 18/05: Boeing Satellite Systems in Los Angeles, CA received a $7.6 million firm-fixed-price contract modification to add Pedigree Reviews of Wideband Gapfiller Satellites (WGS) F1, F2 and F3. The Pedigree Review rigorously audits all critical components and subsystems, and is designed to help ensure that the satellite will work in the “one chance to get it right” environment that characterizes space-based equipment. The Headquarters Space and Missile Systems Center, Los Angeles Air Force Base, CA issued the contract (F04701-00-C-0011/P00112).

FY 2001 – 2005

Boeing wins competition; WGS 1-3 bought.

June 9/05: Boeing Satellite Systems in Los Angeles, CA received a $6.5 million firm-fixed-price contract modification authorizing Satellite 3 launch services to provide launch support and early operations, including orbit-raising on-orbit checkout for Wideband Gapfiller Satellite Flight 3. Boeing Satellite Systems will accomplish this work at their El Segundo, CA facility, Cape Canaveral Air Force Base, FL, and at other locations as required. This contract action will not lengthen the period of performance beyond the current overall period of performance on contract, and work will be complete by January 2007. The Headquarters Space and Missile Systems Center at Los Angeles Air Force Base, CA issued the contract (F04701-00-C-0011, P00105).

Dec 20/02: F3 contract. The Boeing-led team is awarded a contract option to build a third WGS satellite. With the current option for the WGS F3 satellite, Boeing lists the total value of the WGS program contract at approximately $660 million. See Boeing release.

March 6/02: F1-F2 contract. Boeing’s team receives $336.4 million to build the first two satellites in the Wideband Gapfiller Satellite (WGS) system. The contract also includes long-lead material for a third satellite. See Boeing release.

Contracts

Aug 20/01: PDR. The Boeing-led team announces successful completion of a recent series of preliminary design reviews (PDRs), an important early project milestone. Twelve days of PDRs focused on the space and ground segments of the program as well as the overall system. The meetings involved a broad range of customer participation, including Air Force, Army, Navy and Department of Defense agency personnel, as well as their system engineering and technical assistance support contractors. Also included were WGS program teammates and senior technical experts from Boeing. See Boeing release.

Jan 03/01: Boeing wins. A satellite communications industry team led by Boeing wins the contract to develop the Wideband Gapfiller Satellite (WGS) system. A joint-service program funded by the Air Force and Army, WGS is a firm, fixed-price award with an initial value of $160.3 million and a potential total value of $1.3 billion that includes options for as many as six Boeing 702 satellites and their associated spacecraft and payload control equipment. Operational and logistics support and training are also included in the program, and the procuring agency is the Air Force Materiel Command’s Space and Missile Systems Center. See Boeing release.

Additional Readings

• MILSATCOM: WGS

• Boeing – Transformational Wideband Communication Capabilities for the Warfighter (WGS product home page)

• Spaceflight Now – WGS fact sheet

• Boeing – Boeing 702 fleet

• Boeing – Satellite Launch Schedule

• Boeing Feature (Aug 16/10) – Lifeline for the troops. About the WGS program

• Boeing IDS All Systems Go (Vol 1, #3) – Leveraging Technology. Article covers WGS.

• USAF (March 17/08) – New satellite provides more power, better warfighter support

• USAF (Oct 15/07) – Air Force, Boeing team up for early-orbit operations

• USAF (Oct 9/07) – Airmen Train for Wideband Global SATCOM

• DID (Sept 28/06) – GAO 2006 Report on Key US Weapons Programs. Includes coverage of WGS on pages 119-120.

• US Department of Defense (Nov 15/05) – DoD Releases Selected Acquisition Reports. WGS is listed as a program with slipping schedule/costs, and some issues are noted.

• DID (Aug 4/05) – GAO Report: Satellite Programs Show Overruns Across the Board. Including WGS.

Americas

The US Special Operations Command is ordering additional helicopters from Boeing. The awarded contract modification is priced at $42.8 million and provides for four new build MH-47G Chinooks. The MH-47G is a new version of the helicopter platform that first flew in 1962 and has been configured to perform long-range day and night missions, in inclement weather at low levels. The Chinooks feature enhanced digital avionics and flight control systems, as well as a sturdier monolithic airframe increasing survivability. According to the DoD press release, SOCOM needs those additional rotorcraft to satisfy an urgent need for heavy assault helicopters. Work will be performed at Boeing’s factory in Ridley Park.

The Canadian government is entering the next stage of its fighter procurement program. In a draft bid package posted on October 26 procurement officials name five companies that could make the run in the upcoming tender. Canada needs to replace its ageing fleet of fighter aircraft with 88 new ones at a cost of $12 billion. Lockheed Martin’s F-35, the Eurofighter Typhoon, the Dassault Rafale, Saab’s Gripen and the Boeing Super Hornet will likely be considered and the companies are expected to give their feedback by the end of this year. Ottawa plans to receive initial proposals from bidders between summer and winter 2019. A contract is anticipated to be awarded during the winter months of 2021-2022. Canada wants initial aircraft to be delivered in 2025, with IOC achieved by 2026. The Royal Canadian Air Force wants all aircraft delivered by 2031 or 2032, at which time the CF-18 fleet will be retired.

Raytheon is marking another milestone in its Ship Self Defense System (SSDS) program. During a recently held test one of the USMC’s F-35Bs made a successful digital air connection with the USS Wasp. SSDS uses software and commercial off-the-shelf electronics to turn incoming data from several systems into a single picture of prioritized threats. The system then recommends an engagement sequence for the ship’s crew, or (in automatic mode) fire some combination of jamming transmissions, chaff or decoys, and/or weapons against the oncoming threat. “Information is key for any Commander – and shared information from multiple sources and vantage points extends our battlespace and our advantage over enemy threats,” said U.S. Navy Captain Danny Busch, Program Executive Office – SSDS. “Now with the ability to link our sensors and weapons, from sea and air, SSDS is providing a level of interoperability and defensive capability never before available to the Expeditionary fleet.”

Boeing’s new KC-46 tanker receives more certifications as it successfully completes aerial refueling of two additional aircraft types. During recently held tests the KC-46 completed receiver certification testing for the B-52 bomber and the F/A-18 fighter jet, with the F-15 to follow next year. A Boeing spokesperson says that the certification test are in preparation for the start of Initial Operational Test and Evaluation work next year. KC-46A is a militarised version of the 767-2C. Modification include aerial refueling equipment, an air refueling operator’s station that includes panoramic 3-dimensional displays, and threat detection/ countermeasures systems. Boeing recently missed the delivery schedule for its first aircraft which was expected to take place on October 27. The KC-46 acquisition program sees for the delivery of 179 tankers at a cost of $44.3 billion, with the first aircraft expected to be delivered between April and June 2016.

Middle East & Africa

Boeing is being tapped to continue maintenance support for the Royal Saudi Air Force’s fleet of F-15 fighter aircraft. The company is being awarded with a $14.6 million contract that sees for the sustainment of the Aircraft Maintenance Debrief System (AMDS). The F-15 is an all-weather, extremely maneuverable, tactical fighter designed to achieve aerial superiority in combat situations. The contract allows Boeing to provide trained personnel to use and maintain AMDS equipment at six locations throughout Saudi Arabia. The company’s staff also train RSAF members on how to operate and maintain the equipment. Work will be performed at multiple locations in Saudi Arabia and is expected to run through November 4, 2023.

The Turkish government is contracting a team of three Turkish companies to build the country’s first indigenous long-range air and anti-missile system. Turkish President Recep Tayyip Erdogan unveiled the National Long Range Regional Air Missile Defense System (SIPER) project on Wednesday. “This system is crucial for Turkey’s defense and they (the partners) are taking a new step with this project that will upgrade Turkey in the league of defense systems,” Erdo?an was quoted by Defense News’s Burak Ege Bekdil. The SIPER system will be produced by the Turkish state-run military electronics manufacturer Aselsan, state-controlled missile producer Roketsan, and Tübitak Sage, a state research institute. For the next 18 months the companies will conduct a definition study to prepare a a development and production contract for the future system. SIPER is expected to be completed by 2021.

Europe

Germany will be able to integrate Lockheed’s Patriot PAC-3 Missile Segment Enhancement (MSE) missile into its next-generation TLVS missile defense system. TLVS is a highly mobile ground based air and missile defense system for protection against the current and future threat spectrum in the lower tier. TLVS is developed by an MBDA and Lockheed Martin joint venture. Build upon the Medium Extended Air Defense System (MEADS), TLVS is easily transportable, tactically mobile and uses the hit-to-kill PAC-3 MSE missile to defeat tactical ballistic missiles, cruise missiles, unmanned aerial vehicles and aircraft, providing full 360-degree engagement. Since its final decision in 2015 the German government was unable to move forward on its new air-defense system because Lockheed needed US governmental approval to integrate the Patriot missile into the TLVS. A spokesman at the German defense ministry said, “There is new momentum. Both sides are clearly committed to successful completion of the TLVS program.” The new air-defense system was expected to cost about $4.56 billion, however current estimates suggest a cost overrun by several billion. Germany wishes to sign a contract for TLVS in 2019 and field the system in 2025.

Asia-Pacific

India recently conducted a user trial night-time test of its Agni-I ballistic missile. The Agni-I is a short-range ballistic missile that was first launched in 2002. The Agni-I is a single-stage missile developed to fill the gap between 250 km range of Prithvi-II and 2,500 km range of Agni-II. Weighing 12 tonnes, the 15-metre-long Agni-I, is designed to carry a payload of more than one ton, including a nuclear warhead. Its strike range can be extended by reducing the payload. The missile has a specialised navigation system which ensures it reaches the target with a high degree of accuracy and precision. During the user trial a randomly selected unit launches a test missile to prove the system’s overall performance and crew readiness. The trajectory of the trial was tracked by a battery of sophisticated radars, telemetry observation stations, electro-optic instruments and naval ships from its launch till the missile hit the target area with accuracy, the Indian military said. In recent months the decade long conflict Kashmir conflict between India and Pakistan started to resurface.

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Watch: $2 Billion US Stealth Plane in Action Over US States: Northrop B-2 Spirit

Americas

The US Marine Corps is buying an additional training system for its pilots. Lockheed Martin will procure one F-35 training device under the awarded $64.3 million contract modification. The F-35 Full Mission Simulator is fitted with a 360° visual display system, which accurately replicates all sensors and weapons employment and uses the same software as the aircraft. Each simulator carries the most recent software load, or operational flight program (OFP), so it can most accurately replicate the capabilities and handling qualities of the aircraft as it is concurrently developed, tested and fielded through various block upgrades. F-35 pilots complete 45% to 55% of their initial qualification flights in the simulator. Work will be performed at multiple locations including Orlando, Florida; Reston, Virginia and London, United Kingdom. The contract is expected to be completed in July 2021.

The US Navy is modifying a contract with Raytheon. The additional $34.1 million allow Raytheon to support the Navy’s Zumwalt-class ships with integrated logistics support and engineering services. The DDG-1000 ship’s prime missions are to provide naval gunfire support, and next-generation air defense, in near-shore areas where other large ships hesitate to tread. All three Zumwalt-class vessels equipped with latest electric propulsion systems, wave-piercing tumblehome hulls, stealth designs and advanced war fighting technology. The ships will have the capability to carry out a wide range of deterrence, power projection, sea control, and command and control missions once operational. Work will be performed at multiple locations. Around 52% of the work will be performed in Portsmouth, Rhode Island; 24% in Tewksbury, Massachusetts; 10% in San Diego, California; 6% in Nashua, New Hampshire; 5% Bath, Maine; 1% in Marlboro, Massachusetts; 1% in Ft. Wayne, Indiana and last 1% to be done in St. Petersburg, Florida. The contract is expected to be completed by September 2019.

Northrop Grumman is being tapped to continue development of the Common Missile Compartment (CMC). The awarded $10.8 million cost-plus incentive-fee, cost-plus-fixed-fee modification covers a number of technical engineering services; design and development engineering services; component and full scale test services and tactical underwater launcher hardware production services. The CMC will be fitted on the US future Columbia-class and UK Dreadnought-class SSBNs. The new generation of submarines will carry their Trident D5 nuclear-armed SLBMs in multiple “quad pack” Common Missile Compartments, a deliberate decision to simplify the process of building the two types of subs and hopefully save money. Nuclear missile submarines are a nation’s most strategic assets, because they are its most secure and certain deterrence option. Work will be performed at multiple location including – but not limited to – Sunnyvale, California; Kings Bay, Georgia and Barrow-In-Furness, England.

Middle East & Africa

General Electric is being contracted to support the Egyptian Air Force F-16 Service Life Extension Program. The company will deliver an unspecified number of F110-GE-100 engine conversion kits at a cost of $273.5 million. The Egyptian Air Force operates 220 F-16s, making it the 4th largest F-16 operator in the world. The F-16 is the EAF’s primary frontline aircraft. Among other operational roles, the F-16s perform missions which include intelligence, surveillance and reconnaissance, as well as air-to-air and air-to-ground attacks. Also known as the Block 30 powerplant, the F110-GE-100 is the alternate engine for the Block 30/32/40-variants of the F-16 that was fitted from December 1985. Work will be performed at General Electric’s Cincinnati, Ohio facility. This contract involves foreign military sales and is scheduled for completion by October 30, 2023.

Sierra Nevada will upgrade two aircraft as part of the Saudi King Air 350 program. The company will add an intelligence, surveillance, reconnaissance/synthetic aperture radar capability to the two King Air 350 extended range aircraft. The twin-propeller King Air 350 is an affordable, long-endurance option for effective manned battlefield surveillance and attack. US aircraft in their ISR configuration are equipped with signals intelligence (SIGINT) electronic interception capabilities, and carry L-3 Westar’s MX-15i surveillance turrets. One transportable ground station; one fixed ground station; and one mission system trainer are also included in the contract. The definitization modification is priced at $23.8 million and involves 100% foreign military sales to Saudi Arabia. Work will be performed at Sierra Nevada’s facility in Hagerstown, Maryland and is expected to be completed by May 2020.

Lockheed Martin is being tapped to keep two of the UAE’s THAAD batteries operational. The $129.5 million noncompetitive, cost-plus-incentive-fee and firm-fixed-price contract provides for maintenance and sustainment work needed to keep the two Terminal High Altitude Area Defense batteries combat ready. Lockheed Martin will be responsible to provide the United Arab Emirates with software and hardware development, contractor logistics support, engineering services, and missile field surveillance. The THAAD system is a long-range, land-based theater defense weapon that acts as the upper tier of a basic 2-tiered defense against ballistic missiles. Work will be performed at Lockheed’s facilities in Sunnyvale, California; Dallas, Texas; Huntsville, Alabama; Anniston, Alabama; Troy, Alabama; Lakeland, Florida; and the United Arab Emirates. The contract performance period is from November 1, 2018 through July 2, 2021.

Europe

Thales UK is being awarded with the $105 million Future Air Defence Availability Project (F-ADAPT) that seeks to enhance the Starstreak High Velocity Missile (HVM) and Lightweight Multi-role Missile (LMM) systems. The Starstreak is a dual-stage shoulder-fired anti-aircraft missile that flies at 4 times the speed of sound, uses advanced laser-guidance to home in on fast-flying aircraft, pop-up helicopters, or UAVs, then uses a system of 3 individually-guided dart-like projectiles and warheads to shred any target they hit. The LMM is a very short-range, precision strike air-to-surface and surface-to-surface missile designed to deliver high accuracy and precision strike capabilities with low collateral damage effect against a variety of threats encountered by APCs, small vessels and artillery. The upgrades under the F-ADAPT project include thermal imaging which ensures the HVM system can be used 24 hours a day and ‘Friend or Foe’ identification, which will maximize intelligence on potential threats and targets.

Asia-Pacific

India is procuring an air-defense command-and-control (C2) system from Israel. Israel Aerospace Industries (IAI) will deliver the Sky Capture system to the Indian Army at a cost of $550 million. Sky Capture is a C2 system for anti-aircraft artillery and Very Short Range Air Defense (VSHORAD) systems that transforms legacy air defense systems into modern, accurate and effective weapons by applying modern sensors, communications and computing capabilities. The system integrates several sensors, including target acquisition and fire control radar systems which are optimized to detect targets with low radar cross-section, such as low-velocity UAVs and ultralights that can be detected from 40-60 km. This is the second high value deal IAI signed with India in recent weeks, with the first being a $770 million deal for the Barak-8 system.

Today’s Video

Watch: Two lranian fast boats approached the US Wasp-class amphibious assault ship

67% of the fleet
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DID’s FOCUS Article for the DDG-1000 Zumwalt Class “destroyer” program covers the new ships’ capabilities and technologies, key controversies, associated contracts and costs, and related background resources.

The ship’s prime missions are to provide naval gunfire support, and next-generation air defense, in near-shore areas where other large ships hesitate to tread. There has even been talk of using it as an anchor for action groups of stealthy Littoral Combat Ships and submarines, owing to its design for very low radar, infrared, and acoustic signatures. The estimated 14,500t (battlecruiser size) Zumwalt Class will be fully multi-role, however, with undersea warfare, anti-ship, and long-range attack roles. That makes the DDG-1000 suitable for another role – as a “hidden ace card,” using its overall stealth to create uncertainty for enemy forces.

True, or False?
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At over $3 billion per ship for construction alone, however, the program faced significant obstacles if it wanted to avoid fulfilling former Secretary of the Navy Donald Winter’s fears for the fleet. From the outset, DID has noted that the Zumwalt Class might face the same fate as the ultra-sophisticated, ultra-expensive SSN-21 Seawolf Class submarines. That appears to have come true, with news of the program’s truncation to just 3 ships. Meanwhile, production continues.

Zumwalt Class: Program and Participants

As of December 2012, DDG 1000 Zumwalt was about 80% complete and scheduled to deliver in July 2014, with an Initial Operating Capability in July 2016. DDG 1001 Michael Monsoor was about 48% complete, and DDG 1002 (now Lyndon B. Johnson) was just beginning construction preparations.

The most striking thing about the Zumwalt Class program as a whole is the seismic jump in R&D costs. This is hardly surprising given the number of very new technologies involved, and the 2 program restarts along the way. Overall procurement costs have dropped as ship numbers dropped from 32 to 3, but on a per-ship basis they soared from $1.02 billion to $3.71 billion.

The Navy’s build-cost figure has been disputed by past Congressional Budget Office reports, which placed the total even higher at $5.1 billion. The Navy claims that the CBO’s estimate doesn’t consider shipyard improvements that change the build process, a more mature detailed design that has been built several thousand times by computer (a capability developed as a “lesson learned” from the Arleigh Burke program); and the roughly $500 million per ship that is being contracted for on a firm-fixed-price basis. On the other hand, the CBO has been right, and the Navy wrong, when estimating other recent shipbuilding programs.

With DDG 1000 Zumwalt rounding toward completion, we should know who’s right pretty soon. Key members of the DDG-1000’s industrial team include:

Program History: The Long and Winding Road

2006 Schedule
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The Zumwalt Class’ path to fielding has taken a long time, and seen several twists and turns. Given the sheer number of new technologies involved, that may have been a good thing, but the long gestation period has also hurt the program in other ways.

Northrop Grumman Ship Systems’ Ingalls shipyard led the “DD 21 Gold Team” through Phase I (System Concept Design) and Phase II (Initial Systems Design) from 1995-2001, until the program was suspended on May 7/01 pending that Quadrennial Defense Review and other key studies.

In November 2001, the DD 21 Program was restructured as the DD (X) Program. The Navy was directed to conduct a Spiral Development Review (SDR), to revalidate some requirements; and to assess the merits of achieving various levels of capability across a family of ships, including a Littoral Combatant Ship (LCS) and the next-generation CG (X) cruiser. The Request For Proposal for Phase III was issued Nov 30/01.

The Gold Team won on April 29/02, but the contract was delayed until the US Government Accountability Office denied General Dynamics’ protest On Aug 19/02. At that point, a firm winner could be declared. The winning “National Team” was led by Northrop Grumman, and included Raytheon IDS as the prime mission systems equipment integrator for all electronic and combat systems. Other major subcontractors included Lockheed Martin, BAE Systems, and Boeing. It even incorporated “Blue team” leader General Dynamics Bath Iron Works as a subcontractor for design and test activities.

By mid-spring 2005, however, a new DDI (design, development & integration) contract was signed. The Navy designated 4 Prime Contractors, to be coordinated through a Navy-Industry DDG-1000 Collaboration Center run by Raytheon. The current Prime Contractors are:

• General Dynamics Bath Iron works (ship design & build)
  
• Raytheon (mission systems integration which includes sensors, combat systems, electronics, and the PVLS)
  
• BAE Systems (AGS gun system)
  
• Northrop Grumman Ingalls (ship design & build, relinquished build role)

On Nov 23/05, the Undersecretary of Defense for Acquisition signed the “destroyer acquisition memorandum,” approving the DDG 1000 program to proceed with Milestone B, and commencing detail design and construction of the first ships. On April 7/06, the program got its second name change from DD-21 and then DD (X), to its official and formal designation as the DDG-1000 Zumwalt Class.

As construction begins, Congressional resolutions have dissolved the US Navy’s original “winner take all” shipbuilding approach; the first 2 DDG-1000 destroyers will now be built at Northrop Grumman’s Ingalls yard in Pascagoula, MS; and at General Dynamics’ Bath Iron Works in Bath, Maine. This was expected to add up to $300 million to the cost of each ship, but was expected to help to keep the USA’s industrial base options open for future efforts like CG (X) etc.

Strong arguments can be made for both the Navy’s original option and Congress’ mandated approach… and have been. Under the Navy’s proposed new “Dual Lead Ships Strategy,” the USN planned to benchmark these lead ships from each shipyard against each other, and revisit its options around FY 2009.

That became a moot point when the DDG 1000 program was truncated at 3 ships, a development that ironically led the program back to its original single-builder strategy. Zumwalt Class ships will be built at Bath Iron Works, with Northrop Grumman (now Huntington Ingalls) supplying the composite deckhouse superstructure for all 3 ships.

CG (X) was slated for termination in the FY 2011 budget, and will be replaced by DDG-51 “Flight III” destroyers as of about 2016. Those ships will be built in alternating yards by General Dynamics Bath Iron Works and by Northrop Grumman. The question now is whether cost growth and engineering challenges for the Flight IIIs will begin to push them to a level that re-starts debate over building more Zumwalts.

DDG-1000 Key Technologies and Features

DDG-1000: key features
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The Zumwalt Class is currently in the middle of the production phase. When finished, the class is projected at 14,500t, almost 3 times the displacement of some frigates. In other eras, it would have been called a cruiser or even a battlecruiser. A follow-on CG (X) cruiser was also contemplated, and the issues faced by the DDG-1000 Program had a significant influence on its ultimate cancellation. In practice, the 3 DDG-1000s are America’s future cruisers.

Several of the Zumwalt Class’ sub-systems represent entirely new technologies, as seen in the graphics above and below. Some of the key innovations include:

All-aspect Stealth. To achieve survivability in littoral regions close to shore, DDG-1000 ships will be reliant on their ability to see their surroundings and counter threats, while being difficult to detect. The goal is a 50-fold radar cross section reduction as compared to current DDG-51 Arleigh Burke Class destroyers.

To achieve that stealth, the destroyer’s “tumblehome” inward-sloping hull, shaping, composite superstructure, and other stealth measures are meant to reduce radar, infrared, and other signatures. The ship’s shape reduces its visible wake in the water, and its all-electric power system is quieter. Even the ship’s internal lighting system represents advances in this area.

Sensors

Tech features

Dual-Band Sonar. A dual-band hull sonar is a first for American naval ships, and so is its packaging. The Zumwalt Class’ AN/SQQ-90 sonar system includes the AN/SQS-60 hull-mounted mid-frequency sonar; the AN/SQS-61 hull-mounted high-frequency sonar; and the AN/SQR-20 multi-function towed array sonar and handling system. The sonar system can reportedly be operated by 1/3 the number of crew members required for the AN/SQQ-89 systems on current Arleigh Burke Class destroyers and Ticonderoga cruisers, and the range of frequencies should help find submarines in a wider variety of conditions. Correlation between the ship’s 3 sonars may even produce improved resolution, but the Navy isn’t talking.

Like the ship’s computing environment, the sonar system is packaged in Electronic Module Enclosures (EMEs), which roll in as units and combine the commercial off-the-shelf electronics that power the hull-mounted sonars with shock mitigation, electromagnetic interference protection, thermal conditioning, security and vibration isolation. The electronics to power and control the ship’s hull-mounted sonar arrive in a single, smaller package that’s fully integrated and tested, including the transmit/receive amplifiers, and associated processors that distribute signals and data to the ship’s command center.

Total Ship Computing Environment (TSCE). Rather than doing this piecemeal on a per system basis, the idea is to have an integrated but open architecture approach from the very beginning. This creates a single IT framework, and makes it easier to integrate commercial-off-the-shelf (COTS) hardware and software like IBM blade servers and Cisco routers. That allows the Navy and the prime contractors to use more conventional commercial acquisition approaches/ partnerships to support and upgrade the technology, and also improves wider interoperability. A total of 16 factory configured and tested Electronic Modular Enclosures (EMEs) are distributed throughout the ship. EMEs protect the equipment inside, and the client/server architecture ensures that any workstation can run any task, unlike past ships that have depended on task-focused consoles. The entire assembly is controlled by the TCSE software.

TSCE will be about 8 million lines of code, but it actually connects with about 20 million lines of code reused from other programs (AEGIS, SPQ-89, NAVSSI), plus the secured commercial operating systems, databases, and middleware that underpin the entire infrastructure. TSCE’s functionality is being developed as services, with set interfaces to the underlying commercial software and proprietary code. This allows changes to take place on both ends with minimal disruption of each service. The advances made by TSCE will in turn be reused in the new CVN-78 carriers and CV-X cruisers because of its services framework, design for reuse, and open architecture. That’s good, because $117 million per Zumwalt Class ship is a sizeable investment[1].

TSCE is currently at Release 5/6, and coding for Release 6 is underway. IBM is partnered with prime contractor Raytheon for this component; other key subcontractors include Lockheed Martin.

Dual-Band Radar (now just SPY-3 X-band). For detection and self-defense, the DDG-1000 was going to rely on a new approach called the Dual-Band Radar, but will now use only the SPY-3. Raytheon’s X-Band SPY-3 radar provides air and surface detection/tracking, and supports fire control. Its use of active array radar technology makes it far more survivable against saturation missile attacks, since it can track and guide against tens of incoming missiles simultaneously. In comparison, the passive S-band phased array SPY-1D radars that equip American AEGIS destroyers and cruisers are limited to terminal guidance against just 3-4 targets at any one time. Active array radars also feature superior reliability, and recent experiments suggest that they could also be used for very high-power electronic jamming, and high-bandwidth secure communications.

The SPY-3 was to be integrated with Lockheed Martin’s active array S-Band volume search radar, and collectively the SPY-3 fore control radar and SPY-4 search array would comprise the Dual Band Radar (DBR) system. The idea was to have the destroyer benefit from the best capabilities of both X-band’s outstanding medium to high altitude performance, and the S-band VSR’s performance in clutter, in order to create a single combat picture. The goal was a 3x improvement over existing AEGIS ships like the DDG-51 destroyers and CG-47 cruisers. In 2010, however, the S-band SPY-4 was cut from the DDG-1000 program. SPY-4 VSR testing will finish, but Raytheon’s X-band SPY-3 fire control radar would be given volume search upgrades, and become the destroyer’s sole radar. DBR will be retained, in smaller form, on the USA’s new CVN-78 Gerald Ford Class aircraft carriers.

Weapons

BAE’s AGS
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Advanced Gun System. The supposed rationale for the DDG-1000 centers around naval gunfire support for troops ashore. While US battleships with 9 massive 16-inch guns have performed extremely well in this role to date, the DDG-1000 intends to rely on 2 of BAE Systems’ rapid fire 155mm Advanced Gun Systems (AGS), each firing up to 304 advanced Long Range Land Attack Projectile (LRLAP) GPS-guided shells that give the AGS a greatly-extended range of 70-100 nautical miles. The gun will use the AGS Intra-Ship Rearmament System (AIRS) for reloading, providing a safe way of moving AGS pallets between the flight deck and the gun magazine’s pallet hoist, with full performance in conditions up to Sea State 3. Read “Next-Gen Naval Gunfire Support: the USA’s AGS & LRLAP” for fuller coverage of those systems.

BAE is reportedly working on a lighter 155mm AGS assembly that might be suitable for new DDG-51 Flight III destroyers, but it would still weigh twice as much as existing MK45 127/62 caliber naval gun systems. Their joint work with Lockheed Martin on a 5″ LRLAP shell seems likely to pay better dividends,

Beyond the USA, AGS doesn’t have any direct counterparts in other navies yet, but Italy’s OtoMelara has created a rocket boosted, 127/64 caliber GPS-guided shell system called Vulcano, whose shorter range is offset by lower cost compatibility with many existing ships. TBAE and Lockheed Martin are responding with the LRLAP round that fits BAE’s 5″ naval guns, and other firms like Raytheon (Excalibur naval) are offering guided long-range projectiles of their own.

Finally, the Zumwalts have a growth path that other top American ships do not: electro-magnetic weapons. The Zumwalts produce enough power to add lasers for last ditch missile defense and small boat/ anti-helicopter work, once laser technology takes its final operational steps. If enough power can be stored within the ship, future upgrades might even include an electro-magnetic rail gun for ultra-long-range, high capacity guided fire.

Anyone else firing?
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PVLS Missile Launchers. Some additional survivability will come from automated firefighting systems, and even the ship’s missile launchers are designed to contribute. Zumwalt Class destroyers will distribute their 80 missile cells among 20 reinforced launcher sets along the edges of the ship, rather than concentrating them in one central cluster that can be directly targeted by modern missiles. The PVLS system is designed to release and direct the energy from a magazine explosion away from the ship, in order to avoid situations in which the detonation of a round in one cell spreads into catastrophe.

Mk 57 Peripheral Vertical Launching System (PVLS) cells will be larger than the current Mk 41 VLS, allowing them to carry larger missiles, or multi-pack smaller missiles. Raytheon is the prime contractor, with BAE Systems as a subcontractor.

Propulsion

Critical tech & status
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All-Electric Power. Another challenge the Zumwalt Class will face is power. Ship electronics continue to require more and more power, and this class is also envisioned as an all-electric ship wherein even gun turrets and other mechanical systems will be electrical, and having separate systems for propulsion and power will no longer be necessary. The use of electric drive also eliminates the need for drive shaft and reduction gears, which brings benefits in ship space, acoustic signature reduction to enemy submarines, and less interference with the ship’s listening devices. Not to mention better fuel efficiency, and the potential to accommodate new electronics, more powerful radars, or even energy weapons and rail guns. The DDG-1000’s expected electrical output is 78 MW, compared to 7.5 MW for the current DDG-51 Arleigh Burke Class – a capacity limitation that’s endangering plans to refit the Burkes with more advanced radars.

The exact choice of engine systems was somewhat controversial. The concept was originally for an integrated power system (IPS) based on in-hull permanent magnet synchronous motors (PMMs), with Advanced Induction Motors (AIM) as a possible backup solution. The design was shifted to the AIM system in February 2005 in order to meet scheduled milestones; PMM technical issues were subsequently fixed, but the program has moved on. The downside is that AIM technology has a heavier motor, requires more space, requires a separate controller to meet noise requirements, and produces one-third the amount of voltage. Once adopted, however, there was little prospect of going back. These very differences would create time-consuming and expensive design and construction changes if the program wished to “design AIM out”.

The AIM system is made by Alstom, who also makes electric-drive motors for cruise ships. CAE will supply the integrated platform management system. A Rolls-Royce MT30 36MW gas turbine has powered the IPS Engineering Development Model in Philadelphia, and has now been ordered for production ships. The MT30 has 80% commonality with the Rolls-Royce Trent 800 aero engine used on the Boeing 777, and Rolls-Royce states that it is the most powerful marine gas turbine in the world.

DRS Technologies Power Technology unit had received development contracts for the PMM motors, electric drive, and control system for the IPS, but lost that role when the program switched to AIM technology. The firm does retain involvement in the ship’s “Integrated Fight-through Power” modules and load centers that take converted electrical power, condition it to get it to the right voltages, and distribute it to 8 redundant zones. If you lose power on the port side of the ship, for instance, you can cross-connect it to the starboard side.

DDG-1000 Issues and Controversies

Plan B?
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The Zumwalt Class will incorporate a number of new technologies and capabilities that will make it a very formidable combatant – but it has also had its share of controversies that have included questions concerning its stealth, weapon choices, at-sea stability, cost growth, and the Navy’s future force mix.

Stealth. While the DDG 1000 is designed as a low-emissions ship across a number of wavelengths, it is 50% larger than the already large Arleigh Burke Class destroyers – very nearly the same displacement as the WW2 German ‘pocket battleship’ Graf Spee. On the high seas, it’s a very big ocean; but the Navy wants to take them into the shallow-water littoral zone, where a number of alternative technologies (including swarms of small-medium UAVs with electro-optical equipment, or dhows will cell phones) can be used to find a ship. Once the ship fires its weapons, methods for detecting the ship expand further via options like acoustic sensors. Stealth will still make the ship harder to target and engage, but unlike the Iowa Class battleships, a DDG-1000 will not be able to ignore an Exocet missile strike to its hull.

The Navy believes it can still produce a stealthy enough ship, with enough stand-off range to avoid some threats, and to buy reaction time against others. Naval personnel add that they’re testing the platform to ensure that these goals are met. Some observers are less certain. They also wonder whether a serious, realistic ‘hunt the Graf Spee’ test, using a properly equipped opposing force cleared to use innovative approaches, is even thinkable for a Navy that has invested its prestige and several billion dollars. Without such tests, of course, the only way to find out for sure is the hard way, in battle.

Weapons. One of the issues that did a lot of damage to the DDG-1000 program in its late stages was the revelation that its radar system would not be suited to ballistic missile defense roles, and that modifications to make the radar powerful enough would be problematic. This lack of flexibility proved costly, since cheaper DDG-51 destroyers can be made fully ABM capable using known technologies, while the DDG-1000’s SPY-3 radar and combat system would require the same sort of research program the AEGIS ships went through in order to add BMD capability. The Navy also began to contend that the DDG-1000 wouldn’t be able to use Standard family missiles (SM-2, SM-3, SM-6), a charge that has been vehemently and persuasively disputed by Raytheon and others. Raytheon also disputes the charge that its SPY-3 radar would be less suited to the BMD role once software additions were made, contending that its performance would be superior to current ships.

Indeed, Raytheon announced in January 2015 that the Navy has approved the SM-6 for additional Aegis systems, to include those Arleigh Burke-class guided missile destroyers from the 1994-keel-laid The Sullivans (DDG-68) onward.

The other weapons-related issue was the 155mm Advanced Gun System. It will be capable of rapid, long range, accurate fire that far out-ranges even a battleship gun. War is also about intimidation, however; otherwise, the inaccurate, slow, but loud and intimidating musket would never have replaced the faster, longer-range, more accurate, but less intimidating crossbow. A 155mm shell doesn’t have quite the psychological impact of a 16-inch, volkswagen-size battleship round, and rapid fire to create that effect risks exhausting the DDG 1000’s limited ammunition supply very quickly. Reactivating the battleships was considered, and had some supporters in Congress, but never became a serious option.

Meanwhile, other navies are developing rocket-boosted guided ammunition for existing 127mm guns, to give them 60+ mile ranges. Are the expensive and specialized AGS guns simply unnecessary? Can the killing effect of GPS-guided shells from any gun of 5″/127mm or less provide enough suppression and decapitation to make up for lower intimidation value? Even if they could, can the small number of Zumwalts adequately fulfill that role? Or is the AGS/Zumwalt combination simply the wrong concept for naval fire support?

The 3rd issue is that the Zumwalts falter after the AGS gun and PVLS missiles. These huge and expensive ships lack an interior missile defense using systems like RAM missiles, or last-ditch defenses like the radar-guided Phalanx 20mm gatling gun. That’s a troubling weakness for a ship that has to come in close to shore for naval gunfire support. The original design included 2 BAE Mk.110 57mm guns for that purpose, mounted in stealth cupolas near the helicopter hangar. They serve as main guns for the USA’s Littoral Combat Ship and Legend Class Coast Guard Cutters, combining rapid fire fused-fragmentation air defense, and medium-range targeting of inshore enemies like explosives-laden fast boats. The DDG-1000 program said that the Mk.110s didn’t perform as advertised in tests, removed them, and replaced them with 2 less expensive Mk.46 30mm turrets that can’t engage missiles, helicopters, or other aerial opponents. Until and unless the ships add effective laser weapons, this is going to be an important weakness.

In January 2015, General Dynamics was indeed given the contract for Modification 2 M k.46 guns, for $26.2 million in weapons production to be fitted to both the Zumwalt and LCS. This will add to the 38 Mk.46s already delivered and be completed by late 2016, according to the schedule.

Tumblehome hull
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Ship shape. Tumblehome hull designs that slope outward to the waterline have had a less-than-stellar naval history. The design offers important stealth benefits, but some experts believe that the ship could capsize in a following sea at the wrong speed, if a wave at an appropriate wavelength hits it at an appropriate angle. That would be… expensive, on many levels. Then again, so is a missile in your hull. Experiments have been run in simulated conditions up to hurricane-level and with scale models up to 1/4 scale, in order to determine safety. The Navy believes the design to be safe across an array of conditions whose breadth matches current ships.

As a new design type, however, the Zumwalt Class can never have the certainty of designs that are known and proven over the immense array of conditions encountered by thousands of ships sailing over many decades. New capability comes with risk, but if it proves out, the USA will have expertise in stealthy ship design and construction that puts it well ahead of other countries. Are the experts who believe the design to be unsafe rigid traditionalists, of the same species that dismissed the aircraft carrier when it was new? Or are they offering a prescient warning?

Cost Growth. In the end, this is the biggest issue faced by the DDG-1000 program. Originally slated to cost under $1 billion per ship, the program has grown to the point that 2005 GAO estimates placed likely average construction costs at $3.2 billion per ship, with ship life cycle costs at about double that of the DDG-51 Arleigh Burk Class ($4 Billion vs. $2.1 billion). Further cost increases are possible based on technical project risks, with some estimates climbing as high as $5 billion.

At that cost level, even the US Navy will find itself priced out of the water, unable to maintain enough ships to serve in the envisaged role. That cost profile also leads one to ask whether the Navy would really send something that expensive into harm’s way in dangerous shallow waters near an enemy coast, knowing that they’re gambling with a $3+ billion asset whose cost makes it an extremely attractive enemy target.

Force Structure. The original plan called for 32 DD (X) ships. That shrank to 8, and now just 3. Reagan’s 600-ship Navy is now projected to shrink to just 313 ships in official plans, and even this may not be achievable; a 2005 Pentagon study stated that the Navy was likely to be up to 40% short on expected funding toward their 375 ship goal, based on reasonably-expected funding profiles.

Even an 8-ship class certainly isn’t going to succeed in replacing 62 DDG-51 AEGIS destroyers – but something will have to do so beyond 2030, or the Navy’s planned force will start becoming ineffective at all levels, as the intended “high-low” mix fails on both ends. DID has already discussed the light armament profile being built into US Navy versions of the Littoral Combat Ship, and their corresponding and compounding lack of weapon flexibility. As Vice-Admiral Mustin (ret.) and Vice-Admiral Katz (ret.) put it in a 2003 USNI Proceedings article:

“Because the Navy has invested heavily in land-attack capabilities such as the Advanced Gun System and land-attack missiles in DD (X), there is no requirement for [the Littoral Combat Ship] to have this capability. Similarly, LCS does not require an antiair capability beyond self-defense because DD (X) and CG (X) will provide area air defense. Thus, if either DD (X) or CG (X) does not occur in the numbers required and on time, the Navy will face two options: leave LCS as is, and accept the risk inherent in employment of this ship in a threat environment beyond what it can handle (which is what it did with the FFG-7); or “grow” LCS to give it the necessary capabilities that originally were intended to reside off board in DD (X) and CG (X). Neither option is acceptable.”

And yet, here we are in 2012, facing their worst case scenario as our current and future reality.

SSN-21: shared fate?

The SSN-21 Seawolf Class remain the best fast attack submarines in the world, with capabilities – and costs – that no other sub can match. That cost eventually led to program cancellation after 3 boats, and replacement by an SSN-774 Virginia Class that integrated many of their key technologies and design approaches at only 60-70% of Seawolf’s cost. In effect, the Seawolf Class became a set of 3 technology demonstrators.

If the Zumwalt Class cannot overcome these controversies with cost-effective performance, DID warned that it could end up sharing Seawolf’s fate. With the 2008 suspension of construction at 2-3 ships, that appears to be exactly what has happened. Even so, spiraling cost growth for the planned DDG-51 Flight III may yet get the Zumwalt Class back into contention as part of the US Navy’s future. If, and only if, the DDG-1000 program can demonstrate promised build and operational costs.

Zumwalt Class: Contracts and Key Events

DDG-1000 vs. DDG-51/2A
(click to view full)

Contracts for the Zumwalt’s AGS/LRLAP long-range naval gun system, and Dual-Band Radar, are each covered in separate in-depth articles. While both systems are integral to the Zumwalt Class, they’re also present, or have the potential to be retrofitted, in other ship types.

Note that frequent references to “Mission Systems Equipment” can cover a wide range of items: Dual Band Radar, external communications suite, Total Ship Computing Environment set, MK 57 Vertical Launching System, AN/SQQ-90 Integrated Undersea Warfare Combat System, Electro-Optical/Infrared suite, IFF (Identification Friend or Foe) integrated sensor suite; and the Zumwalt ship control hardware, including an integrated bridge, navigation, EO surveillance, and engineering control system components.

Unless otherwise noted, contracts are issued by the USA’s Naval Sea Systems Command in Washington, DC.

FY 2014 – 2018

Zumwalt christened; Why the switch from 57mm to 30mm guns?; Final composite deckhouse delivered.

Float-out
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November 2/18: Support The US Navy is modifying a contract with Raytheon. The additional $34.1 million allow Raytheon to support the Navy’s Zumwalt-class ships with integrated logistics support and engineering services. The DDG-1000 ship’s prime missions are to provide naval gunfire support, and next-generation air defense, in near-shore areas where other large ships hesitate to tread. All three Zumwalt-class vessels equipped with latest electric propulsion systems, wave-piercing tumblehome hulls, stealth designs and advanced war fighting technology. The ships will have the capability to carry out a wide range of deterrence, power projection, sea control, and command and control missions once operational. Work will be performed at multiple locations. Around 52% of the work will be performed in Portsmouth, Rhode Island; 24% in Tewksbury, Massachusetts; 10% in San Diego, California; 6% in Nashua, New Hampshire; 5% Bath, Maine; 1% in Marlboro, Massachusetts; 1% in Ft. Wayne, Indiana and last 1% to be done in St. Petersburg, Florida. The contract is expected to be completed by September 2019.

November 06/17: Raytheon received Tuesday a modified $29 million contract for mission systems equipment for the Navy’s DDG 1000, or Zumwalt-class destroyer. The order calls for the firm to deliver total ship computing environment hardware, and software research, test and development for the Zumwalt—the largest and most technologically advanced guided missile surface combatant ship in the world. Work will be performed across the country, with 46 percent place in Portsmouth, Rhode Island., and the work is expected to be completed by September 2018.

August 14/17: Rolls Royce Marine North America has won a $27.3 million US Navy contract to provide parts and engineering services on power plants for DDG 1000 Zumwalt destroyers. The agreement includes item orders, mounting equipment and other services for DDG 1000 gas-turbine generators, which provide the destroyer’s main source of electric power. Work will be conducted in Indianapolis, Ind., and Walpole, Mass., and is scheduled for completion by September 2022. The power plants are designed for future weapons systems like electromagnetic railguns and lasers, which would require huge amounts of electricity to operate.

June 30/17: BAE Systems and Leonardo are to team up in an effort to offer the latter’s Vulcano guided munitions to the US Navy. Designed in a variety of sizes for the 76mm, 127mm naval guns and 155mm land artillery systems, the joint effort will see the munitions modified to be fired from BAE’s Advanced Gun System (AGS), which is currently installed on the Navy’s Zumwalt-class destroyers. The firms will also seek to offer the munition for use with the M777 and M109 howitzers for the US military.

September 15/15: The final Zumwalt-class destroyer undergoing construction by General Dynamics Bath Ironworks – the future USS Lyndon B. Johnson (DDG 1002) – is facing the chop by an independent team of Pentagon cost assessors, with the third-in-class vessel already under construction. Estimated to cost $3.5 billion, the destroyer was originally supposed to be the third of 32 destroyers, with numbers revised down to first eight then three ships. Cancelling the third ship would effectively cancel the most cost-efficient of the three, as the line becomes more streamlined through each iteration of construction.

Oct 12/14: Weapons. The US Navy has removed BAE’s Mk.110 57mm naval gun from their DDG-1000 Zumwalt Class ships, but it wasn’t clear why (q.v. Aug 5/14). Current revelations now say that the 30mm Mk.46 RWS did better against key target types like small boats than the Mk.110 or notional 76mm guns. That’s more than slightly surprising to some observers, who note that a 30mm cannon’s lethal range is about 1 mile rather than 4-6 miles – but the Navy is saying that they were equally surprised. Program Manager Capt. Jim Downey:

“They were significantly over-modeled on the lethality…. The results of the actual live test-fire data was that the round was not as effective as modeled…. it gets into the range of the threat – the approach of the threat, what the make-up of the threat is and how it would maneuver, how it would fire against our ship. There is a whole series of parameters that are very specific on what the threat is and how you take it out through a layer of defenses…. not what we expected to see.”

Downey categorically denies that the Mk.110’s 10+ ton weight difference was an issue, but doesn’t mention cost. Interestingly, his program’s test findings haven’t been shared with other NAVSEA entities like PEO LCS, let alone the Coast Guard who uses the gun on some cutters. The Navy is working on creating those mechanisms, but they don’t exist yet. Defense News, “Experts Question US Navy’s Decision To Swap Out DDG 1000’s Secondary Gun”.

Oct 2/14: Support. Raytheon Integrated Defense Systems in Tewksbury, MA receives a $6.5 million contract modification for FY 2015 Zumwalt class services engineering efforts, supporting their Mission Systems Equipment (MSE). Raytheon is already the contractor lead for class MSE, and the support contract involves MSE design and analysis, engineering and life cycle supportability, architecture and design studies, concept of operations, crewing, mission and requirements analyses, interoperability, mission support services, and test & evaluation.

Work will be performed in Portsmouth, Rhode Island (48%), Tewksbury, MA (26%), and Sudbury, MA (26%), and is expected to be complete by September 2015. US Navy Naval Sea Systems Command in Washington, DC manages the contract (N00024-10-C-5126).

Aug 7/14: DDG 1001. HII announces that they’ve delivered DDG 1001’s composite deckhouse. Ingalls built and delivered the composite deckhouse and hangar for DDGs 1000 and 1001 at the company’s Composite Center of Excellence in Gulfport, MS, but this will be the last one (q.v. Sept 4/13, Aug 2/13).

The deckhouse will be placed on a barge and shipped to General Dynamics Bath Iron Works in Maine, to be integrated onto the steel hull of DDG 1001. Sources: HII, “Ingalls Shipbuilding Delivers Composite Deckhouse for Michael Monsoor (DDG 1001)”.

Aug 5/14: Weapons. The US Navy discusses the switch away from Mk.110 57mm secondary guns and their tri-mode ammunition, to much smaller Mk.46 30mm guns.

“The results of the analysis for alternative systems to the Mk 110 CIGS [through 2010] were not conclusive enough to recommend a shift in plan.,” but a 2012 review “concluded that the MK46 was more effective than the MK110 CIGS…. In addition to the increased capability, the change from MK110 to Mk 46 resulted in reduction in weight and significant cost avoidance, while still meeting requirements…”

The Mk.110 has a maximum range of about 9 nautical miles, with fuzing modes and rates of fire that can deal with boats, helicopters, or even incoming missiles. Its 30mm replacement has a maximum range of around 2 miles, a lower rate of fire, and lacks the 57mm shell’s fuzing options. It seems to be a puzzling choice, unless it’s simply a weight shift or a sacrifice to shave a small amount off of ship costs. Sources: USNI, “Navy Swaps Out Anti-Swarm Boat Guns on DDG-1000s”.

Cost changes
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May 21/14: CRS Report. The Congressional Research Service talks about the Zumwalt and DDG-51 Flight III programs. This bit about the Zumwalts’ cost history is useful:

“Some of the cost growth in the earlier years in the table was caused by the truncation of the DDG- 1000 program from seven ships to three, which caused some class-wide procurement-rated costs…. a series of incremental, year-by-year movements away from an earlier Navy cost estimate for the program, and toward a higher estimate developed by Cost Assessment and Program Evaluation (CAPE) office within the Office of the Secretary of Defense (OSD). As one consequence of a [2010] Nunn-McCurdy cost breach… the Navy was directed to fund the DDG-1000 program to CAPE’s higher cost estimate for the period FY2011-FY2015, and to the Navy’s cost estimate for FY2016 and beyond. The Navy states that it has been implementing this directive in a year-by-year fashion with each budget submission since 2010, moving incrementally closer each year to CAPE’s higher estimate. The Navy states that even with the cost growth shown in the table, the DDG-1000 program as of the FY2015 budget submission is still about 3% below the program’s rebaselined starting point…”

Sources: CRS, “Navy DDG-51 and DDG-1000 Destroyer Programs: Background and Issues for Congress” update (April 8 and June 25) | USNI, “Two Billion Dollar DDG-1000 Cost Growth Explained”.

Christening

April 12/14: DDG 1000. USS Zumwalt is christened, commander by… Captain James Kirk. Not a joke.

Formal delivery is expected in September 2014. Sources: Pentagon, “Navy to Christen future USS Zumwalt, New Class of Destroyer” | Inquisitr, “USS Zumwalt Destroyer To Have Captain James Kirk At The Helm [Video]”

Zumwalt christened

March 4-11/14: FY15 Budget. The US military slowly files its budget documents, detailing planned spending from FY 2014 – 2019. A subsequent CRS report offers a full breakdown:

“The Navy estimates the combined procurement cost of the two DDG-51s requested for procurement in FY2015 at $2,969.4 million, or an average of $1,484.7 million each. The two ships have received a total of $297.9 million in prior-year advance procurement (AP) funding. The Navy’s proposed FY2015 budget requests the remaining $2,671.4 million to complete the two ships’ combined procurement cost.”

Sources: USN, PB15 Press Briefing [PDF] | CRS, “Navy DDG-51 and DDG-1000 Destroyer Programs: Background and Issues for Congress” update (April 8 and June 25).

Oct 28/13: Float-out. General Dynamics Bath Iron Works successfully launches the DDG 1000 Zumwalt from a floating dry dock, then moors it to a pier on the Kennebec River for final fitting-out.

Construction began in February 2009, and Bath Iron Works will deliver the completed ship in late 2014. Navy tests and trials will follow, and the current schedule would achieve Initial Operating Capability in 2016. Sources: USN, “First Zumwalt Class Destroyer Launched”.

Oct 22/13: MSE. Raytheon Integrated Defense Systems in Tewksbury, MA received a $58 million fixed-price incentive, cost-plus-fixed-fee contract modification for deferred mission systems equipment. The purpose of this modification is to complete the remaining MSE for DDG 1000 and DDG 1001, buy the remaining long-lead mission systems equipment for DDG 1002, and do one-time engineering related to mission system equipment design and development.

DDG 1002 will get”non-hatchable” Mission Systems Equipment. This involves items that are too large to be installed after the ship is built, as they can’t fit through the ship’s hatches. DDG 1002 Lyndon Johnson’s Mk57 VLS, AN/SQQ-90 sonar, etc. all fall into this category. Deferred MSE items for Zumwalt and Michael Monsoor include the MK57 VLS Launcher’s electronics and mechanical kits, below-deck radio terminals for external communications, and dry-end portions of the sonar suite.

Work will be performed in Portsmouth, RI (56%), Dallastown, PA (24%); Minneapolis, MN (16%), and Moorestown, NJ (4%), and is expected to be complete by April 2017.

Oct 11/13: Christening of USS Zumwalt (DDG 1000), originally scheduled for Oct 19/13, is postponed by the Navy because of the government shutdown.

FY 2013

DDG 1000 deckhouse delivered & fitted; Agile software development.

Deckhouse erection
click for video

Sept 26/13: General Dynamics Bath Iron Works, Bath, Maine, is being awarded a $13.3 million contract modification for material and labor to complete work on the DDG 1000 deckhouse, which was provided by Northrop Grumman. $6.7 million in FY 2012 USN Shipbuilding and Conversion funds are committed immediately.

Work will be performed in Bath, Maine, and is expected to be complete by June 2014. The USN Supervisor of Shipbuilding, Conversion, and Repair in Bath, Maine (N00024-06-C-2303).

Sept 25/13: Sub-contractors. Huntington Ingalls Industries announces that they’ve delivered DDG 1001 Michael Monsoor’s 220 ton composite hangar. This follows the peripheral vertical launch system (PVLS) delivery in July 2013, and the deckhouse delivery expected in 1st quarter of 2014 will complete the company’s work on the DDG 1000 program. Sources: HII release, Sept 25/13.

Sept 4/13: Industrial. HII will be closing its Composite Center of Excellence in Gulfport, MS, once they’ve completed work on DDG 1001 Michael Monsoor’s deckhouse and the mast of LPD 27 Portland. That work is expected to finish in early 2014, with closure expected by May.

Total costs of the shut-down are expected to be about $59 million, with over 400 employees affected. Sources: HII, Sept 4/13 release.

Aug 11/13: Industrial. HII’s Composite Center of Excellence in Gulfport, MS is unsure of its future. Fabrication of masts for the LPD-17 San Antonio Class is ending, and the DDG 1002 deckhouse decision shortens their transition period. NAVSEA spokesman Chris Johnson gives $767 million as HII’s estimate for the value of their DDG 1000 & 1001 contracts, and they’ll still be contracted for the aft PVLS cells on DDG 1002, but they’ll need more than that.

Tim Colton suggests selling the center to their next-door neighbor Gulf Coast Shipyard Group, who is “building and repairing all types and sizes of naval and commercial boats, in steel, aluminum and composites, for markets that Ingalls has never had a chance of penetrating.” Sources: Virginian-Pilot, “Navy switch could hurt Ingalls Miss. composite center” | Time Colton’s Maritime Memos, “Curious Developments in Bath”.

Aug 3/13: Industrial. GD Bath Iron Works requests a tax break from Bath, Maine. They want to improve areas like their blast and pain facilities, and create a new 110-foot-high, 51,315-square-foot outfitting hall by 2015. Their submission is blunt about why they want the funds, citing a recent DDG-51 program award that saw them get 4 ships to HII’s 5, calling that “a strong message about where BIW stands relative to its competition.”

Tim Colton is even blunter:

“BIW is not expanding. It already has way more capacity than it needs…. new shop is designed to improve its productivity and, potentially, increase its throughput with minimal increase in employment…. BIW needs a second program [beyond the DDG-51s] for long-term security…. Its best bet is the LSD program and they probably regret now that they traded one third of the LPD 17 program for extra DDGs, after designing their land-level facility specifically for LPD construction. And then there’s the polar icebreaker program, which may be just their thing.”

Sources: Kennebec Journal, “BIW asks Bath for tax break to expand shipyard” | Time Colton’s Maritime Memos, “Curious Developments in Bath.”

Aug 2/13: DDG 1002. GD Bath Iron Works in Bath, ME receives a $212 million firm target fixed-price incentive to build a steel (not composite this time, q.v. March 28/13) deckhouse and hangar superstructure for DDG 1002 Lyndon B. Johnson, and supply the ship’s aft PVLS launchers. That leaves only DDG 1002’s mission systems contract to finish the order. All funds are committed immediately, using a combination of FY 2010 and FY 2013 shipbuilding dollars.

That steel deckhouse will be considerably heavier than its composite counterparts. Subsequent reports involving NAVSEA spokesman Chris Johnson indicate that the Navy thinks they have enough weight margin in the ship to do it.

Work will be performed in Bath, ME (80.5%), Corona, CA (4.1%), Coatesville, PA (2.6%), South Portland, ME (1.4%) and other various locations with less than 1% each (11.4%), and is expected to be complete by December 2016. This contract was a limited competition solicited via FBO.gov by US Naval Sea Systems Command in Washington, DC (N00024-11-C-2306). Sources: Pentagon | BIW Aug 5/13 release | Virginian Pilot, “Navy switch could hurt Ingalls Miss. composite center”.

DDG 1002 will have a steel deckhouse

July 24/13: DDG 1001. HII announces that they’ve delivered DDG 1001 Michael Monsoor’s final aft PVLS assemblies to the US Navy a week early. They’ll go to GD Bath Iron Works, who is building the hull and performing final assembly.

HII manufactures the composite superstructure for DDG 1000 and 1001 at the company’s composite center of excellence in Gulfport, MS, and makes all of the ship’s 4-cell PVLS launchers in Pascagoula, MS. DDG 1001’s first 2 PVLS units were delivered in July 2012, and the rest of the work is expected to be complete in the Q1 2014. HII.

May 23/13: DDG 1001 Keel Laying. Formal keel-laying, which is actually the 4,400 ton, heavily outfitted mid-forebody section of the ship. The ship is named for Michael Monsoor, a Navy SEAL whose Medal of Honor information is an appropriate Memorial Day reminder. GD BIW [PDF].

March 28/13: GAO Report. The US GAO tables its “Assessments of Selected Weapon Programs“. Which is actually a review for 2012, plus time to compile and publish. As of December 2012, the first 2 ships were 80% and 48% complete, with all contracts awarded. TSCE Release 6 software has begun integration and testing, and the follow-on release that would activate the mission systems is under contract.

Even at this late stage, issues remain. Most critical technologies won’t be fully mature and demonstrated in a realistic environment until after they’re installed in DDG 1000. One such technology, the GPS-guided LRLAP long-range shell, recently had its rocket motor redesigned and tested.

DDG 1002 began fabrication in April 2012, with pending contracts for the deckhouse, hangar, aft peripheral vertical launching system, and mission systems equipment. The Navy is considering a downgrade of the deckhouse to save money. Composite materials are better for stealth, but steel is cheaper, and both shipyards report that it’s a feasible alternative.

March 19/13: Support. General Dynamics Bath Iron Works, Bath, Maine receives an $18 million contract modification, exercising an option for DDG 1000 class services. This modification provides technical and industrial engineering in the interpretation and application of the detail design to construction of DDG 1000 class ships.

They seem to need quite a few contracts for this.

Work will be performed in Bath, ME, and is expected to be complete by September 2013. FY 2013 Shipbuilding and Conversion funding is being used, and all funds are committed (N00024-06-C-2303).

Dec 28/12: MSE. Raytheon Integrated Defense Systems in Tewksbury, MA received a not-to-exceed $169 million fixed-price incentive, cost-plus-fixed-fee contract modification for deferred mission systems equipment for DDG 1000 and DDG 1001, scheduled critical DDG 1002 non-hatchable mission systems equipment, and non-recurring engineering applicable to mission system equipment design and development.

Discussion with Raytheon clarified that “non-hatchable” Mission Systems Equipment is too large to be installed after the ship is built, as it can’t fit through the ship’s hatches. DDG 1002 Lyndon Johnson’s Mk57 VLS, AN/SQQ-90 sonar, etc. all fall into this category. Deferred MSE items for Zumwalt and Michael Monsoor include the MK57 VLS Launcher’s electronics and mechanical kits, below-deck radio terminals for external communications, and dry-end portions of the sonar suite.

Work will be performed in Moorestown, NJ (37%); Largo, FL (14%); Marlborough, MA (14%); Portsmouth, RI (13.2%); Cordova, AL (10%); Andover, MA (7%); Tewksbury, MA (2%); Sudbury, MA (1.5%); San Diego, CA (1%), and Aberdeen, MD (0.3%), and is expected to be complete by May 2018. $117 million is committed immediately (N00024-10-C-5126). See also Raytheon.

Dec 14/12: DDG 1000. The future USS Zumwalt has its deckhouse superstructure attached to the ship’s hull. “General Dynamics Bath Iron Works Completes Historic DDG 1000 Deckhouse Module Erection” describes the 900-ton static lift in detail: it involves 4 cranes, lifting a 900-ton, 155 x 60 x 60 foot deckhouse about 100 feet in the air, and moving the 610-foot hull beneath the suspended module using the shipyard’s electro-hydraulic ship transfer system. Total tonnage involved was over 13,000 tons.

With the successful lift and integration of the deckhouse, 9 of 9 ultrablock units are now on land level at Bath Iron Works. Construction is now 80% complete, with ship launch and christening planned for 2013. Construction on DDG 1001 Michael Monsoor continues, with delivery planned in 2016. DDG 1002 Lyndon B. Johnson is expected to reach the Navy in 2018. US Navy | GD Bath Iron Works | Erection on video.

Nov 9/12: Support. Raytheon IDS in Tewksbury, MA received an $19 million contract modification for Zumwalt class services engineering efforts, including participation in the joint test team. Work will be performed in Portsmouth, RI (50%); Andover, MA (15%); Moorestown, NJ (10%); Sudbury, MA (10%); Tewksbury, MA (10%); and San Diego, CA (5%); and is expected to be complete by December 2014. US Naval Sea Systems Command, Washington, D.C., is the contracting activity (N00024-05-C-5346).

Nov 6/12: Agile software. Aviation Week quotes Bill Marcley, Raytheon’s DDG-1000 program manager and VP of Total Ship Mission Systems, who cites the firm’s use of agile software development processes for the ship’s voluminous software. Agile development methods have become common in high-tech industries, and are spreading, but they’re a very uncommon approach in the defense industry. They focus on delivering small bits of working and tested software in a series of short timelines, generally under a month each. The most common status quo alternative involves a series of months-long sequential or slightly overlapping “waterfall” stages of specification, development, testing, and fixes that each encompass the entire project.

Air and missile defense are current foci for Raytheon’s agile ‘stories,’ and a major software review is scheduled for December 2012. Meanwhile, the Navy is sitting in on the scrum teams’ weekly software status reviews, and monthly combat system reviews. One of agile’s benefits is a greater level of assurance and visibility into project progress. It will be interesting to see if this approach spreads within the firm, and the industry. Aviation Week | See also DID: “Sharpen Yourself: The Agile Software Development Trend”

Oct 9/11: Deckhouse. HII’s Ingalls Shipbuilding division has delivered DDG 1000 Zumwalt’s 900-ton composite deckhouse to the U.S. Navy. The deckhouse contains the ship’s bridge, radars, antennas and intake/exhaust systems, and will be welded to DDG 1000 at the steel base plates that are bolted to the core composite structure. Ingalls has also delivered DDG 1000’s composite hangar and aft PVLS units, and has begun work on the composite components for DDG 1001. HII.

DDG 1000 deckhouse

Oct 1/12: HII in Pascagoula, MS receives an $11.6 million cost-plus-fixed-fee contract modification, exercising an option for FY 2013 class services for the Zumwalt Class.

Work will be performed in Pascagoula, MS (95%), and Gulfport, MS (5%), and is expected to be complete by July 2013 (N00024-06-C-2304).

FY 2012

DDG 1000 Zumwalt keel-laying; Could DDG-51 Flight III cost spirals reignite the DDG-1000s?

Deckhouse build
(click to view full)

Sept 19/12: General Dynamics Bath Iron Works in Bath, ME receives a $38.9 million cost-plus-fixed-fee contract modification, exercising options for additional class and engineering services, involving “technical and industrial engineering in the interpretation and application of the detail design.” The firm describes this work as “manufacturing support services such as engineering, design, production control, accuracy control and information technology… [plus] program management, contract and financial management, procurement and configuration/data management.”

Work will be performed in Bath, ME, and is expected to be complete by October 2013 (N00024-11-C-2306). See also GD release.

Sept 5/12: General Dynamics Bath Iron Works in Bath, ME receives a $26 million cost-plus-fixed-fee contract modification, exercising options for additional class and engineering services involving “technical and industrial engineering in the interpretation and application of the detail design.” Work will be performed in Bath, ME, and is expected to be complete by March 2013 (N00024-11-C-2306).

A piece in the Bangor Daily News may offer a more revealing and candid explanation for these continued contracts, so late into the construction process:

Rep. Chellie Pingree echoed the senators’ statements and said the contract will ensure steady design work at BIW through March. “The contract will help keep workers on the job designing and building the DDG 1000 this winter,” she said. “It’s critical to keep up the employment levels at the yard.”

Aug 16/12: Huntington Ingalls Industries in Pascagoula, MS receives a $7.2 million contract modification for research, development, test, and technical services in support of DDG 1000 Zumwalt-class destroyer. DDG 1000 technical services include technology development, analytical modeling, qualification of materials, potential design/process improvements, and design excursions.

Work will be performed in Pascagoula, MS (80%), and Gulfport, MS (20%), and is expected to complete by September 2013 (N00024-06-C-2304).

June 26/12: Move it on over. Huntington Ingalls, Inc. in Pascagoula, MS receives a $9.3 million cost-plus-fixed-fee contract modification. It will pay for the fabrication of cradles, fixtures, and other equipment that are necessary to safely and securely transport their Zumwalt Class assemblies from HII in Pascagoula, MS, to Bath Iron Works in Bath, ME.

Work will be performed in Pascagoula, MS (95%), and Gulfport, MS (5%), and is expected to be complete by June 2014 (N00024-06-C-2304).

May 31/12: General Dynamics Bath Iron Works in Bath, ME receives a $17 million contract modification, exercising an option for “technical and industrial engineering in the interpretation and application of the detail design to support construction and the maintenance of the ship design.” Work will be performed in Bath, ME, and is expected to be complete by September 2012 (N00024-06-C-2303).

April 30/12: Huntington Ingalls Industries, Inc. in Pascagoula, MS receives a $11.5 million contract modification, exercising an option for FY 2012 class services in support of Zumwalt Class product fabrication, delivery, engineering, engineering support and integrated logistics support.

Work will be performed in Pascagoula, MS (95%), and Gulfport, MS (5%), and is expected to be complete by October 2012 (N00024-06-C-2304).

April 16/12: DDG 1002 named. Secretary of the Navy Ray Mabus announces that the last planned ship of class, DDG 1002, will be named after President Lyndon B. Johnson. Johnson was a naval officer in the Pacific theater during World War 2, so all 3 ships have been named after Navy personnel, but American ships named after Presidents have been American carriers. The lone exception had been Jimmy Carter, a submariner who had the 3rd and last SSN-21 Seawolf Class fast attack submarine named after him.

We can’t wait until the new ship visits Cam Ranh Bay. US Navy | US DoD.

April 16/12: Sonar. Raytheon announces delivery of DDG 1000 Zumwalt’s dual-frequency AN/SQQ-90 tactical sonar suite, completely assembled and integrated into its Electronic Modular Enclosure (EME). Both the dual-band hull sonar and the EME represent firsts for American naval ships, and the system can reportedly be operated by 1/3 the number of crew members required for the AN/SQQ-89 systems on current Arleigh Burke Class destroyers and Ticonderoga cruisers.

The AN/SQQ-90 includes the AN/SQS-60 hull-mounted mid-frequency sonar; the AN/SQS-61 hull-mounted high-frequency sonar; and the AN/SQR-20 multi-function towed array sonar and handling system. The EME takes a page from the TSCE, in that it efficiently packages the commercial off-the-shelf electronics that power the hull-mounted sonars with shock mitigation, electromagnetic interference protection, thermal conditioning, security and vibration isolation. The electronics to power and control the ship’s hull-mounted sonar arrive in a single, smaller package that’s fully integrated and tested, including the transmit/receive amplifiers, and associated processors that distribute signals and data to the ship’s command center.

April 2/12: General Dynamics Bath Iron Works in Bath, ME receives a $9.4 million contract modification, exercising an option for additional class services. Specifically, BIW will provide “technical and industrial engineering in the interpretation and application of the detail design to support construction and the maintenance of the ship design.”

Work will be performed in Bath, ME, and is expected to complete by May 2012 (N00024-06-C-2303).

March 2012: The Pentagon’s Developmental Test and Evaluation and Systems Engineering’s FY 2011 annual report offers an update on the class’ IPS and radar testing:

“The preparations and [land based] testing at the [all-electric Integrated Power Systems’] LBTS were exemplary and undoubtedly resulted in avoiding cost and delay… DDG 1000 program is executing to the current approved TEMP [testing program]. The TEMP is inadequate in that it lacks details of the [SYPY-3 Multi-function Radar’s added Volume Search] T&E. Revision E, on schedule for submission for approval in FY 2012, will contain details of the MFR VS test program.”

March 30/12: GAO report. The US GAO tables its “Assessments of Selected Weapon Programs” for 2012. Lead ship delivery is expected in July 2014, with the class expected to be ready to deploy by July 2016. Expected cost per ship remains around $3.5 billion, where it has been for some time now. A number of technologies remain delayed, however, even though the Zumwalt Class has spent more than 3.5x its original R&D projections:

“Three of DDG 1000’s 12 critical technologies are currently mature and the integrated deckhouse will be delivered to the first ship for installation in fiscal year 2012. However, the remaining eight technologies will not be demonstrated in a realistic environment until after ship installation…

“According to program officials, [TSCE] software release 5 has been completed and was used in land-based testing in fiscal year 2011. The program has made changes to release 6, and has prioritized the software needed to support shipyard delivery over… activating the mission systems. This functionality was moved out of the releases and will be developed as part of a spiral… the gun system’s long-range land-attack projectile [LRLAP] has encountered delays, primarily due to problems with its rocket motor. The Navy plans to finalize and test the rocket motor design by March 2012… guided flight tests using older rocket motor designs… demonstrated that the projectile can meet its accuracy and range requirements… Shipbuilders have experienced several challenges in constructing the first and second ships, including issues with the manufacture and installation of certain composite materials.”

Jan 31/12: AGS. BAE Systems in Minneapolis, MN receives a maximum $52 million contract modification, exercising the option for DDG 1002’s Advanced Gun System (AGS). This seems to finalize the Oct 26/11 contract at $125 million.

Work will be performed in Louisville, KY (37%); Cordova, AL (30%); Minneapolis, MN (28%); and Burlington, VT (5%), and is expected to be complete by January 2018 (N00024-12-C-5311).

December 2011: Hand-over. The Pentagon’s Under Secretary of Defense for Acquisition, Technology, and Logistics (AT&L) delegates authority for future DDG 1000 acquisition decisions to the Navy. Source: GAO.

Dec 22/11: General Dynamics Bath Iron Works in Bath, ME receives a $17.6 million contract, exercising an option for DDG 1000 class services, esp. technical and industrial engineering in the interpretation and application of the detail design to support construction, and the maintenance of the ship design profile.

Work will be performed in Bath, ME, and is expected to be complete by April 2012. Contract funds will not expire at the end of the current fiscal year, on Sept 30/12 (N00024-06-C-2303).

Dec 16/11: TSCE order. Raytheon IDS in Tewksbury, MA receives a multi-year, not-to-exceed $254 million letter contract modification. They’ll deliver a set of DDG 1000 Total Ship Computing Environment software for the US Navy’s Self Defense Test Ship, and support post-delivery and post-shakedown work involving the former Spruance Class destroyer Paul F. Foster [DD 964, now SDTS]. They’ll also perform SPY-3 volume search software and firmware development, as their active X-band radar takes over those functions from Lockheed Martin’s active S-band SPY-4. The final set of exercised options and changes here involve general software maintenance in support of the DDG-1000 program.

Work will run until January 2016; $11 million will be provided upon contract award, and will expire at the end of the current fiscal year on Sept 30/12. Work will be performed in Tewksbury, MA (40%); Portsmouth, RI (24.8%); Marlborough, MA (12.7%); Fort Wayne, IN (10.3%); Sudbury, MA (5.8%); Dahlgren, VA (2.7%); Indianapolis, IN (2.3%); and San Diego, CA (1.4%). (N00024-10-C-5126). See also Raytheon’s release says that the DDG 1000 program employs more than 800 Raytheon employees, as well as by approximately 1,800 subcontractors and supplier partners in 43 states across the country.

Dec 2/11: 1002 lead-in. Huntington Ingalls, Inc. in Pascagoula, MS receives a $46.1 million contract modification to procure long lead time material and related support for DDG 1002. A copy of their recent release quotes DDG 1000 program manager Karrie Trauth, who calls the contract strategic to the firm because of the advanced composite shipbuilding capabilities it supports.

Work will be performed at the company’s Composite Center of Excellence in Gulfport/ Pascagoula, MS (28%); as well as Benicia, CA (24%); Burns Harbor, IN (10%); Corona, CA (9%); Monroe, CT (4%); Deerpark, TX (3%); Patterson, NJ (3%); and other various locations with less than 1% of the total (19%). Work is expected to complete by March 2012 (N00024-06-C-2304). See also MarineLog.

Nov 18/11: 1000 keel-laying. The Zumwalt’s Keel is formally laid, in the form of a 4,000 ton ultrablock (vid. Oct 22/11 entry). The physical change is a corollary of using modern block construction techniques. GD-BIW.

Nov 16/11: DDG-51 or Zumwalt? Jane’s Navy International is reporting that DDG-51 flight III destroyers with the new AMDR radar and hybrid propulsion drives could cost $3-4 billion each.

If that’s true, it’s about the same cost as a DDG-1000 ship, in return for less performance, more vulnerability, and less future upgrade space. AMDR isn’t a final design yet, so it’s still worthwhile to ask what it could cost to give the Flight IIIs’ radar and combat systems ballistic missile defense capabilities – R&D for the function doesn’t go away when it’s rolled into a separate program. If the Flight III cost estimate is true, it raises the question of why that would be a worthwhile use of funds, and re-opens the issue of whether continuing DDG-1000 production and upgrades might make more sense. DoD Buzz.

Nov 10/11: Raytheon Integrated Defense Systems in Tewksbury, MA receives a $20.7 million contract modification, exercising options for FY 2012’s DDG-1000 program engineering, production, and integration services. That doesn’t mean the whole ship, just Raytheon’s Mission Systems Integrator role. $5.4 million has already been committed, and the rest will follow if needed.

Work will be performed in Portsmouth, RI (25%); Tewksbury, MA (25%); Marlboro, MA (20%); Dulles, VA (20%); San Diego, CA (5%); and Alexandria, VA (5%), and is expected to be complete by November 2012. Contract funds will not expire at the end of the current fiscal year (N00024-10-C-5126).

Nov 7/11: Aviation Week:

“Enhanced ballistic missile defense (BMD) missions will stretch the future U.S. Navy destroyer force beyond its fleet limits as well as put even more pressure on the service’s already stressed funding accounts, according to an Aviation Week Intelligence Network (AWIN) analysis and a recent Congressional Research Service (CRS) report.”

Nov 1/11: General Dynamics Bath Iron Works in Bath, ME receives a $14.4 million contract modification, exercising options for DDG 1000 class services and class logistics services associated with detail design and construction. Logistics services include development of training curriculum, supply support documentation, maintenance analyses, and configuration status accounting. Work will be performed in Bath, ME, and is expected to be complete by November 2012 (N00024-06-C-2303).

Oct 31/11: Huntington Ingalls, Inc. in Pascagoula, MS received a $13 million cost-plus-fixed-fee contract modification, exercising FY 2012 Zumwalt destroyer class services. They’ll support fabrication, delivery, engineering, and engineering support. Ingalls is building the deckhouse, hangar and peripheral vertical launch systems for DDG 1000 and DDG 1001, with plans to build a third. The deckhouse for DDG 1000 is expected to be delivered in Q2 2012. As HII’s DDG 1000 program manager Karrie Trauth notes:

“This contract modification provides additional funding for the composite work we’re doing on the deckhouse for this shipbuilding program… This is a significant program for our composite shipbuilders in Gulfport, and this award ensures the valuable expertise and technological advancements in composites continue through the detail design and construction of these ships.”

Work will be performed in Pascagoula, MS (95%), and Gulfport, MS (5%), and is expected to be complete by April 2012 (N00024-06-C-2304).

Oct 26/11: AGS. An unfinalized $73 million fixed-price incentive-fee firm target contract action for the Advanced Gun System (AGS) for DDG 1002, the last planned Zumwalt Class ship. This contract includes options, which could bring its cumulative value to $168 million.

Work will be performed in Louisville, KY (40%), Minneapolis, MN (30%), and Cordova, AL (30%), and is expected to be complete by January 2018. This contract was not competitively procured (N00024-12-C-5311).

Oct 22/11: General Dynamics Bath Iron Works completes the largest and most complex ship module movement ever executed at the shipyard, as the move the mid-forebody section of Zumwalt 900 feet inside the Ultra Hall construction facility. The heavily outfitted module is about 180 feet long, over 60 feet high and weighs more than 4,000 tons. The next step will be to integrate it with 3 additional “ultra units” that comprise the ship’s unique wave-piercing hull form. GD-BIW [PDF]

FY 2011

DDG-1001 and 1002 contracts, at last; Program update, incl. TSCE delays.

DDG 1000 Ultrablock
(click to view full)

Sept 30/11: Design. General Dynamics Bath Iron Works in Bath, ME receives a $13 million contract modification for additional class services associated with detail design and construction. It’s mostly industrial engineering in the interpretation and application of the detail design, to support construction, and ship design updates based on feedback. Work will be performed in Bath, ME, and is expected to be complete by September 2012 (N00024-06-C-2303).

Sept 29/11: Design. Exactly the same as the Sept 30/11 contract, but $22.5 million, under another agreement that appears to be the go-forward contract for DDG 1000 class services (N00024-11-C-2306).

Sept 25/11: Progress report. Defense News offers a progress report from program manager Capt. James Downey. Negotiations are now under way with major suppliers HII (composite superstructure, some hull), Raytheon (Radar, electronics, combat system), and BAE (gun, launchers) for DDG 1001 and 1002, and the Navy hopes to come in slightly under DDG 1000’s $3 billion or so overall cost. The whole program is said to be within current time and budget, but that’s not the same as original plans because there have been many revisions over the years.

Tests of the AIM all-electric power system, new AGS guns & LRLAP precision shells, and EMEs (electronic modular enclosures) have gone well, EMEs are already shipping, and re-work on delivered components is under 1%. DDG 1000 Zumwalt is expected to be 60% complete at its keel-laying on Nov 17/11, because of the ship’s modular block construction approach. At 4,000 tons, the forward midbody block alone is heavier than some frigates. The 1,000+ ton composite superstructure is more than 75% complete, and is expected to be barged from Mississippi to Maine in late spring 2012. DDG 1000 Zumwalt is scheduled for launch in July 2013, with initial delivery set for 2014, and completion of the combat system to follow in 2015.

That’s an odd sequence, and managing it effectively will require the Navy to take delivery without releasing the contractors from financial responsibility for fixes – something the Navy has not always been able to do. Part of the issue involves delays in the Total Ship Computing Environment, whose 6th software release will start testing in January 2012, with a combat system release to follow. Both must then be tested on a ship equipped with all of the systems they control, which doesn’t exist yet, and that takes more time. TSCE 6 is scheduled for final delivery from Raytheon in January 2013, but until the combat system gets the final go-ahead in 2015, the ship won’t really be operational, regardless of its official status. The good news, such as it is, is that this qualification is only a problem once – unless issues are discovered later in the ship’s career. DDG 1001 Michael Monsoor is currently about 25% complete, and scheduled for delivery in 2015, so delays to the combat system could affect both ships. DDG 1002 construction won’t really start until spring 2012.

Sept 15/11: 1001 & 1002 contract. General Dynamics Bath Iron Works in Bath, ME receives a $1.826 billion fixed-price-incentive contract to build DDG 1001 and DDG 1002, the 1st major Zumwalt Class contract since February 2008. This contract includes options which could raise its value to $2.002 billion. Work will be performed in Bath, ME (59.9%); Parsippany, NJ (3.5%); Coatesville, PA (3.2%); Falls Church, VA (2.6%); Pittsburgh, PA (1.3%); Augusta, ME (1.3%); and other various locations (28.2%), each having less than 1%. This contract was not competitively procured.

Discussions with GD BIW clarified this is the full shipbuilder’s contract for both ships, which includes remaining construction, integration of many expensive items like the radars, weapons, etc. which are bought separately by the government, and initial testing/ qualification work. The September 2001 contract builds on long-lead materials and initial fabrication that have been bought for both DDG 1001 and 1002, using funds from the February 2008 contract, and subsequent interim awards.

At present, DDG-1000 Zumwalt is over 50% complete, and is scheduled to be delivered in 2014. DDG 1001 Michael Monsoor is currently scheduled for delivery in December 2015, and DDG 1002 is scheduled for delivery in February 2018. (N00024-11-C-2306). See also GD BIW | Sen. Snowe [R-ME].

Aug 4/11: 1001 & 1002 lead-in. General Dynamics Bath Iron Works in Bath, ME receives a not-to-exceed $110.8 million contract modification for more long lead time construction on DDG 1001, long lead time material for DDG 1002, and engineering and production support services. It’s not the big production contract everyone is expecting, but it is the first large award in over 2 years, and a necessary precursor to the full production deal.

Work will be performed in Coatesville, PA (23.3%); Erie, PA (13%); Walpole, MA (12.9%); Parsippany, NJ (11.1%); Loanhead, Midlothian, United Kingdom (5.4%); Deer Park, TX (5.4%); Newton Square, PA (4.5%); Kingsford, MI (4.4%); Milwaukee, WI (2.8%); South Portland, ME (2.7%); and other various locations with less than 2% (14.5%). Work is expected to be complete by October 2011 (N00024-06-C-2303).

July 26/11: After a gap of more than 2 years since the last major contract for this ship class, the US Navy has reached an agreement with General Dynamics-Bath Iron Works for pricing, terms and conditions for DDGs 1001 and 1002. Final contract details are being worked out, and the multi-billion dollar award is expected before the end of FY 2011.

With agreement reached, a 2011 budget passed, and Northrop Grumman’s shipbuilding changes resolved, all elements are now in place for the next step. Once construction on the Zumwalts is finished, Bath Iron Works will continue building DDG-51 destroyers, but the deal that gave it all 3 Zumwalts means BIW is no longer the DDG-51’s lead yard. Sen. Susan Collins [R-ME] | Maine’s Morning Sentinel | Defense News | Portland Press Herald.

July 22/11: IPS. US Chief of Naval Operations (CNO) Adm. Gary Roughead observes a live test of the DDG 1000 Integrated Power System (IPS) at Naval Surface Warfare Center Carderock Division’s land-based Ship Systems Engineering Station (NSWCCD-SSES). The next IPS test, scheduled for early 2012, will integrate and test portions of the DDG 1000 Engineering Control System software with the IPS, to verify compatibility.

The US Navy’s July 28/11 release adds that DDG 1000 Zumwalt is more than 50% complete and scheduled to deliver in FY 2014, with an Initial Operating Capability in FY 2016. DDG 1001 Michael Monsoor is about 20% complete, as key contracts must be forthcoming before much more build work can proceed.

May 11/11: IPS. The U.S. Navy successfully tests DDG 1000’s Integrated Power System (IPS) at full power, at the Philadelphia Land Based Test Site. The test included 1 of 2 shipboard shaft lines, 1 main and 1 auxiliary gas turbine generator set, all 4 high voltage switchboards, 2 of 4 shipboard electrical zones of Integrated Fight Through Power (IFTP) conversion equipment, and 1 of 2 propulsion tandem advanced induction motors with their variable control drives.

The IPS for an all-electric ship like the Zumwalt generates all ship electric power, then distributes and converts it for all ship loads, including electric propulsion, combat systems and ship services. defpro.

May 17/11: 1001 lead-in. General Dynamics Bath Iron Works in Bath, ME receives a not-to-exceed $29.9 million contract modification for DDG 1001 long-lead-time materials, engineering and support services. Work will be performed in Bath, ME, and is expected to be complete by July 2011. (N00024-06-C-2303).

May 4/11: Design. General Dynamics Bath Iron Works in Bath, ME receives an $18.8 million cost-plus-fixed-fee contract modification for “technical and industrial engineering in the interpretation and application of the detailed design to support construction and the maintenance of a safe and operable ship design.”

Work will be performed in Bath, ME, and is expected to be complete by July 2011 (N00024-06-C-2303). Meanwhile, the pattern continues – a lot of minor, “keep ’em working” contracts, without a major purchase contract (vid. Feb 15/11 entry).

March 30/11: TSCE. Raytheon Integrated Defense Systems in Tewksbury, MA receives a $7.6 million contract modification for class services engineering efforts involving their Total Ship Computing Environment.

Work will be performed in Portsmouth, RI (29%); Tewksbury, MA (26%); Sudbury, MA (26%); Moorestown, NJ (10%); Marlboro, MA (6%); Herndon, VA (1%); Houston, TX (1%); Leesburg, VA (0.5%); and Minneapolis, MN (0.5%). Work is expected to be complete by November 2011, but $5.1 will expire at the end of the current fiscal year, on Sept 30/11 (N00024-10-C-5126).

March 21/11: Raytheon Integrated Defense Systems in Tewksbury, MA receives a $10.9 million contract modification, exercising an option for DDG-1000 class services engineering. Efforts include non-recurring engineering in support of mission systems equipment (MSE) system/design verification testing; 1st article factory test site preparation and plans; maintenance of MSE packaging, transportation, assembly, activation, and preservation documentation; maintenance of shipboard MSE installation and check-out plans; as well as the measurement, tracking, and reporting of MSE weight and power usage documentation to support the shipbuilders in meeting lead ship integration and construction schedules.

Work will be performed in Portsmouth, RI (50%); Andover, MA (15%); Moorestown, NJ (10%); Sudbury, MA (10%); Tewksbury, MA (10%); and San Diego, CA (5%), and is expected to be complete by December 2014 (N00024-05-C-5346).

March 18/11: General Dynamics Bath Iron Works in Bath, ME receives a not-to-exceed $28 million contract modification for long lead time material and engineering and support services for DDG 1001, the Michael Monsoor.

Work will be performed in Bath, ME (77.49%); Middletown, NY (7.8%); Stamford, CT (2.28%); Willimantic, CT (2.01%); South Portland, ME (1.69%); Windsor, CT (1.65%); York, PA (1.64%); and various other locations of less than 1.64% each (totaling 5.44%), and is expected to be complete by June 2011 (N00024-06-C-2303). See Feb 15/11 entry, re: efforts to avoid layoffs at Bath Iron Works.

March 10/11: CSC announces a Seaport-e task order from the U.S. Navy to provide engineering and program support for PMS-500, the DDG 1000’s program office. The task order has a 1-year base period and 4 one-year options, bringing the estimated total 5-year value to $110 million.

Under the terms of the task order, CSC will provide engineering and program management support for development, design, building, outfitting and testing, including program, business, financial and risk management; software and mission systems integration; hull, mechanical and electrical systems engineering; and naval architecture.

Feb 15/11: Don’t empty the Bath. The Portland Press-Herald reports that:

“The long-term details aren’t all worked out yet, but the Navy will send enough money to Bath Iron Works to avoid lay-offs at least through April while contracts are finalized for two more DDG-1000 destroyers. Rep. Chellie Pingree, D-1st, said she got that promise earlier today from Navy Secretary Ray Mabus.”

Perusal of this article will bear out the issue at hand. The last significant DDG 1000 program contract was Feb 15/08. At this point, DDG 1000 is mostly funded, and long-lead items for DDG 1001 are funded, but contracts do not exist yet to finish DDG 1001, and build DDG 1002. Bath Iron Works and the US Navy are reportedly still negotiating, and the current budgetary uncertainty can’t be helping.

Feb 14/11: FY 2012 request. The Pentagon issues its FY 2012 budget request, even as the disaster of the 111th Congress leaves the Navy uncertain of its FY 2011 funding, and forces it to make emergency maintenance cuts and other related measures.

For FY 2012, the Zumwalt Class program would receive $453.7 million. US Navy FY 2012 Budget: Shipbuilding & Conversion [PDF].

Feb 14/11: Raytheon Integrated Defense Systems in Tewksbury, MA receives a $7.9 million contract modification, exercising options for DDG-1000 program engineering, integration, and production services like test and evaluation, design solution, and integrated logistics support.

Work will be performed in Portsmouth, RI (65%), Dulles, VA (25%), Largo, FL (8%), Tewksbury, MA (1%) and Washington, DC (1%), and is expected to be complete by November 2011. $1,904,468 will expire at the end of the current fiscal year, on Sept 30/11 (N00024-10-C-5126).

Feb 7/11: Design. General Dynamics Bath Iron Works in Bath, ME receives a $6.7 million contract modification for detail design systems engineering services before the 1st ship’s Post Shakedown Availability. Work includes detail design excursions, shock qualification, production process prototype manufacturing, and life cycle support services. Work will be performed in Bath, ME and is expected to be complete by September 2011 (N00024-06-C-2303).

Jan 25/11: NAVDDX. Raytheon announces that the US Navy successfully tested their Next Generation Navigation System (NAVDDX). System development was a joint effort between Raytheon Integrated Defense Systems (IDS) and the U.S. Navy’s Space and Naval Warfare Systems Center Pacific in San Diego, CaA, through a private party sales agreement.

NAVDDX adheres to the TSCE standards of open architecture, and display of its product (navigation and high-precision time data) to any ship display on board. This makes it a potential add-on to other ships receiving TSCE-derived systems during overhauls, like the CVN-68 Nimitz Class carriers and LPD-17 San Antonio Class amphibious assault ships.

Jan 11/11: Control Systems. Northrop Grumman Corporation says that it has delivered Engineering Control System (ECS) Units for the first 2 Zumwalt ships to Raytheon IDS, nearly 6 months ahead of schedule and under budget. Each ship set involves 16 Distributed Control Units (DCUs) and 180 Remote Terminal Units (RTUs). The ECS takes in all of the destroyer’s hull, mechanical and electrical (HME) signals, which come from a wide variety of systems such as the fire detection systems and the integrated power plant. The RTU then distributes the signals to the DCU for analysis and control.

The company produced and assembled two shipsets of 16 DCUs and 180 RTUs each, for a total of 392 units. The July 2008 cost-plus-incentive-fee contract had a scheduled completion date of May 31/11. Production and assembly of the units were completed 23 weeks ahead of schedule, and inspection and sell-off tasks will be completed in the weeks to come. Northrop Grumman is also developing ensemble software for the DCUs, under a different contract.

Jan 7/10: Raytheon Integrated Defense Systems in Tewksbury, MA receives a $15 million contract modification, exercising an option for DDG 1000 class services engineering efforts to help test mission systems equipment, produce test documentation, conduct component and design level verification tests, and maintain related design and test class documentation.

Work will be performed in Portsmouth, RI (40%); Moorestown, NJ (26%); Sudbury, MA (12%); Tewksbury, MA (8%); San Diego, CA (6%); Marlborough, MA (3%); Minneapolis, MN (3%); and Largo, FL (2%), and is expected to be complete by September 2012 (N00024-05-C-5346).

Dec 29/10: Northrop Grumman Shipbuilding, Inc. in Pascagoula, MS receives a $12 million cost-plus-fixed fee contract modification to ship government-furnished equipment from Northrup Grumman Shipbuilding in Pascagoula, MS, to Bath Iron Works in Bath, ME. This includes material required for the fabrication of cradles, fixtures, and other necessary equipment that are necessary to safely and securely transport these products. Northrop Grumman is no longer a full shipbuilding partner to the program, but it still provides the ships’ composite-built superstructure.

Work will be performed in Pascagoula, MS (95%), and Gulfport, MS (5%), and is expected to be complete by December 2011 (N00024-06-C-2304).

Dec 22/10: 1002 IPS. Converteam, Inc. in Pittsburgh, PA receives a $21.8 million contract modification for DDG 1002’s Integrated Power System high voltage subsystem, including the baseline tactical advanced induction motor and its associated motor drive, and the main turbine generator and auxiliary turbine generator harmonic filters. Work will be performed in Pittsburgh, PA, and is expected to be complete by August 2012 (N00024-09-C-4203).

Nov 29/10: Northrop Grumman Shipbuilding, Inc. in Pascagoula, MS receives a $26.1 million cost-plus-fixed fee contract modification, exercising an option for FY 2011 class services in support of the DDG 1000 program. Services included product fabrication, delivery, engineering, and engineering support to integrated power system operations and the land-based test site; support for work to test and refine the ships’ radar cross section and other selected signatures; and integrated logistics support.

Work will be performed in Pascagoula, MS (95%), and Gulfport, MS (5%), and is expected to be complete by October 2011 (N00024-06-C-2304).

Nov 12/10: General Dynamics Bath Iron Works in Bath, ME receives an $8.5 million contract modification to provide additional systems engineering services associated with Zumwalt Class detail design and construction. Systems engineering efforts include detail design excursions, shock qualification, production process prototype manufacturing, and life-cycle support services before the initial ship’s Post Shakedown Availability.

Work will be performed in Bath, ME, and is expected to be complete by September 2011 (N00024-06-C-2303).

Nov 5/10: Raytheon Integrated Defense Systems, in Tewksbury, MA receives an $8.5 million contract modification, exercising options for Zumwalt Class engineering services. Work includes performing test and evaluation, design solution, shock qualification testing, training, and life time support class services for the parts of the ship that are Raytheon’s responsibility: TSCE, ship control systems, radar and combat system, PVLS launchers, etc.

Work will be performed in Dulles, VA (31.0%); Portsmouth, RI (19.7%); Moorestown, NJ (13.7%); San Diego, CA (11%); Sudbury, MA (6.6%); Bath, ME (5.5%); Philadelphia, PA (5.5%); Arlington, VA (5.5%); Tewksbury, MA (1.1%); and Washington, DC (0.4%). Work is expected to be complete by September 2011, and $3.8 million will expire at the end of the current fiscal year, On Sept 30/10.

Nov 1/10: TSCE. Raytheon Integrated Defense Systems in Tewksbury, MA receives a $10.3 million modification to a previously awarded contract, exercising “an option for the next phase of production design verification for the Zumwalt destroyer program.” A Raytheon representative helped translate this into English:

“Raytheon will be taking the first units of DDG 1000’s Total Ship Computing Environment, command and control systems, and ship control systems and performing extensive testing to ensure that they meet all of the ship’s design requirements. This includes integration testing of subsystems as they are combined into larger systems.”

Work will be performed in Tewksbury, MA (42.3%); Moorestown, NJ (36.6%); Portsmouth, RI (14.2%); Leesburg, VA (2.7%); Sudbury, MA (2.4%); San Diego, CA (1.1%); and Minneapolis, MN (0.7%). Work is expected to be complete by March 2012 (N00024-05-C-5346).

Oct 6/10: General Dynamics Bath Iron Works in Bath, ME received a $27.1 million cost-plus-fixed fee contract modification, exercising an option for additional class services. Specifically, they’re on contract for technical and industrial engineering in the interpretation and application of the Zumwalt Class’ detailed design.

Whether it’s done on computers or on blueprint paper, there’s always a place for engineering where design meets reality. Work will be performed in Bath, ME, and is expected to be complete by December 2010 (N00024-06-C-2303).

FY 2010

Still waiting for significant contracts; Cut to 3 ships; Numbers cut creates cost breach; Dual-Band Radar now just 1 band; GAO report; Long-lead for DDG 1001/1002; Pentagon Value Engineering Award.

BIW builds a Section
(click to view full)

Sept 7/10: TSCE to TRL 6. A key Technology Readiness Assessment by the US Navy certifies that Raytheon’s Total Ship Computing Environment (TSCE) is now at Technology Readiness Level 6. That means that a a representative model or prototype of the system’s hardware and software code has been tested in a “relevant” environment that is similar to the actual platform.

Asked about this certification, Raytheon representatives said that the certification applied to TSCE R5, and progress on the final TSCE R6 version.

See also March 30/10 entry for more background on TSCE progress. As noted above, TSCE encompasses all shipboard computing applications, including the combat management system, command and control, communications, ship machinery control systems, damage control, embedded training, and support systems. Raytheon says that the review “revealed a high pass rate for system requirements as well as low software defect counts… commended the robustness of Raytheon’s simulation environment and the company’s thorough approach to integration and testing.” Raytheon.

Aug 11/10: MSE. Raytheon Integrated Defense Systems in Tewksbury, MA receives a $6 million modification to previously awarded contract (N00024-05-C-5346) for changes to the delivery requirements of Mission Systems Equipment (MSE) for the Zumwalt Class. These changes include additional storage space, and services and shipping fixtures that are required to support the revised DDG-1000 program ship production schedules and in-yard-need-dates at the production shipyards.

Work will be performed in Portsmouth, RI (88%); Tewksbury, MA (11%); Cordova, AL (0.5%); and North Kingstown, RI (0.5%). Work is expected to be complete by December 2013. US Naval Sea Systems Command in Washington, DC manages the contract.

Aug 11/10: MSE. Raytheon Integrated Defense Systems in Tewksbury, MaA receives a $36.1 million contract modification (N00024-05-C-5346) for mission systems equipment (MSE) that will be used on the US Navy’s Self Defense Test Ship, in support of the Anti-Air Warfare Self Defense Enterprise Test and Evaluation Master Plan. The equipment will support the DDG 1000 and CVN 78 classes of ships, in addition to follow-on operation test and evaluation efforts for the Evolved Sea Sparrow Missile (RIM-162 ESSM) and Surface Electronic Warfare Improvement Program (SEWIP).

Work will be performed in Andover, MA (58.7%); Portsmouth, RI (32%); Sudbury, MA (5.4%); Tewksbury, MA (2.7%); and San Diego, CA (1.2%). Work is expected to be completed by March 2013. US Naval Sea Systems Command in Washington, DC manages this contract.

Aug 5/10: Award. The U.S. Navy and members of the DDG 1000 industry team have been honored with a 2010 US Department of Defense Value Engineering Award. Their Surface Ship Affordability Initiative was created by the Navy’s DDG 1000 program office, who partnered with the US Office of Naval Research and industry to improve the efficiency of development, production and shipbuilding processes.

Using program funds, and monies from the USA’s Manufacturing Technology Program, $49 million was invested in 35 manufacturing technology projects during the past several years, with estimated total savings of $138 million. Raytheon.

Aug 2/10: Northrop Grumman Shipbuilding, Inc. in Pascagoula, MS receives a $17.2 million cost-plus-fixed-fee option for FY 2010 class product fabrication, delivery, engineering and engineering support services for the DDG-1000 Zumwalt Class. Work will be performed in Pascagoula, MS (95%), and Gulfport, MS (5%), and is expected to be complete by December 2010 (N00024-06-C-2304).

July 6/10: 1001 & 1002 lead-in. General Dynamics Bath Iron Works in Bath, ME receives a $105.3 million contract modification for long-lead time construction for DDG 1001; long-lead time materials for DDG 1002; and engineering and production support services.

Work is expected to be performed in Bath, Maine (52%); Parsippany, NJ (21%); Iron Mountain, MI (8%); York, PA (7%); Mississauga, Canada (6%); Vernon, CT (3%); and South Portland, Maine (3%). Work is expected to be complete by February 2011 (N00024-06-C-2303).

June 24/10: PVLS. General Dynamics Bath Iron Works in Bath, ME receives an $8.3 million contract modification to support the outfitting of DDG 1000 Peripheral Vertical Launch System (PVLS) units. As noted above, each PVLS compartment holds a MK57 Vertical Launching System, which are spaced around the ship edges to make targeting the “missile farm” impossible, while providing a buffer at the ship edges that helps protect the interior crew and equipment spaces from battle damage.

Work will be performed in Bath, ME (92%); Glendale, CA (6%); and Montville, NJ (2%); and is expected to be complete by December 2010 (N00024-06-C-2303).

June 15/10: IPS. Converteam, Inc. in Pittsburgh, PA receives a $9.9 million contract modification, covering long-lead materials for the DDG 1002’s Integrated Power System, including the baseline tactical Advanced Induction Motor and its associated VDM25000 motor drive, and the main turbine-generator and auxiliary turbine-generator harmonic filters.

Work will be performed in Pittsburgh, PA, and is expected to be complete by December 2011 (N00024-09-C-4203).

June 11/10: Rep. Barney Frank’s [D-MA-4] “Sustainable Defense Task Force” left wing/ libertarian coalition issues its report. They claim to identify $1 trillion in Pentagon budget cuts over the next decade, and the DDG-1000 is one of the programs recommended for complete cancellation, along with any new construction of DDG-51 destroyers. The move would effectively close Bath iron Works, and while the report identifies DDG-1000 cancellation as saving $1.6 billion in FY 2010, that budget is already committed. Procurement savings from FY 2011 onward would be minimal, with most of the savings coming from the difference (if any) between the cost to man and maintain the ships over the 10 years, plus any available refunds on contracts past 2011, minus contract cancellation penalties and ship disposal costs.

It should be noted that the participants do not represent a substantial faction within the American political system, but their recommendations could acquire more weight in the event of a US sovereign debt crisis. Full report [PDF].

June 2/10: DBR removed. As expected, the Pentagon this week certifies that the DDG-1000 destroyer program is vital to national security, and must not be terminated, despite R&D loaded per-ship cost increases that put it over Nunn-McCurdy’s legislated limit. There will be at least one important change, however: Lockheed Martin’s S-band SPY-4 Volume Search Radar will be deleted from the DDG-1000’s DBR.

Performance has met expectations, but cost increases reportedly forced the Navy into a cost/benefit decision. The Navy would not release numbers, but reports indicate possible savings of $100-200 million for each of the planned 3 ships. Raytheon’s X-band SPY-3 has reportedly exceeded technical expectations, and will receive upgrades to give it better volume search capability. The move will save weight and space by removing the SPY-4’s aperture, power, and cooling systems, and may create an opportunity for the SPY-3 to be upgraded for ballistic missile defense – or replaced by the winner of the BMD-capable AMDR dual-band radar competition.

The full DBR will be retained on the USS Gerald R. Ford [CVN 78] aircraft carrier, as Lockheed’s SPY-4 replaces 2 air search radars, and will be the primary air traffic control radar. No decision has been made for CVN 79 onward, however, and AMDR’s potential scalability may make it attractive there instead. Gannett’s Navy Times | US DoD | Maine’s Times Record | Associated Press | Reuters.

June 2/10: Sonar. Tods Defence Ltd. in Portland, UK announces that it has completed and shipped its 2nd composite bow sonar dome for the US Navy’s Zumwalt Class program to Bath Iron Works, in Maine. Tods’ composite domes have been used on other warships, but the firm says that this is the first time the US Navy has specified British designed bow sonar domes.

May 7/10: Design. A $26.8 million modification to a previously awarded contract (N00024-06-C-2303) to provide additional systems engineering services associated with the detail, design, and construction of the DDG 1000 Zumwalt Class destroyer. Systems engineering efforts include detail design excursions, shock qualification, production process prototype manufacturing, and life cycle support services prior to post shakedown availability.

General Dynamics Bath Iron Works in Bath, ME will perform the work and expects to complete it by December 2010.

April 19/10: 1001 lead-in. A $16 million contract modification for long lead time materials, construction, related support, and engineering and production support services associated with the construction of DDG 1001, the Michael Monsoor.

General Dynamics Bath Iron Works in Bath, Maine will perform and/or contract work in Coatesville, PA (41%), Burns Harbor, IN (41%), and South Portland, ME (18%). This funded effort is expected to be complete by July 2010 (N00024-06-C-2303).

April 19/10: A $9.8 million contract modification to support 2010 transportation of DDG-100 Class products to Bath, Maine, in order to meet critical construction milestones. This contract modification procures the labor and material required to fabricate cradles, fixtures, pedestals, etc., as required.

Northrop Grumman Shipbuilding, Inc. in Pascagoula, MS will perform and/or contract work in Pascagoula, MS, and Gulfport, MS, and this funded effort will be complete in December 2010 (N00024-06-C-2303). Northrop Grumman had been a partner in DDG 1000 Zumwalt Class construction, until a major reorganization gave Bath Iron Works all DDG-1000 Class work, while making Northrop Grumman the new lead yard for existing DDG-51 destroyers. Northrop Grumman will also continue to build the Zumwalt Class’ composite superstructures, under the new arrangements.

April 1/10: SAR & breach. The Pentagon releases its April 2010 Selected Acquisitions Report, covering major program changes up to December 2009. The DDG 1000 program features as a major Nunn-McCurdy breach, as a result of its reduction to 3 ships:

“The PAUC (Program Acquisition Unit Cost, incl. R&D) increased by 25.5% and APUC(Average Procurement Unit Cost, no R&D) increased 24.9% to the current and original Acquisition Program Baseline due to the truncation of the number of ships in the program. The original program baseline was for a ten-ship program. That quantity was reduced to seven ships in the fiscal 2009 President’s Budget. However, it did not impact unit costs enough to trigger a Nunn-McCurdy breach. The quantities were further reduced in the fiscal 2011 President’s Budget to the program’s current profile of three ships. Neither reduction was a result of poor program performance. However, the total quantity reduction from ten to three ships resulted in a Nunn-McCurdy breach.”

March 30/10: GAO. The US GAO audit office delivers its 8th annual “Defense Acquisitions: Assessments of Selected Weapon Programs report. With respect to the Zumwalt Class, the GAO reports that lead ship construction began in February 2009 and 68% of the units that make up DDG 1000 are now in fabrication. The Navy anticipates awarding construction contracts for DDG 1001 and DDG 1002 by June 2010. Beyond that, while the GAO acknowledges that “[p]ractical limitations prevent the Navy from fully demonstrating all technologies in a realistic environment prior to installation,” they are concerned that key systems will not be tested before ships are delivered. Those areas include:

Superstructure. GAO states that the Navy planned to fully demonstrate the integrated deckhouse prior to ship construction start in February 2009, but land-based testing was delayed. Testing is now scheduled to complete by March 2010 – over a year after deckhouse construction began. That means expensive rework, if problems are found.

Software. GAO reports that the Total Ship Computing Environment is behind, and will not be complete until after the lead ship’s systems are activated. While TSCE R5 resolved TSCE R4’s problems based on underway integration testing, the US DCMA(Defense Contract Management Agency) expects release 4 & 5’s problems to lead to “higher defect rates than planned” in the final TSCE R6, with additional cost and schedule delays. The Navy responds that The TSCE R5 includes “most” combat system features, and release 6 focuses on engineering control. They believe the software schedule has a margin available before it is needed for land-based and ship testing.

Power. GAO says that the integrated power system will not be tested with the control system until 2011 – nearly 3 years later than planned. In practical terms, that means after its installation on the first 2 of 3 ships. The Navy responds that the power system will be tested on land in 2011, using components of the final DDG 1002 ship, before DDG 1000 testing begins.

Radar. GAO acknowledges that the SPY-4 volume search radar has become more mature, and began testing with the main SPY-3 MFR in January 2009, but without the VSR’s radome and at a lower voltage. Under present schedules, the lead ship’s volume search radar “will be installed in April 2013 – after the Navy has taken custody of the ship.” The Navy does not dispute either of these notes, but says that prototype integration tests are not dependent on the voltage or radome. Full-voltage modules have been produced and tested, and the lead-ship radar will be tested in 2012 with a radome. The installation date is not contested.

Feb 19/10: TSCE. A $27.8 million not-to-exceed modification covers common display system (CDS) hardware and software integration with the DDG 1000’s Integrated Bridge Console and Distributed Control Workstation hardware, to ensure that these changes to the TSCE are incorporated by 2011.

Work will be performed in Portsmouth, RI (66.1%); Tewksbury, MA (22.9%); Moorestown, NJ (8.3%); the remaining 2.7% will be performed in San Diego, CA; Andover, MA; and Sudbury, MA. Work is expected to be complete by May 2012.

Feb 17/10: 1001 lead-in. General Dynamics Bath Iron Works in Bath, ME receives a $7.9 million contract modification for long lead time material (LLTM) associated with the construction of DDG 1001 Michael Monsoor. Materials already bought or manufactured for DDG 1001 under a previously contract awarded contract (N00024-06-C-2303) are expected to be transferred with its associated costs to the as-yet-to-be-negotiated DDG 1001 ship construction contract. This modification adds plate, shapes, and pipe to support a construction start in FY 2010.

Work is expected to be performed in Bath, ME (38%); Coatesville, PA (31%); and Burns Harbor, IN (31%). Work is expected to be complete by August 2010.

Feb 17/10: TSCE. Raytheon announces a successful Total Ship Computing Environment (TSCE) Release 6 software specifications review, which sets a final goal for its coders. Release 6 is meant to be the “Version 1.0” release of mission-ready software for the Zumwalt Class, following years of iterative development. It will implement more than 25,000 software requirements over Release 5, and will raise the total number of delivered lines of software code for Zumwalt to more than 9 million. With this review, all of the Zumwalt software requirements are complete, and more than 80% of software coding is complete.

Raytheon performs software work for the Zumwalt program at a number of mission centers across the country, including IDS Headquarters in Tewksbury, MA; its Seapower Capability Center in Portsmouth, RI; the Surveillance and Sensors Center in Sudbury, MA; and the Expeditionary Warfare Center in San Diego, CA. TSCE infrastructure is also finding its way into upgrades for the USS Nimitz [CVN 68] and USS San Antonio [LPD 17].

Feb 4/10: Design. General Dynamics Bath Iron Works in Bath, Maine receives a $9 million modification to previously awarded contract (N00024-06-C-2303) to provide additional systems engineering services associated with the detail design and construction of the DDG 1000 Zumwalt Class destroyer.

Systems engineering efforts include detail design excursions, shock qualification, production process prototype manufacturing, and life cycle support services prior to post shakedown availability. Work will be performed in Bath, ME, and is expected to be complete by April 2010.

Feb 1/10: Down to 3 ships. The FY 2011 budget request removes the CG (X) and Future Surface Combatant programs. That shrinks the DDG-1000 program’s ship total back to 3, removing the legerdemain that had kept the program’s total cost per ship delivered from breaching legislative limits.

While per-ship construction costs have risen less than 25%, spreading the same R&D dollars over fewer ships results in a technical increase of 86.5%. Under Nunn-McCurdy legislation, that forces cancellation, unless Congress accepts the Pentagon’s submitted justification for continuing the program. With most of the Zumwalt Class shipbuilding funds already spent, and the program already set at just 3 ships, cancellation is very unlikely. See also Jan 26/09 and Feb 4/09 entries for more background. Reuters.

Jan 25/10: TSCE. Raytheon Integrated Defense Systems in Tewksbury, MA received an $11.2 million modification to a previously awarded contract (N00024-05-C-5346) for changes to software development efforts due to revised missile interface control documents and related power density implementation for the DDG 1000 Zumwalt Class destroyer program.

The purpose of this modification is to incorporate software changes that affect the combat system and Dual Band Radar, in light of MICDs Rev B+ and related power density implementation changes to the current TSCE requirements. Work will be performed in Tewksbury, MA, and is expected to be complete by March 2012.

Jan 6/10: General Dynamics Bath Iron Works in Bath, ME receives a $6.9 million modification to a previously awarded contract (N00024-06-C-2303), exercising an option for additional systems engineering and class logistics services associated with DDG-1000 detail design and construction. Work will be performed in Bath, ME, and is expected to be complete by November 2010.

Systems engineering efforts include detail design excursions, shock qualification, production process prototype manufacturing, and life cycle support services prior to post shakedown availability. Class logistics efforts provide for the continued development of integrated logistics support for the DDG 1000 class, including development of training curriculum, supply support documentation, maintenance analyses, and configuration status accounting.

Dec 16/09: IPS. Converteam, Inc. in Pittsburgh, PA received a $7 million modification to previously awarded contract for the DDG 1002 baseline tactical high voltage power distribution switchboard. They will be used at the US Navy’s land-based test site for the ship’s integrated power system. Work will be performed in Pittsburgh, PA, and is expected to be complete by July 2011 (N00024-09-C-4203).

Nov 25/09: Raytheon Integrated Defense Systems in Tewksbury, MA received an $84.4 million modification to a previously awarded contract (N00024-05-C-5346), exercising an option for FY 2010 Zumwalt Class services engineering efforts. Raytheon will help test mission systems equipment, produce test documentation, conduct component and design level verification tests and maintain related design and test class documentation.

Work will be performed in Portsmouth, RI (38.5%); Moorestown, NJ (19.3%); Marlborough, MA (16.6%); Sudbury, MA (12.6%); Tewksbury, MA (5.5%); Minneapolis, MN (3.5%); San Diego, CA (2.2%); and Towson, MD (1.8%); and is expected to be complete by Dec 31/13.

Nov 25/09: Design. Raytheon Integrated Defense Systems in Tewksbury, MA received a $46.6 million modification to previously awarded contract (N00024-05-C-5346), exercising an option for class services engineering to support design assurance, develop verification plans, and conduct tests for the DDG 1000 Zumwalt Class destroyer program. Hard to tell if this is TSCE or MSE.

Work will be performed in Tewksbury, MA (28.3%); Portsmouth, RI (27.1%); Falls Church, VA (12.8%); Sudbury, Mass. (11.9%); Minneapolis, MN (7.4%); Washington, DC (6.9%); Moorestown, NJ (3.7%); San Diego, CA (1.1%); and Marlborough, MA (0.8%); and is expected to be complete by December 2010. Hard to tell if this is TSCE or MSE.

Nov 13/09: Raytheon Integrated Defense Systems in Tewksbury, MA receives a $46.7 million modification to previously awarded contract (N00024-05-C-5346), exercising an option for “the next phase of verification of the production design for the DDG 1000…”

Work will be performed in Moorestown, NJ (48.2%), Tewksbury, MA (38.3%), Portsmouth, RI (7.8%), Sudbury, MA (4.3%), Minneapolis, MN (1.2%), and Marlborough, MA (0.2%), and is expected to be complete by December 2010.

Nov 12/09: TSCE. Raytheon Integrated Defense Systems in Tewksbury, MA receives a $241.3 million modification to previously awarded contract (N00024-05-C-5346) to complete the Total Ship Computing Environment software for the DDG 1000 Zumwalt Class Destroyer Program, and meet lead ship integration and construction schedules. There are 2 major components of the scope for this effort: re-planning of TSCE Release 6 software to align with the re-phasing in detail design and integration Revision F; plus additional Release 6 efforts, implementation of engineering control/damage control human computer interface for distributed contract work stations, Release 4 and 5 software maintenance, and implementation of required changes to support both land-based test site testing and ship activation software deliveries needed to maintain shipyard schedules. See also the March 31/09 entry for the US GAO’s overall report, which includes TSCE concerns.

Work will be performed in Tewksbury, MA (64.7%), Moorestown, NJ (27%), Indianapolis, IN (2.7%), Burlington, MA (1.5%). The remaining 4.1% will be performed at the following locations: Marlborough, MA; Falls Church, VA; King George, VA; Fort Wayne, IN; Aurora, CO; and Marlborough, MA. Work is expected to be complete by March 2012.

Oct 28/09: FY 2010 budget. President Obama signs the FY 2010 defense budget into law. That budget provides the full requested amount of $1,084.2 million to finish the 3rd ship, but the reconciled bill stripped out the $539.1 million in RDT&E funding the Pentagon had requested. White House | House-Senate Conference Report summary [PDF] & tables [PDF].

Oct 21/09: Design. General Dynamics Bath Iron Works Corp in Bath, ME received a $79.5 million modification to a previously awarded contract (N00024-06-C-2303). It exercises an option for additional class services associated with the detail design and construction of the DDG 1000 Zumwalt Class destroyer.

Bath Iron Works will provide technical and industrial engineering in the interpretation and application of the detailed design to support construction and the maintenance of a safe and operable ship design. Work will be performed in Bath, ME and is expected to be complete by November 2010.

FY 2009

GD-BIW handed the lead role; Fixing the books to avoid a breach; GAO points to tech-driven delays; Mission systems pass preliminary readiness review; Radar lightoff; SQQ-90 designated; DDG 1001 named Michael Monsoor; DDG-51 vs. Zumwalt; Still waiting for significant contracts; “I’d like to see how it goes…”.

DDG-1000 concept
(click to view full)

Sept 10/09: MSE. Raytheon Integrated Defense Systems in Tewksbury, MA received a $22.5 million modification to previously awarded contract (N00024-05-C-5346) for continuing Mission Systems Equipment (MSE) software development and additional design verification for the Zumwalt Class Destroyer Program. Work will be performed in Moorestown, NJ (64%), Tewksbury MA (20%), Baltimore, MD (10%) and Dahlgren, VA (6%), and is expected to be complete by March 2012.

Timely software development has been flagged as a potential issue by recent GAO reports (q.v. March 31/09 entry).

Aug 19/09: Small business qualifier Temeku Technologies, Inc. in Herndon, VA received a $7.95 million firm-fixed-price contract for DDG 1000’s Flight Deck Lights (FDL) System, mounted on and near the flight deck and hangar face as next-generation visual landing aids for helicopters.

Work will be performed in Herndon, VA (60%); Bologna, Italy (30%); and Point Mugu, CA (10%) and is expected to be complete in April 2011. This contract was competitively procured via electronic request for proposal, with 3 offers received by the Naval Air Warfare Center Aircraft Division in Lakehurst, NJ (N68335-09-C-0425).

Aug 17/09: Progress report. Gannett’s Navy Times updates the current status of major DDG-1000 sub-systems in “DDG 1000 project quietly logs successes.”

In production: Ship hull, Northrop Grumman’s composite upper-level deckhouse; Raytheon’s Advanced Vertical Launch System; Integrated Power system including RR MT-30 engine; Automatic fire suppression system.

Finished development: Tumblehome hull form; BAE’s 155mm AGS gun, Lockheed Martin’s LRLAP GPS-guided long-range shell; Infrared suppression engine exhaust and heat suppression system, incl. 4 major at-sea tests; Crew multi-skill training plan.

Still in development: Dual-Band Radar (Raytheon’s X-band SPY-3 Multi-Function Radar, Lockheed Martin’s S-band SPY-4 Volume Search Radar), Raytheon’s Total Ship Computing Environment, 3-D CAD models.

The first 2 X-band SPY-3 arrays are being assembled, and “minor” manufacturing issues have been resolved, following completion of at-sea testing in Spring 2009. The DBR has also been installed at the Wallops Island test facility, where aircraft detection tests are ongoing and will continue into the fall. Below-deck components of the S-band SPY-4, are in full-rate production, and 6 arrays are under contract. Of the 3-D CAD models, 90 of 94 are completely released and locked down, and the remaining 4 are expected by September 2009.

July 23/09: AGS. LaBarge, Inc. announces a $6.1 million contract from BAE Systems to continue producing electronic assemblies for the Advanced Gun Systems that will be installed on both ordered Zumwalt Class destroyers. The Company expects this latest award will continue production on the AGS program at its Huntsville, Ark., facility through December 2009.

July 20/09: MSE. Raytheon Integrated Defense Systems in Tewksbury, MA received a $60 million cost-plus-incentive-fee modification to a previously awarded contract (N00024-05-C-5346), exercising an option for Mission System Equipment (MSE) Class Services for the Zumwalt Class Destroyer Program.

Work will be performed at Raytheon facilities (85%) in San Diego, CA; Marlboro, MA; Sudbury, MA; Tewksbury, MA; Towson, MD; and Portsmouth, RI; at Lockheed Martin facilities (12%) in Moorestown, NJ and Akron, OH; and at BAE’s facility in Minneapolis, MN (3%), and is expected to be complete by March 2013.

June 19/09: IPS. Converteam, Inc. in Pittsburgh, PA received a $23 million modification to a previously awarded contract (N00024-09-C-4203). They will provide a DDG 1000 Baseline Tactical High Voltage Power Subsystem (HVPS) for use in the Navy’s integrated power system land based test site. These components will meet the same specification established by the DDG 1000 shipyards for lead ship installation. Work will be performed in Pittsburgh, PA, and is expected to be complete by March 2011.

The HVPS distributes electrical power from the ship’s turbine-generators to the ship’s propulsion and electronic equipment. It includes an advanced induction motor, motor drive, harmonic filters and resistors for dynamic braking and neutral grounding.

May 4/09: Gannett’s Navy Times interviewed US Chief of Naval Operations Adm. Gary Roughead 3 times during March and April 2009, and publishes excerpts. With respect to the DDG-1000, Roughhead sees the new design as something they can only learn from if it’s deployed and used, and he’s especially interested in the real-world, full-scale performance of its radically different hull form. Beyond that:

“I’d like to see how it goes. And if it really is a breakthrough technology, can it be scaled up and can it be scaled down? Because if you start getting into nuclear power and bigger radars [for CG (X)], can the DDG hull form take it? My sense is, it can. But if it can’t and you have to scale up, does it scale?

…There’s no question we will employ those ships once they’re delivered. Deploy them and employ. I see them in the deployment rotation because, quite frankly, it will be important to operate those ships in different environments, get them up in the high latitudes. What happens when that hull form starts to ice up? What’s the effect of that? If people are talking about having to be up in the Arctic areas, it’s a good thing to know. How well are they sustained logistically at great distances? We’ve got to get them out. Get them deployed.”

April 23/09: DBR. Raytheon Integrated Defense Systems in Tewksbury, MA received a $217 million cost plus fixed fee modification to a previously awarded contract (N00024-05-C-5346) for 2 Volume Search Radars (VSR). Work will be performed in Moorestown, NJ (95%) and Sudbury, MA (5%), and is to be complete by March 2013.

These S-band naval radars will be used as part of the Dual-Band Radar (DBR) systems mounted on one of the new Zumwalt Class destroyers, and on the inaugural CVN-21 carrier USS Gerald R. Ford [CVN 78]. See “The US Navy’s Dual-Band Radars” for full coverage.

April 13/09: Builder Shift. Defense News reports details of the agreement between the US Navy and its 2 shipyards for major surface combatants.

The deal reportedly includes a provision for Northrop Grumman’s shipyard in Avondale, LA to continue building LPD-17 San Antonio Class amphibious transport docks. Unfortunately, that shipyard has displayed severe and consistent quality problems building the first 2 ships of class.

Under the agreement, the FY 2010 budget would fund the second half of the 3rd Zumwalt Class ship [DDG 1002], and the Arleigh Burke Class DDG 113, with full ballistic missile defense capabilities installed at the outset. That a departure, because all previous BMD ships in the US Navy have been refits of existing vessels. DDG 113 will be built by Northrop Grumman at Ingalls in Mississippi. That would be the first DDG-51 destroyer ordered since 2002, and it would be followed by orders for similar ships in FY 2011: DDG 114 (Northrop) and DDG 115 (Bath Iron Works).

April 7/09: DBR. Raytheon announces a successful initial “lightoff” test of the Dual Band Radar, which includes the X-band AN/SPY-3 Multi-Function Radar and S-band Volume Search Radar. Both radiated at high power during lightoff at the Navy’s Engineering Test Center in Wallops Island, VA. Following this successful lightoff test, the radar suite will begin an extended period of operational performance testing.

April 7/09: Rep. Gene Taylor [D-MS, Seapower subcommittee chair] announces that the Pentagon has reached agreements with General Dynamics’ Bath Iron Works in Maine, and with Northrop Grumman’s Ingalls Shipyard in Mississippi. Read “Bath, Ingalls Agree to Navy’s Surface Combatant Plans” for details of the arrangements.

April 6/09: US Secretary of Defense Robert M. Gates announces his recommendations for the FY 2010 defense budget:

“…in this request, we will include funds to complete the buy of two navy destroyers in FY10. These plans depend on being able to work out contracts to allow the Navy to efficiently build all three DDG-1000 class ships at Bath Iron Works in Maine and to smoothly restart the DDG-51 Aegis Destroyer program at Northrop Grumman’s Ingalls shipyard in Mississippi. Even if these arrangements work out, the DDG-1000 program would end with the third ship and the DDG-51 would continue to be built in both yards.

If our efforts with industry are unsuccessful, the department will likely build only a single prototype DDG-1000 at Bath and then review our options for restarting production of the DDG-51.”

April 1/09: The Mississippi Press reports that Raytheon Company is footing the bill for the recently created www.ZumwaltFacts.info:

“Spokeswoman Carolyn Beaudry initially denied Tuesday any corporate involvement in the Zumwalt campaign. She later called back to say that others within the company had since told her Raytheon is supporting “a lot of public efforts, including ZumwaltFacts.info,” to provide third-party advocacy.”

This is not unusual for corporations or other organizations when lobbying government; indeed, a recent Washington Times article by USN Adm. James Lyons (ret.) lamented the retreat of America’s shipbuilding industry from its previous public advocacy role. Non-disclosure of such involvement is less customary, though the Times report could also describe a simple mistake that was quickly corrected. When the funding is meant to be covert, the technical term is an “astroturf” (artificial grassroots) campaign.

March 31/09: GAO. The US GAO audit office delivers its 7th annual “Defense Acquisitions: Assessments of Selected Weapon Programs report. It rates 4/12 critical technologies in the DDG-1000 program as fully mature (demonstrated in a sea environment), and 6/12 as approaching maturity, but 5 of the 6 will not demonstrate full maturity until after they’re installed on the ship. Lockheed Martin’s S-band volume search radar, and the Total Ship Computing Environment, are rated as immature. The report adds:

“Land-based tests of the volume search radar prototype originally planned for before ship construction will not be completed until June 2009 – over 2 years later. Software development for the total ship computing environment has proved challenging; the Navy certified the most recent software release before it met about half of its requirements…”

“The integrated power system will not be tested with the control system until 2011 – nearly 3 years later than planned. The Navy will buy a power system intended for the third ship and use it in land- based tests… Land-based tests of the volume search radar prototype will not be completed until June 2009 – over 2 years later than planned… The Navy will not demonstrate a fully capable radar at its required power output until testing of the first production unit in 2011… installation [of the volume search radar) will occur in April 2013 – after the Navy has taken custody of the ship. The Navy initially planned to develop and demonstrate all software functionality of the total ship computing environment (phased over six releases and one spiral) over 1 year before ship light-off… However, the contractor delivered release 4 without incorporating all software system requirements and deferred work to release 5, primarily due to issues with the command and control component. Problems discovered in this release, coupled with the deferred work, may be a sign of larger issues…”

March 17/09: ZumwaltFacts.Info publishes an “admirals’ letter to Secretary of Defense Robert M. Gates from USN Adm. Henry H. Mauz (ret.); USN Rear Adm. Philip A. Dur (ret.); and Phil Depoy, Director of the US Naval Postgraduate School’s Systems Engineering Institute. Zumwalt Facts is 3rd party site chaired by USMC Col. James G. Zumwalt, Esq. (ret.). Full letter [PDF].

March 6/09: MSE. Raytheon IDS in Tewksbury, MA received a $57 million cost-plus-incentive-fee modification to a previously awarded contract (N00024-05-C-5346). These funds will buy selected Zumwalt Class mission system equipment which will be checked out and integrated at Wallops Island, VA, for the program’s Test and Evaluation Master Plan (TEMP) aboard the US Navy Self Defense Test Ship (SDTS). The SDTS is a best described as a barge that can mount and use installed radars and weapons for tests. See also the related Dec 15/08 and Dec 5/08 awards.

Work will be performed in Tewksbury, MA (40%); Andover, MA (40%), Wallops Island, VA (10%) and Portsmouth, RI (10%), and is to be completed by March 2011. Contract funds in the amount of $27.5 million will expire at the end of the current fiscal year.

Feb 12/09: Northrop Grumman Ship Systems in Pascagoula, MS received a $9 million modification to a previously awarded contract for systems engineering, design and technical services. The contract will support the detail design and construction of the DDG 1000 Zumwalt Class Destroyers.

Northrop Grumman is currently expected to design and build DDG-1001, the Michael Monsoor. Work will be performed in Pascagoula, MS, and is expected to be completed by December 2009 (N00024-06-C-2304).

Feb 4/09: DDG-51 vs. Zumwalt. Rep. Gene Taylor [D-MS-4] chairs the US House Armed Services Committee’s Seapower and Expeditionary Forces subcommittee. He is a vocal critic of the US Navy’s current shipbuilding strategy, while remaining one of Congress’ strongest advocates for a larger shipbuilding budget and a larger Navy. His statement on the future of US Navy shipbuilding reiterates his support for more DDG-51 type destroyers, and says:

“For far too many years I have watched as the size of the Navy fleet has decreased… In particular, the failure of the [Littoral Combat Ship] program to deliver on the promise of an affordable, capable, and reconfigurable warship only puts the exclamation point on a Bush administration’s strategy that was neither well envisioned nor properly executed. As for the DDG 1000, we will not know the true cost of that program for a number of years but significant cost growth on that vessel will require diverting funding from other new construction projects to pay the over-run…”

Feb 4/09: “The Navy’s New Battleship Budget Plan” at the naval policy discussion site Information Dissemination addresses the proposed DDG-1000 program approach in an op-ed:

“Of all the different ships in the Navy’s FY10 shipbuilding budget, there are actually only 3 mature ship designs [out of 11 ship types]… This reflects the inability of naval leadership to set requirements. This reflects a long standing policy where accountability has not been a priority. This reflects an industry without enough oversight. This reflects weak political leadership willing to ignore deception and deceit. Let me explain that last point.

…John Young was absolutely right to force the Navy to go through a requirements study process, but the rest of the memo should be raising serious questions in Congress. The very intent of the memo, which comes from the top acquisition official in the Department of Defense, is a signed specific instruction to the Navy to intentionally ‘pad’ the budget of the DDG-1000 program with money from a completely new program… in its first year of construction the DDG-1000 could now potentially go over budget by several hundred million dollars and still not trigger a breach of Nunn-McCurdy… With the leak of this memo, all of our Congressmen and Senators must now intentionally look the other way, with both eyes shut and index fingers jammed into their ears, and ignore that the top DoD financial officer is intentionally padding the books to circumvent the law.”

Feb 2/09: Raytheon announces that the first production equipment has been delivered for the U.S. Navy’s DDG 1000 Zumwalt Class destroyer – a Cooperative Engagement Capability (CEC) planar array antenna assembly.

Jan 26/09: Fixing the books. Pentagon undersecretary for acquisition, technology and logistics John Young’s “DDG 1000 Program Way Ahead” memo sets out alternatives for the program, and touches off controversy.

The reduction from 7 ships to 3 will spread the same R&D funds over fewer ships, raising their accounting cost per ship but not their actual purchase cost. So far, actual program costs and timelines remain on track, but under America’s Nunn-McCurdy procurement laws, the accounting cost change forces the Pentagon to meet 4 tests or cancel the program: (1) the weapon is essential for national security; (2) the new unit costs are reasonable; (3) management structure can control future growth; and (4) that no substitutes exist that provide equal or greater military capability at less cost.

Meeting tests 1 and 4 will be difficult, and the fact that the Navy has never really done a direct comparison of the DDG-1000 Zumwalt Class vs. the existing DDG-51 Arleigh Burke Class in key areas makes the problem worse (see Oct 12/08 “Heritage Foundation: Questions to Ask re: DDG-51 vs. DDG-1000” for more). Young’s memo offers the option of adding a “Future Surface Combatant” class to the DDG-1000 program, increasing the number of ships technically in the program without specifying what type they would be. It appears to be an effort to buy time for a year, while the Navy looks at the actual cost of fielding new-build DDG-51 ships with the radar modifications, software modifications, and power upgrades required to serve in a ballistic defense role. This, too, is something that is not currently known. Information Dissemination explains the accounting | Defense News re: FSC | Defense News: Young on DDG-1000 options and relative ship costs.

Jan 12/08: Defense News reports that a deal may be in the works to build both DDG-1000 Zumwalt and DDG-1001 Michael Monsoor, in exchange for having more of the Arleigh Burke Class destroyers that Congress is expected to ask for built at Northrop Grumman’s Ingalls shipyard in Pascagoula, MS. The Pascagoula shipyard was scheduled to begin fabrication of DDG 1001 in fall 2009.

The move would reportedly leverage Bath Iron Works’ investments toward DDG-1000 production, and keep Pascagoula more focused, given the diverse ship classes (DDG-51, LPD-17, LHD-8) it is already building in Mississippi.

Dec 22/08: Bloomberg News reports that an Oct 31/08 budget memo from Deputy Defense Secretary Gordon England approved shifting away as much as $940 million from the P-8A Poseidon maritime patrol aircraft program, in order to complete payment for the 3rd DDG-1000 destroyer that Congress partially funded in FY 2009. The Navy proposed getting 2 P-8A aircraft instead of 6 during the initial production phases.

Meanwhile, the US Navy faces significant challenges keeping the existing fleet of P-3C Orion maritime patrol aircraft in the air. Almost 1/4 of this aging fleet has been grounded due to safety concerns, and the Navy is forced to retire some aircraft every year. Even though they are in greater demand over key sea lanes, and in overland surveillance roles on the front lines. Early introduction of the P-8A has been touted as critical to maintaining these capabilities, without creating both near-term and long-term shortfalls.

The proposed FY 2010 ship plan also reportedly includes the purchase of 2 more DDG-51 Arleigh Burke Class destroyers.

Dec 15/08: MSE. Raytheon Integrated Defense Systems in Tewksbury, MA received $10.1 million modification to a previously awarded contract. They will furnish the test assets and infrastructure material required, in to support the integration, testing, and facilitation of DDG-1000 Mission Systems Equipment. See also Dec 5/08 entry for more background.

Work will be performed in Burlington, MA (75%) and Tewksbury, MA (25%), and is expected to be complete by September 2009 (N00024-05-C-5346).

Dec 9/08: SQQ-90 named. Raytheon announces that its integrated undersea warfare combat system for the Zumwalt Class has received its official U.S. Navy nomenclature: AN/SQQ-90.

The SQQ-90 includes the ship’s hull-mounted mid-frequency sonar (AN/SQS-60), the hull-mounted high-frequency sonar (AN/SQS-61), and the multi-function towed array sonar and handling system (AN/SQR-20). These systems are fully integrated with the MH-60R helicopter‘s combat system, and improved automation and information management allows the SQQ-90 to be operated by 1/3 the crew of current AN/SQQ-89v15 anti-submarine systems used on DDG-51 and CG-47 AEGIS destroyers and cruisers.

Dec 5/08: MSE. Raytheon Integrated Defense Systems in Tewksbury, MA received a $9 million modification to a previously awarded contract (N00024-05-C-5346) for one time engineering efforts. The purpose of this effort is to initiate the non-recurring engineering work required to make the selected Mission System Equipment (Dual Band Radar SPY-3 Array and REX; MK57 Vertical Launch System Electronics Module Controller Unit; Canister Electronic Units, and Total Ship Computing Environment) compatible with the Navy’s remote controlled Self Defense Test Ship (SDTS). The SDTS test will include the first missile firing with this advanced Mission System, against a difficult target set.

Raytheon will update selected Zumwalt Class Destroyer Mission Systems Equipment (MSE) for initial integration efforts at Wallops Island, VA, and follow-on installation on board the SDTS, in support of the Zumwalt TEMP (test and evaluation master plan). Work will be performed in Portsmouth RI (55%), Tewksbury, MA (25%), and Andover, MA (20%) and is expected to be complete by August 2009. All contract funds will expire at the end of the current fiscal year.

Dec 2/08: MSE. Raytheon announces a successful production readiness review of the mission systems equipment (MSE) for the DDG-1000 program. This comprehensive review was the culmination of more than 90 separate design and production reviews, and afterward the Zumwalt program completed a total ship system production readiness review – the final formal review before ship construction begins.

The Zumwalt Class MSE includes the following major subsystems: the Total Ship Computing Environment; Dual Band Radar; the external communications suite; MK 57 Vertical Launching System; AN/SQQ-90 Integrated Undersea Warfare Combat System; the Electro-Optical/Infrared suite; the Identification Friend or Foe integrated sensor suite; and the Zumwalt ship control hardware, including an integrated bridge, navigation, EO surveillance, and engineering control system components.

Dec 1/08: Design. General Dynamics Bath Iron Works Corp in Bath, Maine received a $45.8 million modification to a previously awarded contract (N00024-06-C-2303). It exercises an option for services associated with the detail design and construction of the DDG 1000 Zumwalt Class Destroyer, and modifies the contract issued on the Feb 15/08 for the first ship of class.

Work will include configuration management and maintenance of class design products; program management; configuration and data management; system and ship integration services; production engineering services; and ship system segment management. Work will be performed in Bath, ME, and is expected to be complete by November 2010. See also GD release.

Oct 29/08: 1001 named. At a Navy SEAL Warrior Fund Benefit Gala at the Waldorf-Astoria Hotel in New York City, Secretary of the Navy Donald C. Winter announced that DDG-1001 will be named USS Michael Monsoor after the Congressional Medal of Honor winner.

Petty Officer 2nd Class Michael Monsoor was a Navy SEAL who was posthumously awarded the Medal of Honor for his heroic actions in Ramadi, Iraq on Sept 29/06. Monsoor was asthmatic as a child, but his determination led him to conquer his condition and pass SEAL training. The 25 year-old machine gunner was providing security at a sniper lookout post with SEAL Team 3, when a fragmentation grenade hit his chest and bounced to the floor. Monsoor was near the only exit, and was the only one who could have escaped. Instead, he threw himself on the grenade before it exploded, and died half an hour later. Though some of his SEAL brethren and their Iraqi allies were wounded, all survived because of his sacrifice. USN release | USN coverage of award ceremony | Official USN Medal of Honor page for Michael Monsoor.

Oct 7/08: DDG-51 or Zumwalt? The right-wing Heritage Foundation publishes its in-depth paper concerning the DDG-1000 vs. DDG-51 debate: “Changing Course on Navy Shipbuilding: Questions Congress Should Ask Before Funding.”

The report can be characterized as leaning toward further DDG-1000 ships, but it offers key questions to ask rather than recommendations. This is more than just a rhetorical device. The answers to those questions could tip the debate either way, and the report points to discrepancies between recent and past Navy statements that need clarification. It also offers research evidence that disputes some recent statements, with an especial focus on the Zumwalt Class’ air defense and anti-submarine capabilities.

FY 2008

DDG 1000/1001 contract; Dead at 2? Asking to build a 3rd; Official SAR drops from 10 to 7 ships; EO/IR suite; Air & missile defense controversy; Deckhouse problems? TSCE release 5; MK 57 PVLS wins system engineering award; DDG-51 vs. Zumwalt.

Zumwalt model

Sept 24/08: The House and Senate Armed Services Committees have reconciled their versions of the FY 2009 defense budget. The reconciled budget provides $2.5 billion for the 3rd Zumwalt Class ship, “without prejudice to any potential future Department of Defense decision to truncate the DDG-1000 class acquisition program in favor of a return to DDG-51 class destroyers.”

House Seapower subcommittee chair Gene Taylor [D-MS] continues to doubt the Navy’s ability to build DDG-1002 for $2.5 billion, a sum that is about half the amount predicted in some CBO reports. He cites the language noted above as a satisfactory compromise, because it allows the Secretary of the Navy to divert the $2.5 billion into more Arleigh Burke Class destroyers if problems continue. MarineLog | Gannett’s Navy Times.

Sept 22/08: Deckhouse problems? Defense News caries a story offering Northrop Grumman’s replies to its own Sept 15/08 publication, which quoted inside sources alleging concerns inside Northrop and the US Navy regarding construction problems involving the ship’s composite superstructure, or deckhouse. The Zumwalt Class uses composites rather than metal, because it improves radar stealth. All composite superstructures will be made by Northrop Grumman in its Gulfport, MS facility, even the structures that will fit on top of ships built by General Dynamics’ Bath Iron Works.

While Defense News’ unnamed sources stand by their assertions, Northrop Grumman replied that the deckhouse design meets all technical and load requirements, that the Navy remains closely involved in all aspects of the process, that over 6,000 test articles fabricated from 2001 onward have surfaced and addressed the risks. Fabrication was supposed to begin in Q4 2008, but Northrop Grumman says they are on track to start fabrication in February 2009.

Sept 17/08: The US Senate passed its FY 2009 defense budget proposal by a vote of 88-8. The bill includes $2.6 billion for a 3rd DDG-1000 destroyer. In contrast, the House bill allocates no funding at all for a 3rd ship. Brunswick Times Record report.

That difference will have to be settled in “reconciliation” conferences, in order to produce a final FY 2009 defense bill. Will the House give up on some of its priorities, or will the Senate have to drop this item?

Aug 31/08: Capabilities controversy. The Los Angeles Times interviews CNO Adm. Gary Roughead, and includes the following quotes in its report:

“I started looking at the DDG-1000. It has a lot of technology, but it cannot perform broader, integrated air and missile defense… Submarines can get very close [due to design compromises], and it does not have the ability to take on that threat… And I look at the world and I see proliferation of missiles, I see proliferation of submarines. And that is what we have to deal with.”

With respect to a 3rd destroyer, the LA Times report writes:

“But he was less enthusiastic about building a third ship. The Navy agreed to the additional vessel because money was already in the current budget proposal, he said. “It will be another ship with which to demonstrate the technologies,” he said. “But it still will lack the capabilities that I think will be in increased demand in the future.” “

Aug 15/08: 3rd Zumwalt? Gannett’s Navy Times reports that the US Navy has changed course, and now plans to ask Congress for the funds to build a 3rd DDG-1000 destroyer.

The question is whether Congress is inclined to give them those funds. The Senate’s FY 2009 defense bill includes $2.6 billion for this purpose, but the House bill had $0, and Seapower subcommittee leaders Taylor [D-MS] and Bartlett [R-MD] appear to have other shipbuilding priorities. The Navy’s reported compromise apparently involves ordering parts for the DDG-51 class, in order to make a production restart feasible. In a letter to Collins, Deputy Defense Secretary Gordon England reportedly wrote that:

“This plan will provide stability of the industrial base and continue the development of advanced surface ship technologies such as radar systems, stealth, magnetic and acoustic quieting, and automated damage control…”

If these reports are true, the US Navy and Department of Defense appear to be betting that House Armed Services Committee Chair Ike Skelton [D-MO] and company will be inclined to give in during reconciliation negotiations, and forgo their proposed funding for projects that matter to key Democrats like Taylor, in order to boost key Zumwalt Class advocates like Sen. Susan Collins [R-ME].

July 31/08: DDG-51 or Zumwalt? The US House Armed Services Seapower and Expeditionary Forces subcommittee holds in-depth hearings regarding the DDG-1000 and DDG-51 programs. Ranking minority member, Roscoe Bartlett [R-MD]

“When the Ranking Member and I first called for this hearing, the purpose was to ensure that all of the facts associated with the capabilities and procurement costs of the DDG 1000 and the capabilities and procurement costs of the DDG 51 were discussed… Predictably, this [subsequent program termination] announcement from the Navy has generated a firestorm here on Capitol Hill… So, we still need a hearing to clear the air on mission capabilities and costs of the two destroyer programs…

This subcommittee was, and is, concerned with cost estimates for the DDG 1000. But let me be very clear – this subcommittee did not recommend canceling the DDG 1000 as we have been accused in the press. What this subcommittee recommended, and the full House adopted in May of this year, was a pause to the third DDG 1000 while the development of technologies and true costs of construction became known on the first two ships… We have two panels of experts today to walk us thorough all these issues…”

See: Rep. Bartlett opening statement | Video of Navy Panel 1 and Analysts Panel 2 [Windows Media] | P1: Allison Stiller – USN Deputy Assistant Secretary, Ship Programs | Vice Admiral Barry McCullough – USN || P2: Ron O’Rourke – Congressional Research Service re: shipbuilding options | Dr. Eric Labs, Congressional Budget Office | Paul Francis, US GAO. All testimonies are PDF format.

July 23/08: Dead in the Water. Widespread reports indicate that the Navy is canceling the DDG-1000 program, capping construction at the 2 ships already ordered.

Reports indicate that the service will keep the DDG-51 Arleigh Burke Class production line open instead, producing either more Flight IIA ships, or inaugurating a Flight III that incorporates some technologies from the DDG-1000 program and/or an active array radars like Lockheed Martin’s S4R. The most reasonable estimates suggest that the trade-off would amount to about 11 DDG-51 destroyers instead of 5 Zumwalt Class light cruisers. The key assumptions behind that figure are twofold. The first assumption involves full funding for the actual cost of the first 2 DDG-1000 ships as an extraneous item, rather than having additional DDG-51s used as bill payers if the CBO’s estimate turns out to be correct again and the Navy is wrong again. Absent that assumption, the trade-off becomes about 9 DG-51s and 2 DDG-1000s vs. 7 DDG-1000s. The second assumption is that any modifications made don’t change the costs for the future DDG-51 destroyers by more than $100 million per ship.

Raytheon’s SPY-3 active array radar, dual-band radar fusion technologies, and open-architecture combat system appear to be the biggest technology losers from this decision, unless elements are incorporated into other ships. General Dynamics’ Bath Iron Works is the obvious contractor loser, unless an equivalent number of DDG-1000 destroyers replaces Zumwalt Class orders at a man-hours ratio of 2.0-2.2 DDG-51s for each DDG-1000 destroyer not purchased from Bath Iron Works. Lockheed Martin’s AEGIS naval combat system is the likely technology winner, via the removal of a key challenger. Sen. Collins [R-ME] confirms it | House Armed Services Committee applauds the decision | Virginia Pilot | Reuters | WIRED’s Danger Room | Navy Times | Maine’s Morning Journal | Wall St. Journal | Associated Press | National Journal’s Congress Daily | NY Times.

The excellent naval blog Information Dissemination includes a full analysis of the decision in “DDG-1000 review“, including this quotes from a May 2008 letter from Adm. Roughead to Sen. Kennedy [D-MA]:

“Since we are phasing out production of the DDG 51 class, there would be start-up costs associated with returning this line to production. As a result, the estimated end cost to competitively procure a lead DDG-51 (Flight IIa – essentially a repeat of the final ships currently undergoing construction) in Fiscal Year (FY) 2009 assuming a truncation of the DDG 1000 class after the two lead ships would be either $2.2B for a single ship or $3.5B for two lead ships (built at competing production yards). This estimate is based on a Profit Related to Offer (PRO) acquisition strategy. The average cost of subsequent DDG 51 Flight IIa class ships would be about $1.8B (FY09) per ship…

While there are cost savings associated with the DDG 1000’s smaller crew, they are largely offset by higher estimated maintenance costs for this significantly more complex ship. Clearly the relative value of the DDG 1000 resides in the combat system (Dual-Band Radar, Volume Search Radar, ASW Suite, etc) that provide this ship with superior warfighting capability in the littoral. However, the DDG 51 can provide Ballistic Missile Defense capability against short and medium range ballistic missiles and area Anti-Air Warfare capability (required in an anti-access environment) where the DDG 1000 currently does not. Upgrading the DDG 1000 combat system with this capability would incur additional cost. The DDG 51 class also possesses better capability in active open ocean anti-Submarine Warfare than does the DDG 1000. On balance, the procurement cost of a single DDG 51 is significantly less than that of a DDG 1000, and the life-cycle costs of the two classes are similar. “

The Congressional Budget Office’s Eric Labs, who has been proven right on several cost estimates for modern shipbuilding programs, estimates construction costs of the first 2 DDG-1000 destroyers are $5.1 billion each, with costs expected to decline to an average of $4.14 billion over the next 5 ships.

July 15/08: Gannett’s Navy Times reports that the DDG-1000 program’s odds of surviving beyond the first 2 ships appear to be fading. The Senate Armed Services committee included funding for a 3rd ship in its FY 2009 budget, but the House Armed Services committee did not. See March 14/08 entry for an indication of the prevailing opinion among HASC leaders. The 3rd ship’s fate will be decided in “reconciliation”, as the House and Senate hammer out a single agreed-upon budget for submission.

Meanwhile, work continues on the US military’s 2010 Program Objective Memorandum that lists multi-year goals and numbers for key projects. Inputs from the services are due by the end of July 2008, and a strained shipbuilding budget could force choices between the DDG-1000 program and closing more than one active shipbuilding line. Chief of Naval Operations Adm. Gary Roughead, Secretary of Defense Gordon England, and Defense Assistant Secretary John Young will meet at the end of July to discuss the DDG-1000 program directly. Meanwhile, the GAO is preparing a report on the program’s status, and the House Seapower subcommittee under powerhouse Rep. Gene Taylor [D-MS] will hold July 31/08 hearings concerning the program. Any one of these events could end up determining the program’s future.

April 7/08: SAR – down to 7. The Zumwalt Class appears in the Pentagon’s Selected Acquisition Report to December 2007:

“Program costs decreased $7,135.4 million (-19.8%) from $36,022.1 million to $28,886.7 million, due primarily to a quantity decrease of 3 ships from 10 to 7 ships (-$8,495.0 million) and revised estimates for budget reductions and inflation impacts on future ships (-$275.8 million).

These decreases were partially offset by increases in fiscal 2009 to fully fund ships 5-7 (+$693.6 million), quantity allocations

• for schedule, engineering, and estimating (+$603.7 million), additional funding for the Advanced Gun System Pallets and Sea Strike capabilities (+$308.3 million), and the application of revised escalation indices (+$291.0 million).

…Note: Quantity changes are estimated based on the original SAR baseline cost-quantity relationship. Cost changes since the original baseline are separately categorized as schedule, engineering, or estimating “allocations.” The total impact of a quantity change is the identified “quantity” change plus all associated “allocations.”

March 14/08: DDG-51 or Zumwalt? The US House Armed Services Seapower and Expeditionary Forces Subcommittee meets to hear testimony on the FY 2009 National Defense Authorization Budget Request for Navy Shipbuilding. The DDG-1000 comes under fire from both sides of the political aisle. Chairman Taylor [D-MS] notes that a:

“…cost overrun of only 10% for the first two ships, which would be excellent for a first in ship class, is still close to $700 million dollars. With all the new technologies that must work for this ship to sail, a cost overrun of 20% or even 30% is not out of the question.”

He relays a scenario he has heard from Navy personnel, and it is amplified by ranking minority Rep. Bartlett [R-MD], who lays that scenario out as a choice:

“…is it wise to buy destroyers that at best will cost $3 billion a copy, and more likely $5 billion a piece if the Congressional Budget Office is right, while we shut down stable, more affordable production lines, such as the DDG-51 line? How much risk are you buying down with only 7 DDG 1000s, at a cost of $21 – $35 billion, when you could likely have at least 14, upgraded DDG-51s for that same amount?”

Read: “US Navy’s 313-Ship Plan Under Fire in Congress” for more excerpts, and additional materials from the day’s testimony.

March 12/08: TSCE. Raytheon announces the successful completion of key electronics system reviews, including the 6th major software review for the Zumwalt program, an applications preliminary design review for Release 5 of the TSCE (Total Ship Computing Environment) software, and a critical design review of the TSCE Release 5 infrastructure. The reviews reportedly verified that Raytheon and its teammates remain on schedule and on budget.

TSCE Release 5 adds 5 million delivered lines of code to the Zumwalt baseline, introducing surface warfare, integrated undersea warfare, information operations and general naval operations capabilities to the combat system. On the combat front, it also adds post-launch missile support for both RIM-162 Evolved Sea Sparrow Missile and Standard family missiles, and can use the full capabilities of the Mk110 57mm Close-in-Gun System and 155mm Advanced Gun System. On the operational front, TSCE R5 provides the framework to support the ship’s engineering control system.

As a point of comparison, TSCE R5 adds almost as many lines of code as Windows NT v3.1 possessed in total. Release 6 will have about 8.1 million lines, and all this is on top of about 20 million reused modules from other programs of record (AEGIS, SPQ-89 towed array programs, NAVSSI), plus all the code that makes up the commercial operating systems, database systems, middleware, et. al. used in the TSCE system. As a modern and familiar set of comparisons, Windows XP possesses about 40 million lines of code in total, and MacOS 10.4 possesses about 86 million.

Feb 15/08: 1000 & 1001 contract. Northrop Grumman Ship Systems in Pascagoula, MS received a $1.402 billion modification to previously awarded contract (N00024-06-C-2304). This contract will begin construction of the as-yet unnamed DDG-1001, as well as and construction of the DDG 1000 superstructure and hangar under a work share agreement with Bath Iron Works. Northrop Grumman Shipbuilding, a newly-formed company sector comprising the former Ship Systems and Newport News divisions, will build the composite deckhouse for all Zumwalt Class destroyers.

Work will be performed in Pascagoula, MS (34%); Gulfport, MS (12%); Pittsburgh, PA (7%); Burns Harbor, IN (4%); McLean, VA (4%); Walpole, MA (1%); Seattle, WA (1%) and various other locations (37%), and is expected to be completed by July 2014. Fabrication of the DDG 1000 Zumwalt’s deckhouse will start in Q4 2008, and construction of DDG 1001 is expected to begin in Q4 2009, with an expected delivery date of 2014. US Navy release | Northrop Grumman release.

Feb 15/08: 1000 & 1001 contract. General Dynamics Bath Iron Works, Inc. in Bath, ME received a $1.395 billion modification to previously awarded contract (N00024-06-C-2303). The effort includes construction of the DDG 1000 destroyer USS Zumwalt, and construction of DDG 1001’s mid-forebody under a work share agreement with Northrop Grumman Ship Systems (NGSS).

Work will be performed in Bath, ME (83%); Pittsburgh, PA (5%); Milwaukee, WI (4%); and various other locations (8%), and is expected to be complete by June 2013. The Zumwalt is currently scheduled to be delivered to the US Navy in 2014. US Navy release | GD release.

Dec 17/07: EO/IR. Raytheon announces a successful critical design review of the DDG-1000’s electro- optical/infrared (EO/IR) system, resulting in approval to advance the design into the production phase. The design review took place at Raytheon’s Maritime Mission Center in Portsmouth, RI, and participants included representatives from Raytheon, NAVSEA, the Naval Surface Warfare Center, Johns Hopkins Applied Physics Laboratory, and Lockheed Martin MS2 in Akron, Ohio. All review objectives were successfully met.

The Zumwalt Class’ EO/IR suite combines 5 individual sets of hardware and embedded software from Lockheed Martin, with the Raytheon-developed Total Ship Computing Environment as resident core software. That core software allows the sensors to be used as one or, when necessary, as 5 individual sensors with 5 different missions – including guidance for the ship’s self-defense gunnery. The system can be operated manually, and also delivers 360-degree, 24-hour situational awareness for the ship via features like automated mine-like object detection, and detection and tracking algorithms that discern targets in day and night, as well as high and low contrast environments. During final integration, Raytheon will complete the entire EO/IR “sensor-to-glass” thread – from target detection to workstation display.

EO/IR systems are becoming popular on modern warships, for two reasons. One is that they improve the ship’s capabilities against unconventional threats like fast boats, and also improve its ability to work in surveillance mode when patrolling near ports, energy infrastructure, and key waterways. The other reason is that modern ships feature more and more stealthy designs, which can be ruined if the ship must emit large amounts of radiation at all times via radar scans.

Dec 13/07: Award. Raytheon announces that the DDG-1000’s MK 57 PVLS sub-program, which enhances ship survivability as well as holding current and future missiles within an open architecture firing system, has been recognized by the Department of Defense and the National Defense Industrial Association (NDIA) as a 2006 Top 5 DoD program award winner for excellence in systems engineering. Members from Raytheon’s joint government-industry team were presented with the award during NDIA’s 10th Annual Systems Engineering Conference in San Diego, CA.

Nov 9/07: 1000 lead-in. Bath Iron Works, Inc. in Bath, ME received a $142 million cost-reimbursement modification to previously awarded contract (N00024-06-C-2303) for DDG 1000 Zumwalt Class Destroyer additional long lead material and pre-production planning to support detail design and construction.

Work will be performed in Bath, Maine (23%); Parsippany, NJ (18%); Pittsburgh, PA (12%); Sanford, ME (3%); Newtown Square, PA (3%); Brunswick, GA (2%); Paterson, NJ (2%); York, PA (2%); Baltimore, MD (2%); Erie, PA (2%); Iron Mountain, MI (2%) and various other locations of 1% or less each (total 29%), and is expected to be complete by January 2008.

Nov 9/07: 1000 lead-in. Northrop Grumman Ship Systems (NGSS) in Pascagoula, MS received a $90 million cost-reimbursement modification to previously awarded contract (N00024-06-C-2304) for DDG 1000 Zumwalt Class Destroyer additional long lead material and pre-production planning to support detail design and construction.

Work will be performed in Pittsburgh, PA (42%); Pascagoula, MS (11%); Parsippany, NJ (7%); Dallas, TX (7%); Walpole, MA (5%); Erie, PA (5%); York, PA (4%); Herndon, VA (4%), Hampton, NH (3%) and various other locations of 2% or less (total 12%), and is expected to be complete by January 2008.

Nov 5/07: PVLS. BAE Systems announces an $8 million contract from Raytheon Company for the first 2 shipsets of MK57 Vertical Launching System (VLS) for the U.S. Navy’s DDG 1000 Zumwalt destroyers, which begins the transition from design to production. Work will be performed at BAE Systems facilities in Minneapolis, Minnesota; Cordova, Alabama; and Aberdeen, South Dakota.

The MK57 VLS is being developed under a collaborative partnership between Raytheon Integrated Defense Systems and BAE Systems. The contract covers the continuation of design, integration, requirements verification, and the initial purchase of materials for the first 2 ship sets; it has the potential to increase up to $64 million, depending on future DDG-1000 production. Work on this contract award begins immediately and continues until January 2012.

Nov 5/07: CEDS. General Dynamics Advanced Information Systems in Fairfax, VA received a maximum $83 million cost-plus-award-fee, fixed-price incentive/ firm-fixed-price hybrid, indefinite-delivery/ indefinite-quantity contracts for the Phase II development, qualification, production, and support of the Common Enterprise Display System (CEDS) Display Consoles. The CEDS is a family of displays that will be implemented across platform systems on Navy surface ships, submarines, and aircraft, providing a common interface to the Platform Open Architecture Computing Environment. Remote displays will be used in conjunction with display consoles.

Work will be performed in Fairfax, VA (69.34%); Fremont, CA (8.52%); Washington, DC (7.64%); Tallman, NY (4.90%); Smithfield, PA (4.65%); Scottsdale, AZ (4.34%); Virginia Beach, VA (.41%); Huntsville, AL (.19%); Arlington, VA (.01%), and is expected to be complete by November 2008. The contract was competitively procured via full and open competition and was solicited through the Navy Electronic Commerce Online and Federal Business Opportunities websites, with 2 offers received (N00024-07-D-5222)

Nov 5/07: CEDS. DRS C3 Systems, LLC in Gaithersburg, MD received a maximum $62.6 million cost-plus-award-fee, fixed-price incentive/ firm-fixed-price hybrid, indefinite-delivery/ indefinite-quantity contracts for the Phase II development, qualification, production, and support of the Common Enterprise Display System (CEDS) Display Consoles. The CEDS is a family of displays that will be implemented across platform systems on Navy surface ships, submarines, and aircraft, providing a common interface to the Platform Open Architecture Computing Environment. Remote displays will be used in conjunction with display consoles.

Work will be performed in Duluth, GA (45%); Gaithersburg, MD (20%); Dahlgren, VA (20%); Johnstown, PA (10%); and Chesapeake, VA (5%), and is expected to be complete by November 2008. This contract was competitively procured and advertised via the Navy Electronic Commerce Online and Federal Business Opportunities websites, with 2 offers received (N00024-07-D-5223).

Oct 30/07: TSCE. Raytheon announces a successful preliminary design review for the “Release 5” of the Total Ship Computing Environment Infrastructure (TSCEI), which comprises six releases of software and more than 5 million lines of code. TSCEI provides computer support for Zumwalt ship control, maintenance, logistics, training and other deployment functions. This level of integration and automation is far ahead of other warships, and is a primary driver for the DDG 1000’s 60% personnel reduction.

Oct 1/07: DBR. Raytheon announces a milestone in advancing the final development of the company’s Dual Band Radar (DBR) for the Zumwalt Class destroyers. Raytheon IDS led the government-industry team in the successful installation of the Lockheed Martin Volume Search Radar (VSR) array at the Surface Warfare Engineering Facility at the Naval Base Ventura County, Port Hueneme, CA. After extensive testing, Raytheon will now integrate the VSR with the SPY-3 X-band Multi-Function Radar to form the DBR.

Another 5 months of extensive testing is set to begin, representing a critical step in testing the maturity of the technology prior to advancing to full system production. Raytheon’s X-band, SPY-3 has successfully completed extensive land- based and at-sea tests over the last 2 years. Raytheon release.

FY 2007

Shipyard shift: Bath Iron Works to build #1; DDG 1000 long-lead; 2 ships authorized; Tumblehome hull risky?; DDG-51 vs. Zumwalt; Naval Fire Support study.

1/4 scale model, testing

Sept 25/07: Jane’s Naval Intelligence reports being told by the US Navy that the first DDG 1000 Zumwalt Class destroyer will be produced by General Dynamics’ Bath Iron Works (BIW) Maine shipyard instead of Northrop Grumman Ship Systems’ (NGSS) Ingalls shipyard. This announcement confirms rumors noted in the July 17/07 entry.

Sept 21/07: MSE. Raytheon Integrated Defense Systems in Tewksbury, MA received a $994.3 million cost-type modification to previously awarded contract (N00024-05-C-5346), covering key mission system equipment (MSE) production and engineering support services for the first 2 ships of class. The MSE includes the total ship computing environment infrastructure; acoustic sensor suite element – including the bow array sensor suite; dual band radar; electro-optic/infrared sensor; ship control system; identification of friend or foe; common array power and cooling systems; electronic module enclosures; and Mark 57 vertical launcher system. Raytheon is the mission systems integrator for the Zumwalt Class ships.

Work will be performed in Moorestown, N.J. (21%); Portsmouth, R.I. (20%); Andover, Mass. (18%); Tewksbury, Mass. (17%); Marlborough, Mass.; St. Petersburg, Fla.; Ft. Wayne, Ind. (17%); and Sudbury, Mass. (7%), and is expected to be complete by December 2012. The MSE is being procured for the program executive office for ships [PMS-500].

Aug 23/07: IASS. Raytheon announces a successful design review of the Zumwalt Class’ integrated acoustic sensor suite. IASS is a modular, open architecture combat system designed to provide the ship with a complete undersea warfare picture. It integrates the ship’s acoustic undersea warfare systems and subsystems, including the dual frequency bow array sonar, towed array sonar, towed torpedo countermeasures, expendable bathythermograph, data sensor, acoustic decoy launcher, underwater communications, and associated software.

The design review – which also determined that predefined space and weight allocations on board a Zumwalt Class ship are adequate to house the components of the acoustic sensor suite – took place at the Raytheon IDS Maritime Mission Center, Portsmouth, R.I. Participants included representatives from Raytheon, Naval Sea Systems Command, the Naval Undersea Warfare Center and the Naval Surface Warfare Center, as well as Lockheed Martin and other subcontractors. Raytheon’s OpenAIR business model also leveraged the help of small businesses including Argon ST, Applied Acoustic Concepts, and Adaptive Methods.

With this success, the U.S. Navy has given Raytheon Integrated Defense Systems (IDS) approval to advance the acoustic sensor suite’s design into production. Raytheon release.

July 24/07: DDG-51 vs. Zumwalt. In a statement before the US House Armed Services Subcommittee on Seapower and Expeditionary Forces, Congressional Budget Office representatives testify that [PDF]:

“The service’s 2008 budget suggests that the Navy expects the first two ships to cost $3.0 billion each and the following five to cost an average of $2.0 billion apiece – meaning that the entire class would have an average cost of $2.3 billion per ship.18 CBO, by contrast, estimates that the first two DDG-1000s would cost $4.8 billion apiece and the next five would cost an average of $3.5 billion each. The average per-ship cost of the class would be $3.9 billion.”

They go on to explain the Navy’s objections to their estimate, as well as their reasons for setting those objections aside. Summary:

“The Navy has stated that if the Congress authorized and bought two additional DDG-51s in 2008 – which would be the 63rd and 64th ships of their class – those destroyers would cost a total of $3.0 billion to $3.1 billion, or $1.5 billion to $1.6 billion apiece (in 2008 dollars). At the same time, the Navy’s 2008 budget submission to the Congress estimates the cost of building the seventh DDG-1000 in 2013 at about $2.1 billion (in 2013 dollars). Deflated to 2008 dollars (using the inflation index for shipbuilding that the Navy provided to CBO), that estimate equals about $1.6 billion – or the same as for an additional DDG-51, which would have the benefit of substantial efficiencies and lessons learned from the 62 models built previously. The lightship displacement of the DDG-1000 is about 5,000 tons greater than that of the DDG-51s under construction today. In effect, the Navy’s estimates imply that those 5,000 extra tons, as well as the 10 new technologies to be incorporated into the DDG-1000 class, will be free.”

July 17/07: Shipyard switch? Defense News reports that U.S. Navy and industry officials are discussing a plan to shift construction of the first DDG 1000 destroyer from Northrop Grumman’s Ingalls shipyard to the General Dynamics yard at Bath, ME. Bath Iron works has begun construction of the last Arleigh Burke Class destroyer (DDG 112), and has no work after it is delivered in 2011. Northrop Grumman Ingalls, meanwhile, is building its own Arleigh Burke ships, an LPD 17 San Antonio class ship, and the Coast Guard’s National Security Cutters.

Navy officials reportedly insist that the proposed shift does not reflect dissatisfaction with Northrop Grumman, which has been stung by public criticism of its work on LPD 17 amphibious ships and the Coast Guard’s Deepwater program. Perhaps, and perhaps not. What is certain is that building the second Zumwalt Class destroyer allows Ingalls to gain lessons learned from the first ship, and may also provide a break from the criticism of problems with its own first-in Class ships (LPD 17 amphibious assault ship, LHA 6 LHA-R mini-carrier, National Security Cutter). As long as they are awarded one of the 2 ships to build, the timing will make little difference to them.

If the Navy and the two shipyards agree on a lead ship swap, Secretary of the Navy Winter will make the final decision, which is not expected before July 23/07.

June 11/07: 1000 lead-in Bath Iron Works Inc. in Bath, ME received a $197.1 million cost-reimbursement type modification to previously awarded contract (N00024-06-C-2303) for DDG 1000 Zumwalt Class Destroyer long lead material, and pre-production planning to support detail design and construction.

Work will be performed in Bath, Maine (44%), Parsippany, NJ (16%), Pittsburgh, PA (10%), Iron Mountain, MI (5%), Erie, PA (4%), Kingsford, MI (4%), Mississauga, Ontario, Canada (4%), York, PA (3%), Kent, WA (3%), Indianapolis, IN (3%), Hudson, ME (2%), and Newton Square, PA (2%).

June 11/07: Northrop Grumman Ship Systems (NGSS) in Pascagoula, MS received a $10 million cost-plus-award-fee modification under previously awarded contract (N00024-06-C-2304) for procurement of DDG 1000 research, development, test and technical services.

Work will be performed in Pascagoula, MS (45.09%); Herndon, VA (26.66%); Annapolis, MD (6.53%); Aberdeen, MD (4%); West Bethesda, MD (3.75%); Linthicum, MD (2.68%); San Antonio, TX (3.76%); Washington, DC (2.32%); Reston, VA (2%); Arlington, VA (1.20%); Pt. Mugu, CA (1.01%); Newport News, VA (0.75%); and Tacoma, WA (0.25%), and is expected to be complete by December 2007.

June 5/07: 1000 lead-in. Northrop Grumman Ship Systems in Pascagoula, MS received a $191.1 million cost-reimbursement type modification to previously-awarded contract (N00024-06-C-2304). It covers DDG 1000 Zumwalt Class Destroyer long lead material such as steel plates, pipe, cable and other major equipment. It also covers production planning labor, integrated logistics support, and systems integration engineering to support detail design and construction.

Work will be performed in Pascagoula, MS (47%), Pittsburgh, PA (30%), Parsippany, NJ (12%), Indianapolis, IN (5%), Erie, PA (4%), and Iron Mountain, MI (2%), and is expected to be completed by November 2007. Northrop Grumman release.

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May 15/07: Fire Support Study. US Joint Forces Staff College JAWS Masters Thesis by Col. Shawn Welch, USARNG, is published: Joint and Interdependent Requirements: A Case Study in Solving the Naval Surface Fire Support Capabilities Gap [PDF]. Wins National Defense University 2007 Award for best thesis. Persuasively argue that current capabilities are insufficient, casts doubt on the DDG-1000 Class as an adequate solution, and makes a case that faulty assumptions have helped to create this problem. Includes a number of interesting anecdotes, as well as analysis.

April 6/07: Northrop Grumman Ship Systems in Pascagoula, MS received a $7.5 million cost-plus-award-fee modification to previously awarded contract N00024-06-C-2304, for DDG 1000 research, development, test and technical services.

Work will be performed in Pascagoula, MS (75.53%); Herndon, VA (9.77%); Aberdeen, MD (3.33%) Annapolis, MD (2.93%); San Antonio, TX (2.00%); El Segundo, CA (1.99%) Pt. Mugu, CA (1.28%); Linthicum, MD (0.69%); West Bethesda, MD (0.67%); Washington, DC (0.57%); Reston, VA (0.51%); Arlington, VA (0.40%); and Newport News, VA (0.33%), and is expected to be completed by September 2007. All contract funds will expire at the end of the current fiscal year.

April 2/07: Tumblehome tumble-over? Defense News runs an article that openly questions the DDG-1000 design’s stability at sea:

“At least eight current and former officers, naval engineers and architects and naval analysts interviewed for this article expressed concerns about the ship’s stability. Ken Brower, a civilian naval architect with decades of naval experience was even more blunt: “It will capsize in a following sea at the wrong speed if a wave at an appropriate wavelength hits it at an appropriate angle”…”

Rigid traditionalism of the same species that dismissed the aircraft carrier? Prescient early warning of a catastrophe? Or something else? Read DID’s report.

March 21/07: 1000 turbines. Rolls Royce Naval Marine, Inc. received a $76.6 million firm fixed price contract for DDG-1000 main turbine generator sets (N00024-07-C-4014). No specifics yet, but see DID’s coverage of the MT30 engine in the technology section, above. Work will be performed in Walpole, MA and is expected to be complete by September 2009. The contract was competitively procured and advertised on the Internet, with 2 offers received. GE Marine would have been the other offeror.

March 20/07: Bath Iron Works Inc. received a $12.6 million cost-plus-award-fee modification under previously awarded contract N00024-06-C-2303, for DDG 1000 research, development, test and technical services.

Work will be performed in Bath, ME (39.08%), Brunswick, GA (19.70%), West Bethesda, MD (12.22%) Groton, CT (9.55%), Arlington, VA (6.10%), Elk Grove, VA (4.33%), Herndon, VA (3.79%), Annapolis, MD (2.73%), Pt. Mugu, CA (1.72%), Montgomeryville, PA (0.50%), Washington D.C. (0.25%), and San Antonio, Texas (0.03%), and is expected to be complete by January 2008. Contract funds in the amount of $3.6 million will expire at the end of the current fiscal year.

March 7/07: PMM research. DRS Power Technology Inc in Fitchburg, MA received a $19.7 million cost-plus-fixed-fee contract for Integrated Power Systems research, and development of a Permanent Magnet Motor (PMM) System Land Based Test Site and Next Generation Design.

DRS’ PMM was taken out of the DDG 1000 design to keep it on schedule, and a proven but heavier and less productive AIM system was installed instead. Continuing research could add new options to future Zumwalt Class destroyers – or more likely, to successor ships like the CG (X). See full DID coverage.

Feb 12/07: PVLS. Raytheon Integrated Defense Systems and BAE Systems announce completion of a restrained test firing of a Standard Missile-2 Block IV MK72 rocket booster on the new MK57 PVLS missile launcher. The test at White Sands Missile Range, NM demonstrated the system’s ability to safely withstand a static burn of an MK72 rocket motor in the new launcher. See Raytheon release.

Feb 12/07: 1000 MSE. Raytheon Integrated Defense Systems in Tewksbury, MA received a not-to-exceed $305.7 million cost-type modification to previously awarded contract (N00024-05-C-5346) for DDG 1000 Mission System Equipment (MSE) and engineering support services. Work will be performed in Tewksbury, MA (47%); Portsmouth, RI (28%); and Moorestown, NJ (25%), and is expected to be complete by September 2007.

This is part of the DDG 1000 Ship Systems Detailed Design and Integration effort, and the hardware involved includes: Total Ship’s Computing Environment Infrastructure; Acoustic Sensor Suite Element – including the Bow Array Sensor Suite; Dual Band Radar; Electro-Optic/ Infrared Sensor; Ship Control System; Identification of Friend or Foe; Common Array Power and Cooling Systems; Electronic Module Enclosures; and the Mark 57 PVLS Vertical Launcher System.

Feb 6/07: IPS R&D. General Atomics in San Diego, CA, who is also well known for designing power distribution systems used by the US Navy on its aircraft carriers, receives a $10.7 million cost-plus-fixed-fee contract to research and develop Integrated Power Systems (IPS).

A spokesman for the Space and Naval Warfare Systems Center in Charleston, SC said that the contract is not specifically geared to any platform already under construction like the DDG 1000. Instead, technologies developed and lessons learned under this R&D contract will be integrated into future IPS systems generally.

Jan 29/07: Design. Northrop Grumman Ship Systems in Pascagoula, MS received a $268.1 million cost-plus-award-fee/ cost-plus-fixed-fee modification under previously awarded contract (N00024-06-C-2304) to exercise an option to complete the detail design of the Zumwalt Class Destroyer. The total value of the detail design effort is $307.5 million (see Aug 31/06 entry).

The contract funds further DDG 1000 detail design and procurement of vendor-furnished information and long-lead materials, and runs through 2013. Work will be performed at Northrop Grumman Ship System’s Pascagoula, MS; Gulfport, MS; and Washington DC facilities. See also Northrop Grumman release.

Jan 29/07: Design. Bath Iron Works Inc. in Bath, ME received a $257.5 million cost-plus-award-fee/cost-plus-fixed-fee modification under previously awarded contract (N00024-06-C-2303) to exercise an option to complete Zumwalt Class Destroyer detail design. The total value of the detail design effort is $337.4 million – $79.9 million for advanced zone detail design was awarded as part of the basic contract (see Aug 8/06 entry).

DDG-1000: night moves…
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Jan 19/07: Lighting. Skyler Technologies Group subsidiary RSL Fiber Systems, LLC in Salem, New Jersey announces a contract from Northrop Grumman Ship Systems in Pascagoula, MS to supply the Advanced Lighting System (ALS) for the U.S. Navy’s DDG-1000 Zumwalt Class. Their Advanced Lighting System offers significant benefits to stealth, durability, and maintainability, and has already been installed in several new US Navy ships.

In a conversation with DID, RSL Fiber systems estimated a total contract value is in excess of $12.5 Million for the six (6) DDG 1000 class ships planned. The estimated contract value for the two (2) DDG 1000 class ships already approved by Congress is in excess of $4.9 Million, and includes engineering support services and the supply of remote source lighting systems and related hardware. See our article “DDG-1000 ‘Destroyers’ to get ALS Lighting System” for more coverage of ALS details, advantages, and resources.

Nov 7/06: TSCE. Raytheon announces the delivery of a complete set of specifications, design documents, source code and user guides for the DDG-1000 Total Ship Computing Environment Infrastructure (TSCEI) Release 4.1, which will be made available to other US Navy open architecture programs via the PEO IWS SHARE (Software-Hardware Asset-Reuse Enterprise) repository. The TSCE is a robust, enterprise-network computing system on which all DDG-1000 application software programs run. IBM blade servers are the Zumwalt Class’ hardware medium.

Under the Navy’s DDG-1000 Detail Design and Integration contract awarded in 2005, Raytheon IDS serves as the prime mission systems equipment integrator for all electronic and combat systems. See Raytheon release.

Oct 24/06: DBR. Raytheon reports successful on-schedule integration of Lockheed Martin’s engineering development model S-Band array with receiver, exciter, and signal/data processing equipment for the Volume Search Radar (VSR) portion of the DDG-1000 destroyer’s Dual Band Radar (DBR). Raytheon had already developed and tested the X-band component of the DBR, known as the AN/SPY-3. Now the challenge is to integrate them together.

Oct 17/06: 2 ships authorized. President George W. Bush signs the FY 2007 defense appropriations bill into law as Public Law 109-364. The final bill authorizes the buildout of 2 DDG-1000 ships, to be incrementally funded. It is silent re: future years or future ships, imposing no limits.

FY 2006

Milestone B go-ahead; Design & reviews ongoing.

Zumwalt concept: inshore

Aug 31/06: QTA, DDI IBR. Raytheon issues a release reporting the successful completion of two significant events for the DDG-1000 Zumwalt Class Destroyer Program: the third Quarterly Technical Assessment (QTA) and the Detail Design and Integration (DDI) Integrated Baseline Review (IBR), both of which were conducted at the DDG 1000 Collaboration Center in Washington, DC.

The QTA reviewed and assessed the following major design and development categories: System Integration, Ship Detail Design, Mission System Equipment Development, Mission System Design and System Software Development. Participants included representatives from the U.S. Navy PEO Ships/PMS 500, PEO IWS, Naval Surface Warfare Dahlgren Division and the DDG-1000 industry teammates including Raytheon, Northrop Grumman Ship Systems, Lockheed Martin, BAE Systems and General Dynamics/Bath Iron Works.

The program’s DDI IBR involved the US Navy assessing the program scope, resources, Integrated Master Schedule and Earned Value Management processes. This key milestone was also successfully completed, and concluded with the Navy’s approval of the $2.7 billion Program Management Baseline. Firms involved in this stage included Raytheon, Lockheed Martin, BAE Systems, General Dynamics/ Bath Iron Works, Northrop Grumman Defense Missions Systems, Boeing and L-3 Communications.

Aug 31/06: Design. Northrop Grumman Ship Systems (NGSS), Pascagoula, MS is being awarded a $95.9 million cost-plus-award-fee/ cost-plus-fixed-fee contract for DDG-1000 Zumwalt Class destroyer detail design, maintenance of the DDG-1000 integrated data environment for those designs (IDE), and procurement of vendor furnished information (VFI) and long lead material (LLM) to support detail design. Work will be performed in Pascagoula, MS and is expected to be complete by September 2007. The contract was not competitively procured by the Naval Sea Systems Command in Washington, DC (N00024-06-C-2304).

The total value of this detail design effort is $307.5 million, with $39.4 million funded at contract award for advanced zone detail design. The remaining detail design efforts are included in a priced option valued at $268.1 million. The IDE maintenance effort will be fully funded at contract award in the amount of $11.5 million, and Northrop Grumman will be awarded a Not-to-Exceed (NTE) line item for vendor furnished information and long-lead materials valued at $45 million. The maximum amount for which the Government is liable under that NTE is $22.5 million, prior to further definitization.

Aug 8/06: Design. General Dynamics subsidiary Bath Iron Works Inc. (BIW) in Bath, Maine recently received a $115.8 million cost-plus-award-fee/ cost-plus-fixed-fee contract for DDG-1000 Zumwalt Class Destroyer detailed design, and procurement of vendor furnished information (VFI) in support of the detailed design. Work will be performed in Bath, ME and is expected to be complete by December 2008. Per the previous contract announcement, this contract was not competitively procured by the Naval Sea Systems Command in Washington DC (N00024-06-C-2303).

The total value of the detail design effort is actually $336.3 million. This initial award consists of $78.5 million funded at contract award, plus a not-to-exceed (NTE) line item for procurement of “vendor-furnished information” valued at $37.3 million, for a total of $115.8 million. Note that the maximum amount for which the government is liable under the NTE line item prior to definitization is $18.6 million, so the $115.8 million total may not be reached. The remaining detail design efforts are included in a priced option valued at $257.7 million.

May 25/06: DBR. Raytheon announces that the U.S. Navy’s first shipboard active phased array multifunction radar, Raytheon’s AN/SPY-3, has successfully participated in a series of at-sea tests, including the first time the radar has acquired and tracked a live controlled aircraft while at sea. Raytheon release.

May 1/06: Reader Justin Hughes notifies us that under a motion approved by the US House Force Projection Subcommittee, the DDG-1000 program would be capped at 2 ships as a technology demonstrator for the forthcoming CG (X) cruiser program. This is all part of the US FY 2007 defense budget process, and does not represent a final decision, but could be influential. Chairman Bartlett [R-MD] did acknowledge that the CG (X) cruiser are slated to incorporate a new type of radar that “might not be ready for use for a decade.” See Defense News article.

There’s also an interesting but completely unofficial discussion here re: what might be done with those funds – see esp. the information re: the DDG-51 Arleigh Burke Class upgrades. This tip would prove prophetic.

April 13/06: Design. Bath Iron Works in Bath, ME receives a $42.8 million cost-plus-award-fee modification to previously awarded contract (N00024-05-C-2310) for the continuation of DD (X) transition design efforts and initial detail design and long lead material procurement for DD (X) ship construction.

This effort is for transitional and detail design for DD (X), such that work can be accomplished prior to the award of a detail design completion contract in order to minimize impact on the ship industrial base. Work will be performed in Bath, ME and is expected to be complete by June 2006.

April 12/06: DID’s “The Lion in Winter: Government, Industry, and US Naval Shipbuilding Challenges” reproduces a speech by Secretary of the Navy Donald Winter. In many ways, the DDG-1000 class is a poster-child example of the shipbuilding dynamics he discusses. This has implications for overall US naval policy, and also for the program’s future.

March 2/06: Design. Northrop Grumman Ship Systems in Pascagoula, MS received a $42.8 million cost-plus-award-fee, level of effort modification to previously awarded contract (N00024-05-C-2311) for continuation of DD (X) transition design efforts, initial detail design and long lead material procurement for DD (X) ship construction.

Work will be performed in Pascagoula, MS and is expected to be complete by June 2006.

Nov 23/05: Milestone B Go-ahead. See DID coverage, and Navy Times article.

Nov 11/05: DAB Review. DD (X) Destroyer Program Has Its Defense Acquisition Board Review. Inside Defense goes over some of the issues and considerations.

FY 2005

$3 billion mission systems integration contract; Flag-level Critical Design Review passes; IBM picked for TSCE; PVLS passes factory acceptance testing; TSCE R2 software certified; SPY-3 radar passes Milestone B; Underwater eXplosion testing.

DD (X) Destroyer

Sept 30/05: Design. Bath Iron Works in Bath, ME (N00024-05-C-2310) and Northrop Grumman Ship Systems in Pascagoula, ME (N00024-05-C-2311) each receive a not-to-exceed ceiling price $53.4 million (with a limitation of $26.7 million) cost-plus-award-fee, level of effort letter contract for the Phase IV DD (X) program transition design effort. They will provide vendor furnished information for key equipment, completion of system diagrams and maintenance of the DD (X) integrated data environment for design.

Work will be performed in Bath, ME and Pascagoula, MS and is expected to be complete by January 2006 (BIW: N00024-05-C-2310, NGC: N00024-05-C-2311).

Sept 14/05: CDR. The DD (X) Program’s Flag-Level Critical Design Review (CDR) is completed for the overall system design, marking the end of Phase III and a process advertised as being “on schedule and within 1% of stated budget.” See the release for more details, which include important information about the program.

Note that this effort included an unusually thorough approach of CDRs for each of 10 Engineering Development Models, representing a judgment that they have achieved enough have achieved both technical maturity and cost insight. The 10 EDMs were:

• Wave-Piercing Tumblehome Hull
  
• Infrared Mockups
  
• Composite Deckhouse and Apertures
  
• Dual Band Radar (DBR)
  
• Integrated Power System
  
• Total Ship Computing Environment (TSCE)
  
• Integrated Undersea Warfare System (IUSW)
  
• Peripheral Vertical Launching System (PVLS)
  
• Advanced Gun System (AGS)
  
• Autonomic Fire Suppression System (AFSS)

Aug 4/05: IBM for TSCE. Raytheon Integrated Defense Systems has selected IBM to supply core computing and storage equipment for the DD (X) multi-mission destroyer. The equipment will form the backbone of the Total Ship Computing Environment (TSCE), based on an Open Architecture approach that makes it easier to integrate commercial-off-the-shelf (COTS) hardware and software and makes wider interoperability easier.

The selection of IBM followed a competition in which Raytheon solicited proposals from leading computer suppliers, noting the complex requirements of the TSCE and the challenges of operating electronic equipment in the harsh environment aboard a surface combatant. IBM will work with Raytheon to complete detailed specifications and supply COTS equipment to Prime contractor Northrop Grumman for the first DD(X) ship delivery.

August 2/05: PVLS. The MK57 Vertical Launching System (VLS) Engineering Development Model (EDM) successfully passes Factory Acceptance Testing two weeks ahead of schedule. The testing was designed to prove that the MK 57 PVLS system has a sound open architecture, capable of receiving and processing missile select and launch commands within the mission timelines. See release. Back on June 23/05, another release noted a Maximum Credible Detonation Event (MCDE) test at the Aberdeen Test Center. That test was designed to confirm that that weapons stored in a PVLS module will not detonate during a worst case scenario in an module next to it.

July 26/05: DID’s “DD (X) Program Passes Review, But Opposition & Reports Cloud Future (Updated)” Notes political opposition from various circles. Also notes recent Congressional testimony from the CBO and GAO discussed cost estimates that have risen from $1 billion to $3.2 billion average per ship, ship life cycle costs likely to be about double that of the DDG 51 Arleigh Burk Class ($4 Billion vs. $2.1 billion), possible further cost increases, and technical project risks that still remain.

July 19/05: GAO. US GAO submits a briefing to Congress: “Progress and Challenges Facing the DD (X) Surface Combatant Program.” The Congressional Budget Office also submits a briefing: “The Navy’s DD (X) Destroyer Program” [PDF].

AGS fires LRLAP
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July 18/05: The National Team announces that they have successfully completed the Initial Critical Design Review for the DD (X) overall system design, allowing the program to pass on toward the Flag level review in September 2005 and enter detail design. This was a DD (X) Phase III program event that addressed the total system’s design maturity, and overall progress made to date on DD (X) engineering-development models of hardware and software components that have already been built, tested and reviewed by the National Team and the Navy. Examples include the integrated deckhouse and apertures, total ship computing environment, dual-band radar system, integrated under-sea warfare system, MK 57 advanced vertical launching system, automated gun system and wave-piercing tumblehome hull.

July 5/05: DID’s “DD (X) Program: Developments & Alternatives.” Notes ongoing Congressional discussions re: cost caps, despite Congressional action that had hiked the price per ship. Also notes the lobbying effort underway to reactivate Iowa Class battleships instead.

June 14/05: “GAO Delivers DD (X) Program Interim Report.” Among other things, it says that technology development for the U.S. Navy’s advanced DD (X) destroyer is still lagging despite progress in a number of areas.

June 1/05: UX testing. The DD (X) National Team announces the successful completion of Underwater Explosion testing on the ship’s Quarter Scale Model. The tests were done to determine the unique destroyer hull form’s reaction to underwater explosions. Explosive charges were placed at predetermined distances from the model, and the intensity of the charges was stepped up as the test series progressed. The release reports that the new design’s wave-piercing bow, tumblehome cross section, step deck area and rising stern responded as envisioned. See release.

May 23/05: $3 billion contract for DD (X). A consortium led by Raytheon Co. Integrated Defense Systems (IDS) in Tewksbury, MA received a cost-plus award-fee letter contract with a not-to-exceed ceiling of $3 billion for DD (X) ship system integration and detail design. Raytheon and its partners will develop systems for the new destroyers that improve on existing technology, including radar, sonar, the ships’ computing network and external communications network and missile launchers. The consortium will also be integrating the systems to make sure they work together.

Work will be performed by Raytheon IDS in Tewksbury, MA; Lockheed Martin Maritime Systems and Sensors in Moorestown, NJ; BAE acquisition United Defense LP in Minneapolis, MN; Northrop Grumman Mission Systems in King George, VA; and Ball Aerospace & Technology Corp. in Westminster, CO; and is expected to be complete by December 2009. This contract was not competitively procured. The Naval Sea Systems Command, Washington, D.C. issued the contract (N00024-05-C-5346).

April 18/05: “Senate Hearing On DD (X) Procurement Strategies.” The legislature doesn’t like the “winner take all” approach, and wants the funding spread around. The Navy disagrees, citing additional costs of up to $300 million per ship. DID covers the issue.

March 31/05: TSCE. Software Release 2 of DD (X) Total Ship Computing Environment (TSCE) receives formal certification from the Navy, after successfully meeting all entrance and exit criteria. Two successful demonstrations of Software Release 2 at the U.S. Navy’s Open Architecture Test Facility (OATF) in Dahlgren, VA demonstrated that the open-architected TSCE is easily portable between different computing platforms, can be reconfigured quickly without having to write new code, and delivers the functionality essential for DD(X) to perform its multiple missions.

The first large-scale implementation of the US Navy’s Open Architecture (OA) strategy, the TSCE integrates all shipboard warfighting and peacetime operations into a single, common enterprise computing environment. This approach gives the Navy increased ability to use standardized software and commercial-off-the-shelf (COTS) hardware across a family of ships. See release.

March 9/05: Design. Northrop Grumman Ships Systems in Pascagoula, MiS received a $10 million cost-plus-fee modification to previously awarded contract (N00024-02-C-2302) to refine the DD (X) Program Life Cycle Cost Estimate deliverable. This effort modifies Contract Data Requirements List A.20 with additional requirements in order to provide greater detail into the DD (X) Program Life Cycle Cost Estimate.

Work will be performed in Tewksbury, MA (35%); Pascagoula, MS (23%); Bath, Maine (18%); Minneapolis, MN (7%); Moorestown, NJ (4%); Farmington, UT (4%); King George, VA (4%); Chantilly, VA (3%); and Alexandria, VA (2%), and is expected to be complete by March 2005.

Jan 14/05: DBR. DD (X) AN/SPY-3 Multi-Function Radar Passes Milestone B Criteria Tests. The Engineering Development Model (EDM) for the AN/SPY-3 S-Band Multi Function Radar has successfully completed the Milestone B test event at the Navy’s Wallops Island, VA test range. The test served to assess radar performance with regard to environmental, detection, and tracking performance.

FY 1998 – 2004

DD-21 becomes DD (X); Northrop Grumman wins DD-X, 2.9 billion contract; DD-21 development contracts.

April 14/04: Design. $78 million to Northrop Grumman under DD (X).

April 29/02: Design. Northrop Grumman Ship Systems (NGSS) division Ingalls Shipbuilding Inc. in Pascagoula, MS wins the down-select, and a $2.879 billion cost-plus-award-fee contract for DD (X) Design Agent activities. These include the design, build and test of engineering development models (EDMs) for major subsystems and components for the DD (X) destroyer.

Work will be performed in Pascagoula, MS and Bath, ME (38%); Portsmouth, RI (16%); Minneapolis, MN (13%); Tewksbury, MA (9%); Reading, MA (4%); Andover, MA (4%); Newport News, VA (3%); Fullerton, CA (2%); Fort Wayne, IN (2%); Bethesda, MD (2%); Anaheim, CA (2%); Cincinnati, OH (2%); Hudson, MA (2%); and Philadelphia, PA (1%) and is to be complete by September 2005.

This contract is incrementally funded; funding in the amount of $273.2 million has been committed with this award (N00024-02-C-2302). It was competitively procured via publication in the Commerce Business Daily and the solicitation was posted to the Navy Electronic Commerce Online (NECO) Internet web page, with 2 offers received.

See also US assistant secretary of the Navy for research, development and acquisition John Young, Jr’s briefing regarding the downselect:

“The award will be made to Ingalls Shipbuilding, Incorporated, the Gold Team lead. Their proposal was selected due to its overall management and technical approach, coupled with superior engineering development models and exceptional specified performance features of the proposed design. The superior EDMs and features included an innovative peripheral vertical launch system, dual-band radar suite, two-helicopter spot flight deck, and stern boat-launching system.

The contract was competitively awarded based on best value… The source selection process was the first of a kind for a Navy shipbuilding program and will be the model for future Navy acquisitions… BIW will continue to be involved in the design of the ship and development of the EDMs, to ensure that both shipbuilders can product DD(X) and can compete for the detailed design and construction of the lead ship in fiscal year 2005.”

Dec 21/01: End of DD-21, Birth of DD (X). US under secretary of defense for acquisition, technology and logistics Pete Aldridge announces that the DD-21 program has been terminated, following the Quadrennial Defense Review. It will be replaced by a program called DD (X). Pentagon transcript.

Oct 25/01: $60.2 million to the DD-21 Alliance (N00024-98-9-2300).

June 14/01: A not-to-exceed $124.3 million firm-fixed-price advance agreement modification for the extension of the DD 21 Phase II period of performance.

Work will be performed by the “Blue Team” (42%) led by Bath Iron Works in Bath, Maine and Lockheed Martin Government Electronic Systems in Moorestown, N.J.; the “Gold Team” (42%) led by Ingalls Shipbuilding in Pascagoula, MS, with Raytheon Systems Co. in Falls Church, VA; and United Defense Limited Partnership (UDLP) in Minneapolis, MN (16%). Work is expected to be complete by September 2001 (N00024-98-9-2300, modification 0037)

May 31/01: $7.1 million to the DD-21 Alliance (N00024-98-9-2300).

May 29/01: $6.7 million to the DD-21 Alliance (N00024-98-9-2300).

May 17/01: $7.1 million to the DD-21 Alliance (N00024-98-9-2300).

May 1/01: $5.4 million to the DD-21 Alliance (N00024-98-9-2300).

April 2/01: $29 million to the DD-21 Alliance (N00024-98-9-2300).

Jan 9/01: $12 million to the DD-21 Alliance (N00024-98-9-2300).

Jan 9/01: 7 million to the DD-21 Alliance (N00024-98-9-2300).

Nov 2/2000: $10.6 million to the DD-21 Alliance (N00024-98-9-2300).

May 1/2000: $16 million to the DD-21 Alliance (N00024-98-9-2300).

Nov 23/99: A $238 million contract modification to the DD-21 Alliance for the DD-21 Phase II effort, which includes the development of 2 competitive DD-21 initial systems designs with accompanying DD 21 virtual prototypes.

Work will be performed in Bath, Maine (21%); Moorestown, NJ (21%); Pascagoula, MS (21%); Falls Church, VA (21%); and Minneapolis, MN (16%), and is expected to be complete by January 2001 (N00024-98-9-2300).

Feb 17/99: $12 million to the DD-21 Alliance (N00024-98-9-2300).

Aug 18/98: The DD-21 Alliance, comprised of Bath Iron Works Corp. in Bath, Maine, and Ingalls Shipbuilding in Pascagoula, MS received is being awarded a $16.5 million agreement modification to a previously awarded contract (N00024-98-9-2300) for the Phase I development of DD-21 design concepts. Bath Iron Works Corp. has been selected by the DD-21 Alliance to lead the alliance and execute the Phase I agreement, which provides for the establishment of 2 competing teams who will perform requirements analyses and trade studies, and develop 2 competitive DD-21 system concept designs. Each team will implement total ship systems engineering and cost as an independent variable principles in order to achieve significant reductions in ship procurement costs, operation and support costs, and manning levels over current Navy combatants. This agreement has a potential cumulative value of $68.5 million.

Work will be performed in Moorestown, NJ (30%), Pascagoula, MS (25%), Falls Church, VA (25%), and Bath, Maine (20%), and is expected to be complete in October 1999. The Naval Sea Systems Command in Arlington, VA is managing the contract.

Additional Readings & Sources

• US Navy PEO Ships – DDG 1000

• Naval Technology – Zumwalt DD (X) Class – Multimission Destroyer: Advanced Technology Surface Combatants, USA

• Raytheon – DDG 1000 Zumwalt Class Destroyer: Critical technologies

• Carbon Fiber Guru, via WayBack – The Navy’s Carbon Fiber Composite Stealth Warship. The deckhouse that sits on DDG 1000/1001 is.

• DID – Next-Gen Naval Gunfire Support: the USA’s AGS & LRLAP

• DID Spotlight – The US Navy’s Dual Band Radars

• Maritime Business Strategies, LLC, via WayBack – The Cost of the DDG-1000. Lists and totals all contracts under the DD-21, DD (X), and DDG-1000 programs. Note that the total given assumes that every contract spent its maximum, which is not necessarily so.

• Raytheon, via WayBack – Raytheon’s Electronic Modular Enclosure for DDG 1000. They contain the Total Ship Computing Environment.

• ZumwaltFacts.Info – A 3rd party site chaired by Col. James G. Zumwalt, Esq. (USMC Ret.). It was supported by external donors, which include Raytheon.

• DDG-1000 National Team Site. Since deactivated, archived from end 2008. See also the DD (X) National team site archive, which covered the period up until September 2005 very well.

Official Reports

• US Congressional Research Service (#RL32109, April 8/14 update) – Navy DDG-51 and DDG-1000 Destroyer Programs: Background and Issues for Congress. Compare to Sept 11/08 update.

• US House Armed Services Subcommittee on Seapower and Expeditionary Forces (July 24/07) – Congressional Budget Office, Statement of J. Michael Gilmore, Assistant Director for National Security and Eric J. Labs, Senior Analyst: The Navy’s 2008 Shipbuilding Plan and Key Ship Programs [PDF]

• US Government Accountability Office (GAO-06-279R, Dec 13/05) – Issues Related to Navy Battleships. Just looks at the various issues and options around reactivating Iowa Class battleships, and states the various positions, without doing a lot of in-depth analysis.

• Pentagon Office of Force Transformation’ (2005) – Alternative Fleet Architecture Design study [PDF]. Note esp. their estimates re: the lack of realism in US Navy funding, and hence ship-building, projections. The US Congressional Research Service also tabled an April 2007 research report discussing this and other Navy force structure studies.

• US Government Accountability Office (GAO-05-924T, July 28/05) –
  

Defense Acquisitions: Progress and Challenges Facing the DD (X) Surface Combatant Program [PDF]. Paul L. Francis, GAO director of acquisition and sourcing management, in testimony before the House Committee on Armed Services, Subcommittee on Projection Forces.

• US Government Accountability Office Briefing (GAO-05-924T, July 19/05) – Defense Acquisitions: Progress and Challenges Facing the DD (X) Surface Combatant Program. Paul L. Francis, GAO director of acquisition and sourcing management, in testimony before the House Committee on Armed Services, Subcommittee on Projection Forces. Includes GAO cost estimates.

• US Congressional Budget Office (Doc #6561, July 19/05) – The Navy’s DD (X) Destroyer Program [PDF]. Statement of Assistant Director for National Security J. Michael Gilmore before the House Committee on Armed Services, Subcommittee on Projection Forces. It’s worth looking at their methodology for calculating program costs, and the conclusions they’ve come to.

• US Congressional Research Service (June 24/05) – Navy DD (X) and CG (X) Programs: Background and Issues for Congress

• US Government Accountability Office (GAO-05-752R, June 14/05) – Progress of the DD (X) Destroyer Program. Report to the Senate Committee on Armed Services, Subcommittee on Seapower; and the House Committee on Armed Services, Subcommittee on Projection Forces. Discusses the state of various key technologies in the program.

News & Views

• USN All Hands (May 27/14) – An inside look at the Navy’s newest destroyer class. USS Zumwalt, with 13,800 volt power and the capacity to deliver 12MW of spare power while stealing at 30 knots.

• AOL Defense, via WayBack (Nov 12/12) – Can Navy Afford Next-Gen DDG-51 Destroyer, Packard Award Or Not? The official estimate is $2.6 billion, but the unofficial estimate is up to $3.6 billion – which may be equal to or higher than a DDG-1000.

• DID – USA: A 21st Century Maritime Posture for an Uncertain Future. Guest article by the Heritage Foundation.

• Information Dissemination (Aug 10/10) – Happy Thoughts and DDG-1000. “The real reason the Navy is dropping the VSR on DDG-1000 is because the Navy intends to put… AMDR [vid. DID article] on the DDG-1000… because the timeline works out. The thing is the Navy can’t actually say this because there is no official AMDR program yet and the DDG-1000 isn’t supposed to be a ballistic missile defense ship – remember? This story in Navy Times is what it is because when it comes to US Navy shipbuilding, the Navy under CNO Roughead is never completely honest with the American people about what the Navy is doing. Sorry if the truth hurts.”

• c|net, via WayBack (Aug 4/10) – Inside the Navy’s next-generation destroyer. A bit breathless in tone. Conveys program intent and some technical aspects, but without critical analysis.

• Ganett’s Navy Times, via WayBack (Aug 17/09) – DDG 1000 project quietly logs successes [now subscriber-only]. Updates current progress on major systems.

• Heritage Foundation, via WayBack (Oct 7/08) – Changing Course on Navy Shipbuilding: Questions Congress Should Ask Before Funding. Looks at the issue of DDG-1000 vs. DDG-51 designs.

• US Naval Institute Proceedings Magazine, via WayBack (Aug 2007) – The Navy and Its DDG-1000 – Heading Wrong [member-only]. By Captain Robert H. Smith, U.S. Navy (Retired). One can also find an excerpt in the Information Dissemination milblog’s Aug 7/07 entry: “14,500 Tons of Littoral Cruising, Invisible, Survivable, Multi-Mission Capable, NSFS, Sea Striking, Deep Reach Firepower.”

• US Joint Forces Staff College (May 15/07) – JAWS Masters Thesis by Col. Shawn Welch, USARNG: Joint and Interdependent Requirements: A Case Study in Solving the Naval Surface Fire Support Capabilities Gap. National Defense University 2007 Award for best thesis; persuasively argue that current capabilities are insufficient, casts doubt on the DDG-1000 Class as a solution, and makes a case that faulty assumptions have helped to create this problem. Includes a number of interesting anecdotes, as well as analysis:

“The history of NSFS, current national strategy, joint and service specific doctrine, current and alternative capabilities associated with providing NSFS are evaluated against current attempts to bridge NSFS gaps with naval aviation and missiles alone. This study will demonstrate a credible case for re-examining major caliber guns and the ships that mount them as part of the NSFS solution set. This thesis identifies five [5] courses of action to meet the NSFS requirements to defeat a future near-peer competitor in the littorals in a timely and affordable manner.”

• Popular Science, via WayBack (November 2006) – The Invisible Warship. Of course, the moment it begins performing naval gunfire support, triangulating its location with acoustic sensors becomes very possible. Missile firings present smaller but similar issues.

• Sea Power magazine, via WayBack (September 2006) – Integrated Fight Through Power Provides Electrical Redundancies

• DID (April 12/06) – The Lion in Winter: Government, Industry, and US Naval Shipbuilding Challenges. Lays out, and discusses, Secretary of the Navy Winter’s speech concerning the state of the Navy and its future. Money quote:

“The greater the capabilities, generally, the higher the costs – which means that the Navy can afford to buy fewer platforms. But that too drives up the cost per ship. Both factors – greater capability and lower numbers of ships – are pushing the cost of shipbuilding to prohibitive levels.”

• LA Times, via WayBack (Nov 24/05) –

SSBN Vanguard Class
(click to view larger)

The USA’s Ohio/ Henry M. Jackson Class and Britain’s Vanguard Class SSBNs (i.e. nuclear missile submarines) will begin experiencing age-related risks by the late 2010s, and military programs of this type can easily take 15-20 years from concept to fielding. The Common Missile Compartment (CMC) sub-program will help to define one of the next-generation SSBN’s most important constraints.

CMC aims to define the missile tubes and accompanying systems that would be used to launch new ballistic missiles, successors to the current Trident II/ D5 missile fleet used by the USA and Britain. Key options under consideration include a widened diameter for each tube from 2.21m – 3.04m, and the potential for flexibility beyond nuclear missiles.

Imperatives and Opportunities

Trident D5 (larger)
and C4 predecessor
(click to view larger)

The USA needs new SSBN submarines. Their existing Ohio Class boats will begin to retire at a rate of 1 hull per year, beginning in 2027, as they reach the end of their 42-year operational lifetimes. Britain, meanwhile, relies on its Vanguard fleet for the entirety of its nuclear deterrent. Their alternative to replacement involves becoming a non-nuclear power. In both cases, the first step involves a new Common Missile Compartment and Advanced Launcher for current and future nuclear missiles. Both countries have also taken the next step, and begun designing the submarines that will carry CMC.

The USA and Britain aren’t alone in their pursuits. At present, France, India, Russia, and China are all working on successor sub-launched ballistic missile systems and/or SSBN submarines.

CMC: Present and Future

Virginia Block III bow
(click to view full)

The new CMC/AL assemblies are slated for production in blocks of 4 tubes, allowing each partner to tailor the total number of missile tubes to its final submarine design. Current American Ohio Class SSBNs have 24 tubes, but SSBN-X currently plans to reduce that to 16 tubes. Britain’s current Vanguard Class has 16 tubes, but the number of tubes in its Successor Class hasn’t been set yet.

While CMC will define key constraints for America and Britain, it may also create opportunities.

One is built-in: commonality between their respective launch systems makes it easier to share changes and advances.

The other opportunity is about flexibility. There is no question that the future Common Missile Compartment will be built around the nuclear deterrence mission as its primary focus. That is unlikely to be its sole use, however, and it would not be surprising if some of those other potential uses ended up influencing the CMC’s design.

Converted Ohio class SSGNs, for instance, have already replaced nuclear missiles with American special forces, land attack missiles, and UAVs. In a similar and related vein, the Virginia Class Block III fast attack submarine replaced their 12 vertical-launch cruise missile tubes with 2 Common Weapon Launcher (CWL) “six-shooters” derived from the SSGNs’ converted missile tubes. The size of those CWLs allows Virginia Class Block III submarines to launch cruise missiles, UAVs, UUVs, and more from these same tubes.

Nuclear missile submarines are a nation’s most strategic assets, because they are its most secure and certain deterrence option. One does not commit them casually, to any purpose. As key trends like cheaper sensors and the Robotic Revolution grind onward, however, the next 40 years will see big changes in the underwater environment. SSBNs will need the flexibility to adapt and leverage these changes if they intend to survive. For the USA and Britain, the CMC needs to be part of that adaptation.

Contracts and Key Events

BAE is hiring

Unless otherwise indicated, the The US Strategic Systems Programs in Washington, DC manages the contract.

FY 2018

SSBN-X design.

SSBN-X concept
(click to view full)

November 2/18: Development Northrop Grumman is being tapped to continue development of the Common Missile Compartment (CMC). The awarded $10.8 million cost-plus incentive-fee, cost-plus-fixed-fee modification covers a number of technical engineering services; design and development engineering services; component and full scale test services and tactical underwater launcher hardware production services. The CMC will be fitted on the US future Columbia-class and UK Dreadnought-class SSBNs. The new generation of submarines will carry their Trident D5 nuclear-armed SLBMs in multiple “quad pack” Common Missile Compartments, a deliberate decision to simplify the process of building the two types of subs and hopefully save money. Nuclear missile submarines are a nation’s most strategic assets, because they are its most secure and certain deterrence option. Work will be performed at multiple location including – but not limited to – Sunnyvale, California; Kings Bay, Georgia and Barrow-In-Furness, England.

FY 2013 – 2014

April 7/14: Specifications. The US Navy has reportedly finalized the specifications for their new SSBNs. They’ll be about as long as the current Ohio Class, but with 8 fewer missile tubes (16 total). The submarines will have a new electric propulsion system, and the same kind of no-refuel reactor enjoyed by recent US boats.

The latest Navy figures reportedly estimate $110 million per boat per year in operating costs. Sources: USNI, “Navy Has Finalized Specifications for New Ohio-Replacement Boomer”.

March 31/14: GAO Report. The US GAO tables its “Assessments of Selected Weapon Programs“. Which is actually a review for 2013, plus time to compile and publish. With respect to SSBN-X, the numbers are very large: $95.103 billion total for 12 boats, split $11.718 billion RDT&E and $85.385 billion in procurement costs.

“The Navy has set initial configurations for areas including the torpedo room, bow, and stern. In 2014, the program expects to complete initial specifications, set ship length – a major milestone – and start detailed system descriptions and arrangements.”

Navy officials are trying to reduce costs for boats 2-12 from an estimated FY10$ 5.6 billion to FY10$ 4.9 billion, and one approach is to seek commonalities with the Virginia Class and the UK’s Successor SSBN. The CMC itself is already doing some of that.

ULRM
(click to view full)

Feb 28/14: Long-lead. GD Electric Boat Corp. in Groton, CT receives a $16 million cost-plus-fixed-fee modification to previously awarded contract for CMC missile tube long-lead-time materials. This contract combines purchases for the government of the United Kingdom (67%) and the US Navy (37%) under the Foreign Military Sales (FMS) Program.

All funds are committed immediately, using British FMS and USN FY 2014 RDT&E funds. Work will be performed in Groton, CT, and is scheduled to be complete by February 2016. The Supervisor of Shipbuilding Conversion and Repair in Groton, CT manages the contract (N00024-13-C-2128).

Jan 30/14: UUV launcher. A joint effort between the US Navy and General Dynamics Electric Boat is now testing a prototype Universal Launch and Recovery Module (ULRM) system that would launch and capture underwater drones from SSBN/SSGN vertical launch tubes, and from the Virginia Payload Module on forthcoming Virginia Class submarines. Diagrams show payloads up to a pair of Bluefin-21 (future SMCM mine countermeasures) UUVs, but the extend and launch method itself is adaptable to any new UUV that fits within the space.

This isn’t a development that touches the CMC directly, nor is it new. Indeed, engineer Steve Klinikowski’s idea was tabled in 2005, and a model was exhibited at DSEi 2011 in Britain. This article is particularly helpful in showing pictures of the mechanisms, and in confirming that ULRM has progressed to testing. If there was any doubt that the CMC’s tubes are likely to include payload options beyond nuclear missiles, those doubts are effectively removed. The time to contemplate those needs is right now, during the CMC’s design phase. Engineering.com Designer Edge, “Navy Begins Test of UUV Launch System” | Fox News, “Navy, Electric Boat test tube-launched underwater vehicle”.

Jan 28/14: DOT&E Testing Report. The Pentagon releases the FY 2013 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). CMC is included indirectly, as part of the “SSBN Ohio Class Replacement Program”.

SSBN-X is currently slated to include a new propulsor, a new electric drive system, and a degaussing system, all of which should make the new submarines harder to detect. The new nuclear reactor won’t require mid-life refueling, a long refit whose operational impact would have forced the USA to build 14 submarines instead of the planned 12. CMC provides the main weapons interface, and there’s currently a debate about whether to even give the SSBNs torpedo tubes. The Strategic Weapon System includes the Trident II D5 Life Extension missile, launcher, fire control, navigation systems, and associated support systems. Most of the SWS will be carried over from existing submarine classes, as will items like communications, sonar, and internal computer networks.

From September 2012 – July 2013, the Navy conducted an Early Operational Assessment (EOA) – an extensive review of Ohio and Ohio Replacement documentation to identify program risks, and a modeling and simulation study to compare the survivability of the existing and future submarine classes. The EOA did come up with some program risks, which are classified. The modeling and simulation was informative, but the acoustic and threat models need updating.

Jan 9/13: Long-lead. GD Electric Boat in Groton, CT receives a $15 million cost-plus-fixed-fee contract modification for integrated tube and hull long-lead-time material in support of the Ohio Class Replacement Program. This contract combines purchases for the US Navy (50%) and the Britain (50%).

All funds are committed immediately, using FY 2014 RDT&E budgets and UK government monies. Work will be performed in Groton, CT, and is scheduled to be complete by November 2016. The USN’s Supervisor of Shipbuilding Conversion and Repair in Groton, CT manages the contract (N00024-13-C-2128).

Dec 19/13: R&D. Lockheed Martin Space Systems Co. in Sunnyvale, CA, is being awarded a maximum $61.1 million, sole-source, cost-plus-fixed-fee contract for engineering services and various low-value missile test hardware to support CMC integration and design/development. This contract covers integration of the Trident II missile and reentry subsystems into the CMC, designing a testing fixture for nozzle shield retention, and designing an integrated test facility that will be compatible with existing and new submarine fleets. Efforts will address integration impacts to the deployed and expected future configurations of the Trident II SWS.

Work will be performed at Cape Canaveral, FL (52%); Sunnyvale, CA (33%); Magna, UT (7%); Groton, CT (2%); Titusville, FL (1%); and other locations of less than 1%, with an expected completion date of Dec 18/18.

Funding is complex, involving $57.2 million in immediate commitments from 8 different US and UK budget lines stretching from FY 2014 – 2016. The USN total is $51.5 million, while the UK commits $5.7 million. Strategic Systems Programs, Washington, DC, is the contracting activity (N00030-14-C-0013).

Dec 6/13: Support. BAE Systems Technology Solutions Inc. in Rockville, MD receives a $56.5 million cost-plus-fixed fee, cost-plus-incentive fee base year contract to support the USA and UK’s D5 strategic weapons systems (SWS) programs, U.S. guided missile submarine attack weapons systems programs, Nuclear Weapons Security, and future concepts. Services will include both research and operations-related activites. All base year funds are committed immediately, using $10.3 million from the UK, and the rest from various FY 2012-2014 USN procurement and operations budget lines. The maximum dollar value, including the base period and 2 option years, is $171.4 million.

BAE will provide coordination documentation; electrical diagrams; systems publications; shipyard installation test support; test equipment and test data analysis; support for re-engineering the SWS as appropriate in response to guidelines resulting from continuous improvement initiatives, configuration management through SSP Alterations program, logistics engineering, Preventive Maintenance Management Plan, Standard Maintenance Procedures; systems level documentation and training curriculum support; logistics planning; logistics engineering; field logistics services; network development and maintenance.

In addition, BAE Systems will provide the following products for the Common Missile Compartment (CMC) concept development effort to ensure that the existing TRIDENT II (D5) SWS is compatible with the Concept Development efforts being pursued for the CMC Program: weapon system coordination, class engineering, configuration management, logistics engineering, systems-level documentation, network development and maintenance and facility engineering and design support. They will also provide technical and engineering support to the CMC concept development efforts for SWS life cycle cost control evaluations.

Work will be performed at Rockville, MD (73%); Washington, DC (13%); Silverdale, WA (5%); St. Mary’s, GA (4%); Portsmouth, VA (3%); San Diego, CA (1%); the United Kingdom (0.6%), and Mechanicsburg, PA (0.3%). The base year will last until Sept 30/14, at which point $34.3 million in funding will expire if not used. This contract was a sole source acquisition in accordance with 10 U.S.C. 2304(c)(1) via US Strategic Systems Programs in Washington, DC (N00030-14-C-0009).

Nov 15/13: GD Electric Boat Corp. in Groton, CT receives a $28.9 million cost-plus-fixed-fee modification to previously awarded contract for procurement of missile tube integrated tube and hull weldment fabrication, missile tube assembly fixture design and manufacture, and missile tube material procurement. This contract combines purchases for the United States (71%) and the United Kingdom (29%) under the Foreign Military Sales program.

All funds are committed immediately. Work will be performed in Groton, CT, and is scheduled to be completed by November 2016. The Supervisor of Shipbuilding Conversion and Repair, Groton, CT manages the contract (N00024-13-C-2128).

Nov 14/13: CMC. GD Electric Boat Corp. in Groton, CT receives a $22.5 million cost-plus-fixed-fee modification to previously awarded contract for continued procurement of CMC prototype material for the UK, plus manufacturing and test. All funds are committed immediately.

Work will be performed in Groton, CT, and is scheduled to be complete by October 2015. The Supervisor of Shipbuilding Conversion and Repair in Groton, CT manages the contract (N00024-13-C-2128).

Jan 26/13: Electrical. TG Daily reports that the next American SSBNs will be doing away with their mechanical drivetrain, which connects the reactor turbines directly to the boat’s propellers. In order to make the boat quieter, and free up electricity for other functions, power from the reactor would flow into an all-ship electrical grid. Some of that power would be harnessed by electric motors connected to the shortened propeller shafts, and it would probably be more than the 20-25% available in more conventional nuclear designs.

This kind of “all-electric” system is becoming more and more common on naval surface ships, so its adaptation to next-generation submarines is unsurprising. Even so, the cramped, no-failure world of submarine design always adds new engineering challenges. The USN also plans to field its new SSBN submarines with reactors that don’t require mid-life refueling, something they’ve already accomplished on the Virginia Class fast attack boats.

Jan 17/13: Electric Boat Corp. in Groton, CT receives a $12.8 million cost-plus fixed-fee modification for continued CMC work, including materials and testing of the equipment that will manufacture CMCs for the USA’s Ohio Replacement Program.

Work will be performed in Steelton, PA (60%), and Spring Grove, IL (40%), and is scheduled to be completed by November 2015. All contract funds are committed immediately by the Supervisor of Shipbuilding Conversion and Repair in Groton, CT (N00024-09-C-2100).

Sub design 101
click for video

Dec 21/12: SSBN Design. Electric Boat Corp. in Groton, CT receives a $1.849 billion cost-plus-fixed-fee with special incentives contract to design America’s new class of ballistic missile submarines. GDEB will also undertake shipbuilder and vendor component and technology development; engineering integration; concept design studies; cost reduction initiatives using a design for affordability process; and full scale prototype manufacturing and assembly. Additionally, this contract provides for engineering analysis, should-cost evaluations, and technology development and integration efforts. This contract includes options which could bring the cumulative value to $1.996 billion.

Other efforts contemplated under this contract include the continued design and development of US unique Common Missile Compartment efforts; and continuing the design and development of the joint US Navy/UK CMC. About 8% of the contract involves foreign military sales to the United Kingdom.

Work will be performed in Groton, CT (91%); Newport News, VA (7%); Quonset, RI (1%); and Bath, ME (1%), and is expected to be complete by September 2017. $183.1 million is committed immediately, with the rest allocated as needed; $8 million will expire at the end of the current fiscal year, on Sept 30/13. This contract was not competitively procured in accordance with FAR 6.302-1 by US Naval Sea Systems Command in Washington, DC (N00024-13-C-2128).

Initial design for Ohio Class Replacement SSBN

Nov 20/12: Electric Boat Corp. in Groton, CT receives a $61.7 million cost-plus-fixed-fee contract modification for continued procurement of CMC prototype materials, manufacturing, and test for the Ohio Replacement Program. This contract combines purchases for the U.S. Navy (79%) and the Government of Great Britain (21%) under the Foreign Military Sales Program.

Work will be performed in Groton, CT and is expected to be completed by October 2015. $48.6 million will expire at the end of the current fiscal year, on Sept 30/13. The US Navy Supervisor of Shipbuilding Conversion and Repair in Groton, CT (N00024-09-C-2100). See also GD release.

FY 2012

TD prep. The case for the program.

Ohio class SSBN, tubes open
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Sept 28/12: TD Phase prep. Northrop Grumman Systems Corp. in Sunnyvale, CA receives a $76.8 million firm-fixed-price, fixed-price-incentive, cost-plus-incentive-fee, cost-plus-fixed-fee contract to support the Trident II fleet, which could rise as high as $111 million with options. This will include:

1) Ongoing SSBN/SSGN fleet support including engineering refueling overhaul shipyard support, spares (SSP), SSP alterations and non-compliance report projects for the USA & UK, launcher trainer support for the USA & UK, vertical support group e-mount and shims, nuclear weapons safety and security review, missile hoist overhaul, underwater launch technology support, gas generator refurbishment, and case hardware.

2) Specialized technical support includes missile tube closure production, technical engineering services, and tactical hardware production efforts for the New Strategic Arms Reduction Treaty.

3) New designs. Technical engineering services and analysis to support the USA & UK’s Advanced Launcher Development Program and Common Missile Compartment concept development and prototyping. This work will support the military’s efforts to pick a preferred system concept, including both critical costs, and clear awareness of risks from immature launcher technologies and/or immature requirements. The technology development phase for the next-generation launcher will be based on those conclusions.

The contract was not competitively procured. Work will be performed in Sunnyvale, CA (79%); Kings Bay, GA (10%); Silverdale, WA (10%); and Camarillo, CA (1%), and will run to Sept 30/15. Contract funds will not expire at the end of the current fiscal year. This contract was not competitively procure in accordance with l0 U.S.C. 2304c1, and 10 U.S.C. 2304c4 (N00030-13-C-0010).

Sept 27/12: Integration. Lockheed Martin Space Systems Co. in Sunnyvale, CA receives a sole-source $51.6 million cost-plus-fixed-fee contract for engineering efforts to support next-generation SSBN programs. The firm was deemed to be the only company that could integrate the TRIDENT II Missile and Reentry Strategic Weapon System subsystems into the CMC, and design an updated missile service unit that will be compatible with both current and new submarine fleets. With options, this contract could rise to $52.2 million.

Work will be performed in Cape Canaveral, FL (50%); Sunnyvale, CA (34%); Syracuse, NY (10%); Magna, UT (2%); Washington, DC (1%); yet to be determined locations (2%); and other locations of less than 1% (1% TL); and will run until Dec 31/17 (N00030-12-C-0058).

Sept 24/12: Program Risk. US Navy Director, Undersea Warfare Rear Adm. Barry Bruner pens a blog post about the Ohio Class Replacement Program. He defends the Navy’s vision of 12 sub marines instead of 14, with 16 tubes each instead of 24, at a target cost of $FY10 4.9 billion per hull for boats 2-12. At the same time, he acknowledges that the existing SSBN force will have a problematic period, which will become very problematic if the replacement program suffers any significant delays:

“Because ship construction of the Ohio Replacement shifted from the year 2019 to 2021, there will be fewer than 12 SSBNs from 2029 to 2042 as the Ohio-class retires and Ohio replacement ships join the fleet. During this time frame no major SSBN overhauls are planned, and a force of 10 SSBNs will support current at-sea presence requirements. However, this provides a low margin to compensate for unforeseen issues that may result in reduced SSBN availability. The reduced SSBN availability during this timeframe reinforces the importance of remaining on schedule with the Ohio Replacement program to meet future strategic commitments. As the Ohio Replacement ships begin their mid-life overhauls in 2049, 12 SSBNs will be required to offset ships conducting planned maintenance.”

If the Ohio Class Replacement Program manages to come in on time, and anywhere close to its budget, it will be a very unusual example within recent US Navy shipbuilding programs. The higher-odds bet, unfortunately, is that the USA is headed for serious problems with the readiness of its SSBN deterrent.

Sept 6/12: SSBN-X Specifications. US Navy, “Navy Signs Specification Document for the Ohio Replacement Submarine Program, Sets forth Critical Design Elements”:

“The Navy formalized key ship specifications for both the United States’ Ohio Replacement and United Kingdom’s Successor Programs in a document signed Aug. 31 at the Washington Navy Yard…. Ship specifications are critical for the design and construction of the common missile compartment, which will be used by both nations’ replacement fleet ballistic missile submarine (SSBN) programs. Specifically, the First Article Quad Pack Ship Specification establishes a common design and technical requirements for the four missile tubes and associated equipment that comprise each quad pack.”

CMC specifications

Dec 21/11: General Dynamics Electric Boat Corp. in Groton, CT receives a $191.3 million contract modification for continued engineering, technical services, concept studies, and design of a common missile compartment for the United Kingdom Successor SSBN and the Ohio replacement SSBN. This contract will be incrementally funded with $23.1 million up front, and the firm says that the FY 2009 contract could end up having a total value over $708 million, if all options are funded.

Work will be performed in Groton, CT (93%); Quonset, RI (3%); Newport News, VA (2%); and Newport, RI (2%), and is expected to be complete by December 2012. US Naval Sea Systems Command in Washington, DC (N00024-09-C-2100). See also General Dynamics.

Dec 9/11: BAE Systems in Rockville, MD receives a $58.3 million cost-plus-fixed-fee, cost-plus-incentive-fee contract to provide Systems Engineering Integration support for the TRIDENT II D5 Strategic Weapon System (SWS) Program, the SSGN Attack Weapon System (AWS) Program, and the Common Missile Compartment (CMC) Program. Options could bring the contract’s total value to $123.3 million.

Work will be performed in Rockville, MD (70%); Washington, DC (20%); St. Mary’s, GA (5%); Bangor, WA (4%); and Barrow-in-Furness, Cumbria, United Kingdom (1%), and is expected to be completed Sept 30/12, or Sept 30/13 if the options are exercised. $38.3 million will expire at the end of the current fiscal year, on Sept 30/12. This contract was not competitively procured (N00012-C-0009).

Dec 2/11: Northrop Grumman Electronic Systems – Marine Systems in Sunnyvale, CA, received an $83.2 million firm-fixed-price, cost-plus-incentive-fee, cost-plus-fixed-fee contract to provide FY 2012 support for the TRIDENT II D-5 launchers, submarines, and next-generation development efforts. This contract contains options, which could bring its total value to $123.1 million.

Northrop Grumman will provide services to help with existing SSBN/SSGN Underwater Launcher Systems; Engineering Refueling Overhaul shipyard support; spares procurement; United States and United Kingdom launcher trainer support; Vertical Support Group E-mount and shim procurement; TRIDENT II D-5 missile tube closure production; Launcher Initiation System (LIS) Critical Design Review and Nuclear Weapons Safety and Security Review; TRIDENT II D-5 missile hoist overhauls; underwater launch technology support; U.S. and U.K. Strategic Systems Programs alterations and non-compliance report projects; gas generator refurbishment and case hardware production; LIS Trainer Shipboard Systems Integration Increment 11 conversion; and ancillary hardware and spares.

Technical engineering services and container production restart efforts for the New Strategic Arms Reduction Treaty will also be included, as will technical engineering services to support the Advanced Launcher Development Program and Common Missile Compartment concept development and prototyping efforts for the U.S. and U.K.

Work will be performed in Sunnyvale, CA (80%); Bangor, WA (10%); and Kings Bay, GA (10%); and will end with the fiscal year on Sept 30/12, whereupon $45.3 million of these funds will expire; or it will end on Sept 30/14 if all options are exercised. The contract was not competitively procured (N00030-12-C-0015).

Nov 30/11: Electric Boat Corp. in Groton, CT receives a $9.5 million contract modification for continued procurement and testing of Common Missile Compartment prototype materials and manufacturing equipment.

Work will be performed in Switzerland, and is expected to be complete by December 2013. This contract combines purchases for the US Navy (50%), and the government of the United Kingdom (50%); it’s managed by the US Navy Supervisor of Shipbuilding Conversion and Repair in Groton, CT (N00024-09-C-2100).

Nov 25/11: General Dynamics Advanced Information Systems, Inc. in Pittsfield, MA receives a $96 million cost-plus-incentive-fee, cost-plus-fixed-fee, fixed-price incentive contract to provide FY 2012 and FY 2013 engineering support to United States and United Kingdom Trident II SSBN Fire Control Subsystems, Ohio Class SSGN Attack Weapons Control Subsystem, and the Common Missile Compartment. This contract contains options which could bring its total value to $225 million over almost 4.5 years.

Work will be performed in Pittsfield, MA, and could run to April 14/16. $35.1 million will expire at the end of the current fiscal year, on Sept 30/12. This contract was not competitively procured by the US Strategic Systems Programs in Washington, DC (N00030-12-C-0006). See also GD-AIS release.

Oct 18/11: No Virginia. The US Navy has reportedly shelved the idea of a Virginia Class SSBN variant (vid. July 20/11), in favor of a new and quieter SSBN design that will carry the CMC. The question is whether that stance can last, given the new design’s current estimated cost of $7 billion per boat. If those costs rise, or budgets shrink, that Navy may find itself with fewer submarine platform choices than it would like. AOL Defence

Oct 12/11: Electric Boat Corp. in Groton, CT receives a $7.1 million contract modification for preliminary design of an integrated tube and hull robotic welding system, as part of continued CMC procurement. New designs require new manufacturing techniques.

This contract action combines purchases for the U.S. Navy and the government of the United Kingdom. Work will be performed in Fort Collins, CO (48%), Knoxville, TN (32%), and Coatsville, PA (20%). Work is expected to be complete by March 2013. The USN Supervisor of Shipbuilding Conversion and Repair in Groton, CT manages the contract (N00024-09-C-2100).

FY 2011

Britain is in.

HMS Vanguard
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Aug 19/11: GD Electric Boat Corp. in Groton, CT receives a $21 million contract modification for CMC manufacturing and testing equipment, under the Ohio [Class] Replacement Program. The majority of the work will be performed in Groton, CT, and is scheduled to be complete by May 2013.The US Navy’s Supervisor of Shipbuilding Conversion and Repair in Groton, CT manages the contract (N00024-09-C-2100). GDEB’s release adds that:

“The $21 million award modifies a $76 million contract announced in December 2008… If all options are exercised and funded, the overall [2008] contract has a potential value of more than $692 million.”

July 29/11: GD Electric Boat Corp. in Groton, CT receives a $16.2 million contract modification for CMC manufacturing and testing equipment, under the Ohio [Class] Replacement Program. The majority of the work will be performed in Groton, CT, and is scheduled to be complete by August 2013. The US Navy’s Supervisor of Shipbuilding Conversion and Repair in Groton, CT manages the contract (N00024-09-C-2100).

July 20/11: Virginias? To date, the assumption in America has been that CMC would equip a newly designed SSBN submarine, and GD Electric Boat has been hiring with the idea in mind. Connecticut’s The Day now quotes vice-Adm. Cartwright, Vice-Chair of the Joint Chiefs of Staff, as saying that budget cuts may force the Navy to lengthen its Virginia Class attack submarine, in order to fit ballistic missile compartments and act as an SSBN.

By nature fast attack submarines tend to be less optimized for stealth than SSBNs, though the Virginia Class is said to be remarkable in that respect. A more challenging difference is the weight/ size gap. Ohio Class SSBNs are about 18,750 tons submerged. Britain’s Vanguard Class SSBNs are 17,800 tons, and France’s Triomphant Class SSBNs are 15,800 tons. In contrast, the basic Virginia Class is about 7,800 tons. Even with fewer missile tubes on board, finding a solution that offers an affordable extension, instead of a full submarine redesign that defeats the point of starting with the Virginia Class, will be challenging. The Day.

July 6/11: General Dynamics Electric Boat Corp. in Groton, CT receives a $15.8 million modification to previously awarded contract (N00024-09-C-2100) for continued engineering, technical services, concept studies, and design of a common missile compartment for the United Kingdom Successor SSBN and the Ohio replacement SSBN submarine.

Work will be performed in Groton, CT (93%); Quonset Point, RI (3%); Newport News, VA (2%); and Newport, RI (2%). Work is expected to be complete by December 2011. US Naval Sea Systems Command in Washington, DC manages the contract.

May 18/11: British go-ahead. Defence Secretary Dr Liam Fox announces government approval for the early phase of design to replace the existing Vanguard Class. The new submarines will be powered by a new nuclear propulsion system known as the Pressurised Water Reactor 3, which is more expensive but safer. The design phase as a whole could be worth up to GBP 3 billion.

The Initial Gate approval ensures that more detailed design work will be undertaken and long-lead items ordered, even though the main build decision for the submarines will not be taken until 2016. Under current plans, the first replacement submarine is expected in 2028. For all further coverage of Britain’s new submarines, see “New Nukes: Britain’s Next-Gen Missile Submarines“.

Britain in

Jan 6/11: General Dynamics Electric Boat Corp. in Groton, CT receives a $152 million contract modification for continued engineering, technical services, concept studies, and design of a common missile compartment for the United Kingdom successor SSBN and the Ohio-class replacement SSBN.

Work will be performed in Groton, CT (93%); Quonset, RI (3%); Newport News, VA (2%); and Newport, RI (2%), and is expected to be complete by December 2011 (N00024-09-C-2100).

FY 2008 – 2010

Initial concept studies.

USS Ohio
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June 28/10: Backward compatibility. Lockheed Martin Space Systems Co. in Sunnyvale, CA received a $29.7 million sole source cost-plus-fixed-fee contract for systems engineering services, to help integrate current Trident D5 nuclear missiles into the new submarine’s common missile compartment.

Work will be performed in Sunnyvale, CA (53.38%); Cape Canaveral, FL (40.02%); Magna, Utah (3.54%); Groton, CT (1.55%); Olathe, KS (0.67%); Melbourne, FL (0.50%); Bangor, WA (0.27%); Dallas, TX (0.03%); and Port Washington, NY (0.01%). Work is expected to be complete by the end of FY 2011, on Sept 30/11. The US Strategic Systems Programs in Arlington, VA issued the contract (N00030-10-C-0043).

June 16/10: Northrop Grumman receives a $148.6 million sole-source cost-plus-fixed-fee contract to work on the CMC’s advanced launcher development program for FY 2010-2011. Specific efforts include technical engineering services to support the common missile compartment concept development and prototyping effort.

Work will be performed in Sunnyvale, CA from June 16/10 through June 15/11, with an additional one-year option to June 15/12. The Navy Strategic Systems Programs (SSP) in Arlington, VA manages this contract (N00030-10-C-0024).

May 6/10: General Dynamics Electric Boat Corp. in Groton, CT received a $6.4 million contract modification to design special tooling for the CMC. The award modifies a $76 million contract announced in December 2008 (see Dec 23/08 entry) for engineering, technical services, concept studies and design of the CMC for the United Kingdom Successor SSBN and the Ohio Replacement SSBN. If all options are exercised and funded, the overall contract (N00024-09-C-2100) would have a value of more than $638 million.

Feb 16/10: General Dynamics Electric Boat Corp. in Groton, CT received an $26.3 million modification to a previously awarded contract (N00024-09-C-2100) for continued procurement of common missile compartment prototype material, as well as manufacturing and testing activities for the United Kingdom Successor SSBN and the Ohio Replacement SSBN. Work will be performed in Groton, Conn., and is expected to be complete by January 2012. The Naval Sea Systems Command in Washington, DC manages the contract.

The award modifies a $76 million contract announced in December 2008 for engineering, technical services, concept studies and design for the CMC (see Dec 23/08 entry) If all options are exercised and funded, the overall contract would have a value of more than $630 million. GDEB release.

Jan 21/10: General Dynamics Electric Boat Corp. in Groton, CT received an $118.2 million modification to a previously awarded contract (N00024-09-C-2100), exercising options for continued engineering, technical services, concept studies and design of a common missile compartment for the United Kingdom Successor SSBN and the Ohio Replacement SSBN. Work will be performed in Groton, CT (89%); Newport News, VA (7%); Quonset, RI (3%); and Newport, RI (1%), and is expected to be complete by December 2010. The Naval Sea Systems Command in Washington, DC manages the contract.

This modification exercises an existing option that provides for continuation of CMC design, CMC concept studies, ship concept studies, engineering, and technical services, and whole ship integration engineering and concept studies to determine key ship attributes that impact CMC design. Additionally, this contract action will support completion of studies and design work including completion of a preliminary design review, a missile tube critical design review, and a missile module critical design review. See also GDEB release.

Sept 28/09: General Dynamics Advanced Information Systems in Pittsfield, MA receives a $152.8 million cost-plus-incentive fee contract, with 2 parts to it. General Dynamics will perform the work in Pittsfield, MA, and expects to complete it by December 2012. The US Navy’s Strategic Systems Programs in Arlington, VA manages the contract (N00030-10-C-0005).

One part provides for FY 2010 and FY 2011 production and deployed systems support for the US and UK SSBN fire control system (FCS) and the SSGN Attack Weapon Control System (AWCS). GD AIS will provide annual and other periodic procurements of support equipment and SSP alterations (SPALTs) necessary to sustain the SSBN FCS and the SSGN AWCS, including engineering support, performance evaluation, logistics, fleet documentation, reliability maintenance, engineering services, and training.

In addition, this contract includes the FY 2010 and FY 2011 US and UK Sea Based Strategic Deterrent (SBSD) Strategic Weapons System (SWS) fire control subsystem efforts necessary for the concept development, prototyping, and initial design efforts for a common missile compartment (CMC), prior to and following, the initiation of a ACAT 1D class program to replace the SSBN Ohio class. This part of the contract will provide technical and engineering support to the CMC concept development efforts for SWS life cycle cost control evaluations, related to the fire control subsystem, and verify the operational and ongoing sustainment requirements for the SSBN FCS and SSGN AWCS, including training, support, and advanced development laboratory equipment.

March 17/09: British Prime Minister Gordon Brown says that Britain’s next class of SSBN missile submarines will carry just 12 launch tubes, instead of the current Vanguard Class’ 16, or the 24 tubes on American Ohio class boats. Jane’s report.

Dec 23/08: General Dynamics Electric Boat Corporation, Groton, CT receives a $75.6 million sole-source, cost plus fixed fee contract to perform concept studies and design of a Common Missile Compartment (CMC) for the United Kingdom Successor SSBN and the USA’s Ohio Class Replacement program. This contract includes options which would bring the cumulative value of this contract to $591.8 million, and take design work to December 2013.

Work will be performed in Groton, CT (92%), Newport News, VA (4%), Quonset, RI (3%), and Newport, RI (1%), and is expected to be complete by December 2009 for the base contract, and December 2013 if all options are exercised. This contract was not competitively procured, and is formally run through the Naval Sea Systems Command, Washington, DC (N00024-09-C-2100). At present, this contract involves Foreign Military Sales to the United Kingdom (100%), but that may change.

Initial concept studies

Additional Readings

• DID – New Nukes: Britain’s Next-Gen Missile Submarines

• Defense One (April 30/14) – Funding to Replace Nuclear Subs Up in the Air. It may be moved outside the Navy shipbuilding budget, as a national strategic item.

• Defense Tech (Oct 24/13) – Ohio Replacement Submarine Starts Early Construction

Tag: ssbncmc, cmcssbn

IqAF 350-ISR
(click to view full)

In recent wars, a lot of high tech gear has been upstaged by a surprising contender. Countries like the USA, Canada, Britain, Egypt, Iraq, and others are flying low-end turboprop business aircraft fitted with an array of sensors and a small crew. They’re cheap to buy, don’t use technology that makes export approval difficult, and are easy to maintain. Operating them is well within the capabilities of any country with an air force. Their sensors also offer more diversity and power than all but the highest-cost UAVs, in exchange for having just 1/2 to 1/3 of a high-end UAV’s mission endurance. No wonder many countries see them as a good complement to, or substitute for, existing UAV offerings.

Saudi Arabia has the money and clout to buy the expensive stuff. Nevertheless…

Contracts & Key Events

350 ISR layout
(click to view full)

A number of years ago, the Saudis had 3 of their military’s Boeing 707 derivatives converted into RE-3 TASS planes that perform light battlefield surveillance, as well as COMINT/SIGINT roles intercepting enemy communications and electronic signals. Unfortunately, those planes will be in the shop until 2015. They need a quick substitute that will still be useful when the RE-3s come back. It turns out that the substitution won’t be very quick after all, but their new planes will still be useful.

November 2/18: Sierra Nevada will upgrade two aircraft as part of the Saudi King Air 350 program. The company will add an intelligence, surveillance, reconnaissance/synthetic aperture radar capability to the two King Air 350 extended range aircraft. The twin-propeller King Air 350 is an affordable, long-endurance option for effective manned battlefield surveillance and attack. US aircraft in their ISR configuration are equipped with signals intelligence (SIGINT) electronic interception capabilities, and carry L-3 Westar’s MX-15i surveillance turrets. One transportable ground station; one fixed ground station; and one mission system trainer are also included in the contract. The definitization modification is priced at $23.8 million and involves 100% foreign military sales to Saudi Arabia. Work will be performed at Sierra Nevada’s facility in Hagerstown, Maryland and is expected to be completed by May 2020.

April 4/16: Sierra Nevada Corp. has been awarded a $71.4 million contract to participate in the Saudi King Air 350 program. The contract includes modification of two King Air 350 extended range (KA350ER) aircraft with intelligence, surveillance, reconnaissance/synthetic aperture radar (ISR/SAR) capability, one transportable ground station, one fixed ground station and one mission system trainer. Completion of the contract is expected for April 2020.

Aug 21/14: L-3 Communications’ Integrated Systems Group in Greenville, TX receives a $61 million firm-fixed-price, undefinitized contract to modify 2 King Air 350s, and integrate intelligence surveillance and reconnaissance capabilities. $30 million is committed immediately, and the price suggests that L-3 will also buy the planes from Beechcraft.

Work will be performed at Greenville, TX and is expected to be complete by Dec 31/15. The USAF Life Cycle Management Center at Wright-Patterson AFB< OH manages the contract on behalf of its Saudi client (FA8620-14-C-4023).

2 ordered

Aug 15/12: The US DSCA announces [PDF] an official request from the Kingdom of Saudi Arabia (KSA). The Saudis want to buy:

• Intelligence, Surveillance, and Reconnaissance (ISR) suites to be provided and installed in 4 King Air 350ER aircraft, which the Saudis themselves will provide.
  
• 4 new King Air 350ER ISR planes with enhanced PT6A-67A engines and the same ISR suites pre-installed.
  
• 10 Link-16 capable data link systems and associated ground support.
  
• Ground Stations for processing the data.
  
• Plus spare and repair parts, support equipment, publications and technical data, personnel training and training equipment, aircraft delivery, and other forms of U.S. Government and contractor support.

Each ISR suite includes:

• A modern, fully qualified CNS/ATM cockpit.
  
• RF-7800M-MP High Frequency Radios with encryption.
  
• AN/ARC-210 VHF/ UHF/ Satellite Communication Transceiver Radios with Have Quick II and encryption.
  
• A high speed Datalink.
  
• An AN/APX-114/119 Identification Friend or Foe Transponder.
  
• Embedded Global Positioning System/Inertial Navigations Systems (GPS/INS) with a Selective Availability Anti-spoofing Module (SAASM) to make jamming difficult.
  
• AN/AAR-60 Infrared Missile Warning and AN/ALE-47 Countermeasures defensive systems.
  
• An unspecified Electro-Optical Sensor.
  
• An unspecified SIGINT(SIGnals Intelligence) System.
  
• An unspecified Synthetic Aperture Radar to scan the ground.

The estimated cost is up to $257 million, but contract prices will depend on successful contract negotiations. As the DSCA puts it:

“The RSAF needs additional ISR capability to provide persistent, real-time route surveillance, facility, infrastructure and border security, counter-terrorism and smuggling interdiction, support for naval and coastal operations, internal defense and search and rescue operations. Currently, the RSAF’s RE-3 aircraft is in depot maintenance and will not be available until after 2015. In the interim, the King AIR 350ER-ISR aircraft will allow the RSAF to perform a portion of the RE-3 mission. All systems will be compatible with and will continue to supplement the capabilities of the RSAF RE-3 aircraft. The KSA will have no difficulties absorbing and using these King Air ISR aircraft.”

DSCA request: 4 King Air 350ER ISR

Americas

South Korea is equipping three of its guided missile destroyers with a new Aegis combat system. The foreign military sales contract between Lockheed Martin and South Korea is priced at $365.7 million. Lockheed Martin will provide the Republic of Korea Navy with development and integration of the weapon system in its Baseline K2 configuration. The Aegis Combat System manages all combat essential elements on Arleigh-Burke and Ticonderoga-class ships and ensures that the missile launching element, the computer programs, the radar and the displays are fully integrated to work together. The contract covers services such as combat system installation, including staging and integrated logistics support required for the installation; program management, system engineering and computer program development; ship integration and testing; technical manuals and planned maintenance system documentation. Work will be performed at multiple national and international locations, including Moorestown, New Jersey and Ulsan, South Korea. Work on all three vessels is expected to be completed by July 2026.

Boeing is being contracted to supply multiple US foreign military sales customers with anti-ship missiles. The $244.7 million not-to-exceed, firm-fixed-price contract enables the company to procure long lead material for the Harpoon full-rate production Lot 91. The Harpoon Block II is an over-the-horizon, anti-ship missile capable of performing land-strike and anti-ship missions. The missile leverages progress on several other weapons to reduce its cost. The Harpoon’s GPS/INS guidance system is taken from Boeing’s JDAM program, and its GPS antennae and software are found on Boeing’s SLAM. The missile’s 500 pound blast warhead can deliver lethal firepower against targets like coastal missile batteries and ships in port. Work will be performed at multiple locations including – but not limited to – St. Charles, Missouri, Galena, Kansas and Elkton, Maryland.

The Air Force is upgrading the refuelling system for its C-17 Globemaster III short field, heavy-lift transport jets. Bodell Construction will construct the refueling hydrants and ramp expansion at a cost of $20.3 million. A hydrant system is a loop of pipeline located under the aircraft parking ramp that delivers fuel straight from the hydrant fuel tanks to the aircraft. A mobile pantograph allows for continuous fuel delivery to aircraft within 135 feet of a hydrant pit. With the hydrant system about 420 gallons a minute can be transferred to the C-17, which reduces the overall refueling time by half, compared to the current truck refueling method. Work will be performed in Charlotte, North Carolina and is expected to be completed by December 2020.

Middle East & Africa

Israel’s defense industry can expect a major influx of Boeing investments. The aerospace giant signed a “reciprocal procurement” agreement on Tuesday, that calls for Boeing to collaborate with Israeli industry to the value of at least 35% of all government deals exceeding $1 million. As Israel is expecting to award Boeing with contracts totalling at $10 billion over the next decade, the agreement could possibly add $3.5 billion in new business to Israel’s economy. “A reciprocal purchase agreement on such a scale is a significant achievement which will lead to the growth of many companies in the domestic market, and to expand their activities and success in international markets,” said Economy Minister Eli Cohen. Boeing is currently competing for a number of Israeli defense procurement contracts, including new F-15 fighter aircraft, aerial tankers and a squadron of transport helicopters.

Europe

The German air force will soon test a new passive radar system in the country’s southern province of Bavaria. During the week-long test German electronics specialist Hensoldt will deploy three of its newly developed TwInvis systems in the Munich area and one roughly 70 miles west, near the city of Ulm. The TwInvis system uses the signal echoes of existing third-party transmitters to detect and track aircraft. According to the company the one radar unit can monitor up to 200 aircraft in 3D within a radius of 250 kilometers. Passive radars have the advantage that they cannot be located by the enemy and are very hard to jam, however to properly function the radars are dependent on a sufficiently strong commercial broadcast activity in the targeted area. The company first unveiled the TwInvis passive radar system at the Berlin Air Show in April, where it was rumored as a technology with the potential to detect stealthy aircraft like the F-35.

Asia-Pacific

India’s Coast Guard (ICG) is upgrading its fleet of maritime reconnaissance aircraft (MRA). The upcoming mid-life upgrade of the 17 licence-built Dornier Do-228s is expected to cost about $129 million. The aircraft will help the ICG to monitor the country’s 3,370 mile long coastline and over 77,000+ square miles of India’s Exclusive Economic Zone. According to the Defence Acquisition Council (DAC) the aircraft will be fitted with “state-of-the-art technology” and Pollution Surveillance Systems. Primary contractor will be India’s state-owned Hindustan Aeronautics Limited (HAL) which acquired the production licence of Do-228s in 1986.

KBRwyle Technology Solutions is being contracted to support the US Army’s Prepositioned Stock Four (APS-4) located in South Korea. The $14.8 million contract modification covers the provision of logistics support services until November 2019. APS-4 is located in Japan and South Korea and supports the Pacific theatre with two armored battalions and one mechanized infantry battalion. The Army maintains a strategic inventory of sustainment supplies as part of Army Pre-positioned Stocks (APS). These stocks sustain forward-deployed and initial follow-on ground forces, and include major end items such as engines, repair parts, medical supplies, packaged petroleum products, barrier/construction materials, operations rations, and clothing required to sustain combat operations. The APS-4 is located at Camp Caroll near Waegwan, about 132 miles southeast of Seoul.

Today’s Video

Watch: NATO stages biggest military exercise since end of Cold War

Americas

A major component of the B61-12 nuclear bomb will now be produced at the Y-12 National Security Complex in Oak Ridge. The Complex is one of the nation’s most important national security assets. The 811 acre site contains the world’s largest stockpile of highly enriched uranium, enough to build 14.000 nuclear warheads. Y-12 is now qualified to manufacture the B61-12’s canned subassembly, which is the second stage of a modern thermonuclear weapon, and is also part of the nuclear explosives package. Y-12 Site Manager Bill Tindal said, “We are delivering a key contribution to global security through this program. I couldn’t be more proud of how all organizations pulled together to accomplish this difficult task.” The B-61 is currently undergoing a life extension program, which will consolidate four versions of the bomb into one. The nuke can be launched from B-2A, B-21, F-15E, F-16C/D, F-16 MLU, F-35 and PA-200 aircraft. Delivery of the first production unit is scheduled for March 2019.

Colonna’s Shipyard is being contracted to work on the Navy’s first Spearhead-class ship during the ship’s upcoming regular overhaul and dry docking phase. The firm-fixed-price contract is valued at $7.9 million and provides for a 67-calendar day shipyard availability. The contractor will be responsible to conduct structural inspection of the hull, perform a variety of repairs, support the main propulsion engine’s overhaul, replace heater exchangers and perform gear maintenance. The USNS Spearhead is an Expeditionary Fast Transport ship that was launched in 2011, it is designed for the fast, intra-theater transportation of troops, military vehicles and equipment with aviation support. Work will be performed at Colonna’s shipyard in Norfolk, Virginia. The Regular Overhaul availability is expected to be completed by January, 2019.

National Industries for the Blind is being awarded with a contract modification that extends a one-year base contract for the second year in a row. The modification is priced at $13.1 million and allows for the continued production for the advanced combat helmet (ACH) pad suspension system. The ACH is made of a new type of Kevlar to provide improved ballistic and impact protection. The helmets are also designed to allow an unobstructed field of view and increased ambient hearing capabilities for the wearer. Modular, flame-retardant, and moisture-resistant pads act as the suspension system between the wearer’s head and the helmet. This allows a soldier to fight more effectively when wearing body armor. Work will be performed at facilities in Virginia, Pennsylvania and North Carolina. This second option period is set to run through October 26, 2019.

Contitech is being tapped to provide the US Army with vehicle tracks for its M109 Paladin artillery system. The firm-fixed-price contract is valued at $20.1 million and will run through July 8, 2021. The M109 family of systems has been in service since 1962. The latest variant is the BAE produced Paladin M109A7 next-generation artillery system. The new variant incorporates upgrades to hull, turret, engine, and suspension systems that offer increased reliability, survivability and performance over its predecessor. The 155 mm cannon is mounted on the chassis structure common to the Bradley tracked fighting vehicle. Work will be performed at Contitech’s factory in Fairlawn, Ohio.

Middle East & Africa

Saudi Arabia may be blocked from future arms purchases as world leaders are calling on the government to provide more information on the death of journalist Jamal Khashoggi. German chancellor Angela Merkel recently said that future weapon deliveries to the Middle-Eastern nation are highly unlikely until an investigation into the journalist’s death has been carried out. The German parliament approved exports worth $416.4 million to Saudi Arabia in 2018 alone, making it Germany’s second biggest defense customer, right after Algeria. One of the largest deals in recent year included the Saudi purchase of 270 Leopard A2 Main Battle Tanks. Germany is currently calling on other countries to consider setting up bans on the sales of arms to Riyadh.

Europe

Belgian news agency, Belga reports that the country has chosen Lockheed Martin’s F-35 JSF over the Eurofighter Typhoon to replace its old fleet of F-16s. Despite the final deadline being set for October 29, government sources are confident that the US-made fighter jet will make the cut. Lockheed spokeswoman Carolyn Nelson told Reuters that “the F-35 offers transformational capability for the Belgian Air Force and, if selected, will align them with a global coalition operating the world’s most advanced aircraft.” The potential deal could also strengthen Lockheed’s position in forthcoming tenders in Switzerland, Finland and Germany. The order for jets due for delivery from 2023 is estimated to be worth $4.14 billion. European countries that currently fly the F-35 include Britain, the Netherlands, Denmark, Italy and Norway.

Jane’s reports that the Romanian Ministry of Defence is expected to soon make a decision on the procurement of new multirole corvettes. The planned acquisition program sees for the delivery of four corvettes at a cost if $1.85 billion. The new 2.500 ton-class vessels must come with capabilities across the ASW, anti-surface warfare, AAW, EW, SAR and naval gunfire support spectrum. Current bidders include Damen Schelde Naval Shipbuilding of the Netherlands, Italy’s Fincantieri, and France’s Naval Group. All bidders are currently in line with Romanian stipulations for local industry participation. The French Naval Group, has associated with local Constanta Shipyard, Dutch group Damen Shipyards, owns the Galati shipyard and is in the process of acquiring the Mangalia shipyard, Italian group Fincatieri, controls the Tulcea and Braila shipyards. The corvette program is the centrepiece of Romania’s naval modernization process that seeks to mitigate the growing Russian military threat in the Black Sea.

Asia-Pacific

India’s sole operational aircraft carrier will start sea trials by the start of next week. The INS Vikramaditya recently completed its second refitment at Cochin Shipyard, a process which cost close to $96 million. Captain Puruvir Das, the carrier’s commanding officer, told the New Indian Express “soon, we will start the sea trials, which will take place off the Kochi and Goa coasts. We are hopeful of returning to the Western Naval Command without delay.” During the refitment major work was carried out, including an extensive hull survey and repainting, as well as some large scale repair of the ship’s shaft system. “The refitment will enhance the operations of Vikramaditya. It will be ready for sea operations once the trials are completed,” added Captain Das. The Kiev-class former Russian Navy aircraft carrier has been in service since 2013 and upgrade of its infrastructure were started in September 2016.

Today’s Video

Watch: GAO: Flight Test of a B61-12 Nuclear Bomb

Austal MRV/JHSV concept
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When moving whole units, shipping is always the cheaper, higher-capacity option. Slow speed and port access are the big issues, but what if ship transit times could be cut sharply, and full-service ports weren’t necessary? After Australia led the way by using what amounted to fast car ferries for military operations, the US Army and Navy decided to give it a go. Both services leased Incat TSV/HSV wave-piercing catamaran ship designs, while the Marines’ charged ahead with very successful use of Austal’s Westpac Express high-speed catamaran. These Australian-designed ships all give commanders the ability to roll on a company with full gear and equipment (or roll on a full infantry battalion if used only as a troop transport), haul it intra-theater distances at 38 knots, then move their shallow draft safely into austere ports to roll them off.

Their successful use, and continued success on operations, attracted favorable comment and notice from all services. So favorable that the experiments have led to a $3+ billion program called the Joint High Speed Vessel. These designs may even have uses beyond simple ferrying and transport.

The JHSV Ships

Austal concept
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The design specifications established for the JHSV described an ocean-going vessel 450 feet in length or less, capable of carrying 600 short tons of cargo up to 1,200 nautical miles at a speed of 35 knots. It must also have seats for at least 312 passengers, and must be able to provide long-term berthing and galley facilities for at least 104 of those passengers in addition to the vessel’s 41 crew.

A single firm was ultimately selected to produce all planned JHSV ships, and Austal beat their rival Incat for the contract. Austal’s design ventured slightly beyond the program’s specifications. Length is just 103.0m/ 337.9 ft, with a Beam of 28.5m/ 93.5 ft, and a miniscule Draught of just 3.83m/ 12.57 ft.

The ship’s 4 Wartsalia WLD-1400-SR waterjets are powered by the same MTU 8000 class diesel engines used on Austal’s Independence Class Littoral Combat Ship, and the Hawaii Superferries. Specifically, JHSVs use 4 MTU 20V8000 M71Ls, rated at a maximum of 9.1 MW each. These engines and waterjets can push the ships to the required 35 knots at full cargo load, or 43 knots unloaded.

Austal’s design offers embarked troop berthing for 150 (104 permanent, 46 temporary) that can support 14 days of operations. Alternatively, airline-style seating for 354 troops, in addition to the crew of 41, allows the ship to support 96 hours of operations. Cargo capacity is up to 700 short tons/ 635 metric tons, in a usable cargo area 1863 m2/ 20,053 ft2, with a clear height of 4.75m and a turning diameter of 26.21m. The cargo area also has 6 ISO TEU (20′ ISO container) interface panels, for containers that need power. The Austere Loading Ramp Arrangement can support vehicles up to 70 ton M1A2 Abrams tanks, per requirements, and a telescoping boom crane can lift 18.2 metric tons at 10m, dropping to 12.3 metric tons at 15m.

The ship is required to be able to transport 600 short tons of troops, supplies, and equipment 1,200 nautical miles at an average speed of 35 knots, through wave height of up to 4 feet. It won’t quite manage that, in part because its 12.5 short tons overweight. Required range will also suffer a bit at 23 knots cruise speed (4,018 nmi vs. 4,700 nmi).

The JHSV’s flight deck can support all current Navy helicopters up to and including the Marines’ current med/heavy CH-53E Super Stallion, and Vertical Replenishment has been tested using a tilt-rotor MV-22 Osprey. Flight operations will be handled by Kongsberg Maritime’s night-capable Helicopter Operations Surveillance System (HOSS).

HSV-2 Swift, frontal
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As NAVSEA noted:

“[JHSV] will be capable of transporting Army and Marine Corps company-sized units with their vehicles, or reconfigure to become a troop transport for an infantry battalion. Its 35-45 nautical miles per hour speed allows for rapid deployment and maneuver of conventional or special operations forces.

The JHSV will not be a combatant vessel. Its construction will be similar to high-speed commercial ferries used around the world, and the design will include a flight deck and an off-load ramp which can be lowered on a pier or quay wall – allowing vehicles to quickly drive off the ship.

JHSV testing

JHSV’s shallow draft will allow it access to small austere ports common in developing countries. This makes the JHSV an extremely flexible asset ideal for three types of missions: support of relief operations in small or damaged ports; as a flexible logistics support vessel for the Joint Commander; or as the key enabler for rapid transport of a Marine Light Armored Reconnaissance Company or an Army Stryker unit.”

It has taken time, but the US military is beginning to expand its thinking beyond these obvious applications, and begin thinking about ways to employ the JHSV’s vast internal space and mobility in front-line missions. The most dramatic example may involve mounting a 32MJ railgun on USNS Millinocket [JHSV 3] in 2016.

The JHSV Program

Incat JHSV concept – lost
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The Joint High Speed Vessel’s Initial Capability Document received approval from the Department of Defense Joint Requirements Oversight Council on Nov 1/05, with all 4 military services concurring. The initial goal was 5 Army vessels, and 3 Navy vessels, for a program worth about $1.6 billion, but the Navy’s interest has continued to grow. The contract signed in November 2008 called for up to 10 ships, split evenly between the Army and Navy. An initial Memorandum of Agreement (MOA) allowed the U.S. Navy to use its surface ship acquisition expertise to buy these vessels on the Army’s behalf, with Army participation – until program changes moved all of these ships to the Navy’s procurement budget and operation.

All of the JHSVs were then transferred to Maritime Sealift Command under a May 2011 agreement. The first 4 / 10 projected vessels will be crewed by civil service mariners. JHSV 5-10 are slated to be crewed by contracted civilian mariners working for a private company. Military mission personnel will embark with either set, as required by mission sponsors. The goal was for JHSV to achieve Initial Operational Capability in 2012, and JHSV 1 just made it.

All ordered JHSV ships have been named now, and ships with the USNS listing have been delivered to US Military Sealift Command:

• JHSV 1 USNS Spearhead (has deployed)
  
• JHSV 2 USNS Choctaw County (accepted)
  
• JHSV 3 USNS Millinocket
  
• JHSV 4 USNS Fall River
  
• JHSV 5 Trenton Resolute
  
• JHSV 6 Brunswick
  
• JHSV 7 Carson City Courageous
  
• JHSV 8 Yuma
  
• JHSV 9 Bismarck (North Dakota, not Otto von) Sacrifice
  
• JHSV 10 Burlington

• HSV USNS Guam (ex-Huakai)
  
• HSV USNS Puerto Rico (ex-Alakai)

The Pentagon’s April 2011 Selected Acquisition Report placed the program at 18 ships, and its total cost at about $FY08 3.5 billion. That changed as FY 2013 budget plans cut all ships beyond the 10 in the current contract, and the US Navy is negotiating over cancellation of its JHSV 10 contract due to sequestration cuts. Annual budgets to date have included:

FY 2008: $231.9 million, 1 ship funded.
Navy: $18.4M RDT&E
Army: $5M RDT&E, $208.6M production, 1 ship

FY 2009: $364.2 million, 2 ships funded.
Navy: $11.6M RDT&E, $181.3M production, 1 ship
Army: $3.0M RDT&E, $168.3M production, 1 ship

FY 2010: $391.1 million, 2 ships funded
Navy: $8.2M RDT&E, $202.5M production, 1 ship
Army: $3.0M RDT&E, $177.4M production, 1 ship

FY 2011: $390.1 million, 2 ships funded.
Navy: $3.5M RDT&E, $203.9M production, 1 ship
Army: $3.0M RDT&E, $179.7M production, 1 ship

FY 2012: $376.4 million, 2 ships funded.
Navy: $4.1M RDT&E, $372.3M production, 2 ships

FY 2013 request: $376.4 million, 1 ship funded.
Navy: $1.9M RDT&E, $189.2M production, 10th & final ship

Note that advance materials purchases for future years are included in each year’s procurement budgets. After FY 2013, JHSV budgets are very small, reflecting only minor post-shakedown work.

Supplements: From Leased to Bought

Hawaii Superferry
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At present, 1 leased vessel remains in military service, following the end of Incat’s HSV-2 Swift lease. Austal’s HSV 4676 Westpac Express catamaran continues to serve in Military Sealift Command in the Pacific around Guam and Japan, working closely with the Marine Corps as a troop and cargo transport.

HSV-2 Swift’s influence lives on in the JHSV concept of operations. The ship had supported relief operations in Indonesia post-tsunami, and in the Gulf Coast region following hurricane Katrina. In both cases, Swift’s high speed and shallow draft combined to make it an ideal platform for the delivery of relief supplies and support of other platforms operating in the area. During operations following Katrina, Swift was able to use ports that were inaccessible to other ships of the logistics force. It has also been a platform for UAV and aerostat experiments.

It’s likely that both charters will soon be replaced, thanks to a recently-purchased alternative with many similarities to the JHSV.

After its ferry service was forced into bankruptcy by environmental lawfare, the Hawaii Superferries Huakai and Alakai were pressed into service by their main creditor: the US Department of Transportation’s Maritime Administration (MARAD). They were called into service in the wake of the 2010 Haiti earthquake, and these Austal-built ships were very successful in that role. Both ferries were ultimately bought by the US Navy in 2011, for just $35 million. Once their $35 million conversions are done, they’re likely to replace Westpac Express and Swift as USNS Guam (ex-Huakai) and USNS Puerto Rico (ex-Alakai, slightly smaller). The superferries will offer more troop-carrying berths than their similar JHSV counterparts, in exchange for less military flexibility.

USNS Guam is expected to relieve Westpac Express in the Pacific some time in FY 2015.

Contracts & Key Events FY 2014-2018

JHSV 1 passes trials & deploys; JHSV 3 passes acceptance trials; JHSV 4 launched.

JHSV 1 deploys
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October 24/18: EPF-1 ROH Colonna’s Shipyard is being contracted to work on the Navy’s first Spearhead-class ship during the ship’s upcoming regular overhaul and dry docking phase. The firm-fixed-price contract is valued at $7.9 million and provides for a 67-calendar day shipyard availability. The contractor will be responsible to conduct structural inspection of the hull, perform a variety of repairs, support the main propulsion engine’s overhaul, replace heater exchangers and perform gear maintenance. The USNS Spearhead is an Expeditionary Fast Transport ship that was launched in 2011, it is designed for the fast, intra-theater transportation of troops, military vehicles and equipment with aviation support. Work will be performed at Colonna’s shipyard in Norfolk, Virginia. The Regular Overhaul availability is expected to be completed by January, 2019.

October 22/18: EPF-13 Austal is being tapped to start building the Navy’s next Expeditionary Fast Transport (EPF) ship. The undefinitized contract action is valued at $57.8 million and allows for the procurement of long-lead-time material and production engineering services. The Spearhead-class vessels are designed for the fast, intra-theater transportation of troops, military vehicles and equipment with aviation support. Bridging the gap between low-speed sealift and high-speed airlift, EPFs transport personnel, equipment and supplies over operational distances with access to littoral offload points including austere, minor and degraded ports often found in developing countries. The vessels are able to transport 600 short tons of military equipment to a range of 1.200 nautical miles at speeds of up to 35 knots. Work will be performed at multiple locations, including – but not limited to – Novi, Michigan; Mobile, Alabama and Rhinelander, Wisconsin. The US Navy’s 13th EPF is expected to be completed by November 2021.

February 28/18: Christening Ceremony The US Navy has christened its latest Spearhead-class expeditionary fast transport, the USNS Burlington, during a ceremony in Mobile, Alabama, on Saturday. It is the tenth of 12 Expeditionary Fast Transports being built for the Navy at a cost of $1.9 billion. Overseeing the event were the ship’s primary sponsors US Senator Patrick Leahy and his wife Marcelle Pomerleau. Marcelle Leahy said naming the ship after the Vermont city of Burlington was “fitting because Vermonters have long heeded the nation’s call to service.” Built by Austal USA, the vessel is designed to transport troops and equipment at high-speeds and in shallow waters for rapid deployment. The Navy says it can “carry 600 short tons of military cargo for 1,200 nautical miles, at an average speed of 35 knots.” This equates to the Burlington being able to carry 1,200,000 pounds for 1,380 miles at an average speed of 40 mph. It also has a flight deck for helicopter operations and an off-loading ramp for disembarkment missions.

Sept 26/14: Naming. “Secretary of the Navy Ray Mabus announced the next joint high speed vessel (JHSV) will be named USNS Trenton during a ceremony in Trenton, New Jersey, Sept. 25.” Um, OK. Trenton, which is still under construction, was publicly named by the Secretary of the Navy on April 12/13 (q.v.) Sources: US Navy, “SECNAV Names the Next Joint High Speed Vessel”.

Sept 16/14: #4 delivered. Austal delivers USNS Fall River to US Military Sealift Command. Construction update:

“Preparations are underway for the launch of Trenton (JHSV 5) later this month with construction on Brunswick (JHSV 6) progressing well. Metal cutting began for Carson City (JHSV 7) in early September.”

Sources: Austal, “Austal Delivers Fourth Joint High Speed Vessel”.

USNS Fall River

June 13/14: Aerostat zapped. From US Naval Forces Southern Command:

“During routine testing off the coast of Key West, the Aerostat tethered off the Joint High Speed Vessel USNS Spearhead (JHSV-1) was struck by lightning at 12:21 in the morning, June 12…. The lightning strike caused the Aerostat to deflate and land in the water. Response efforts were delayed as the thunderstorm moved into the area. The Aerostat was subsequently sunk so to pose no hazard to other vessels or navigation.”

Aerostats are tethered blimps, used to dramatically expand a JHSV’s field of view (q.v. April 27/13). This can be very useful for survey and interdict deployments like Operation Martillo (q.v. March 31/14). Sources: US Navy, “USNAVSO/US 4th Fleet Statement regarding AEROSTAT”.

May 20/14: JHSV 3. USNS Millinocket will become the 1st JHSV deployed to the far east, where it will operate alongside the leased ship Westpac Express [HSV-4676] and the former Hawaii Superferry USNS Guam [HST-1].

MSC’s JHSV project officer Mike Souza says that USNS Millinocket is preparing for a move to San Diego, CA. She’ll serve as a display platform for the two EM Railgun prototypes during the May 26/14 International Symposium on Electromagnetic Launch Technology in La Jolla, CA. Some final post-delivery tests and trials will follow, including some interface testing with a Mobile Landing Platform ship. Once the post shakedown availability trials and fixes are done, Millinocket head to an unspecified new homeport in the Far East. Sources: Seapower, “Millinocket Will Be the First JHSV in Westpac”.

April 7/14: Experiment: Railgun. The US Navy plans to use JHSV 3 Millinocket as a test platform for one of its newest weapons in 2016: a 32MJ rail gun that can fire projectiles about 100 miles at Mach 7 speeds. JHSV was picked as the trial platform because it has the space to carry the large system on its deck and in its cargo bay. The gun itself isn’t unusually large, but once you throw in the capacitors for power storage, any additional power needs, extensive maintenance tools and parts, and ammunition, it adds up fast. Rolling and bolting that onto a JHSV is much easier than using any warship, and the trial underscores JHSV’s usefulness as a concept testbed.

On the weapon’s side of the equation, ONR Chief Rear Admiral Matthew Klunder touts the railgun’s economic benefit, as well as its military edge in extending the bombardment range of naval guns and the number of rounds on board. It’s true that $25,000 for a defensive railgun shot against incoming missiles is orders of magnitude better than a RIM-116 RAM ($900,000) or RIM-162 Evolved SeaSparrow Missile ($1.5 million), assuming the unproven assumption of equal effectiveness. One must also compute operating and maintenance costs over the railgun’s lifetime, however, which are going to be far higher than they would be for an All-Up-Round missile in its canister. The JHSV tests will offer some early data re: the gun’s robustness under trial conditions at sea, and that cost data point could end up being as valuable as any performance data. Sources: Reuters, “U.S. Navy to test futuristic, super-fast gun at sea in 2016”.

March 31/14: Operations. USNS Spearhead [JHSV 1] is preparing for a 2nd deployment, this time to the 4th Fleet’s waters around the Caribbean and South America. The US military is taking cautious steps to expand JHSV uses, and is explicitly following in the footsteps of HSV-2 Swift’s 2013 deployment. It’s well short of full innovation toward mothership roles, but still a step forward.

These extensions still have JHSV 1 operating primarily in a ferry capacity, with “adaptive force packages.” They’ll be carrying the USMC’s 4th Law Enforcement Battalion and equipment to the Dominican Republic. After the Marines are ferried back to Florida, a trip to Belize will involve a Navy Seabee explosive ordnance disposal detachment, and a riverine crew. From Belize, a a mobile diving and salvage unit and an explosive ordnance disposal team will be ferried from Guatemala to Colombia, before all of the units that were in Guatemala and Columbia end up ferried to Honduras.

In between, USNS Spearhead will “conduct detection and monitoring activities” in support of the multinational anti-drug Operation Martillo. Spearhead’s exact role isn’t made clear, but Spearhead works well with helicopters, Swift has shown that UAVs can be used from these ships, and it would be possible to have boarding teams embarked. Sources: US Navy, “Plans Finalized for USNS Spearhead’s Deployment to 4th Fleet AOR”.

March 21/14: #3 delivered. Austal delivers USNS Millinocket to US Military Sealift Command. They add that:

“Ships currently under construction are JHSV 4, which was christened in January and is being prepared for sea trials, JHSV 5, which has begun final assembly, and JHSV 6, which commenced construction in January in the module manufacturing facility. Five Independence-variant Littoral Combat Ships are also in construction at Austal’s US shipyard…”

Sources: Austal, “Austal Delivers Third Joint High Speed Vessel” | GD-AIS, “Austal Delivers USNS Millinocket (JHSV 3)”.

USNS Millinocket

March 10/14: JHSV 5. Trenton’s keel is formally laid. Sources: Austal USA, “Austal Commemorates Keel Laying for Trenton (JHSV 5)”.

Jan 28/14: DOT&E Testing Report. The Pentagon releases the FY 2013 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). JHSV will be able to carry 354 passengers for 96 hours, which is better than the required 312, but it’s overweight by 12.5 tons, and will fall short of required ranges at 23 knots (4,018 nmi vs. 4,700) and 35 knots (won’t make 1,200 nmi) transit speed. The extra weight amounts to about 4% fuel load, or 3,565 gallons.

Overall testing results have been positive. Loading tests demonstrated suitability up to M-1A2 tank loading onto a floating causeway. If the ships need replenishment at sea, both USNS Spearhead and USNS Choctaw County have successfully conducted fuel-only underway replenishments. For other supplies, vertical replenishment tests have included an MH-60S helicopter at night, and MV-22 Osprey tilt-rotos by day, and Aircraft Dynamic Interface testing has included MH-53E Minehunting helicopters. DOT&E says that “manning and facilities can accommodate handling of all required helicopters, with the exception of fuel and power.” Finally, DOR&E says that with an embarked security team and weapons, JHSV can engage a moving surface threat. The bad news, aside from ship range?

“The JHSV’s organic container load trailer is not effective for loading 20-foot long metal storage containers. During the IOT&E, the test team took five hours to connect the container load trailer with a storage container and failed to load it…”

Jan 17/14: JHSV 4. Fall River is launched at Austal’s Mobile, AL shipyard, after a side trip to BAE. Instead of moving down a slipway, launches are now float-off affairs from a BAE floating drydock. Getting to the drydock requires a transfer onto a barge, using Berard Transportation rollers. The ship was christened on Jan 11/14, and will be formally delivered to the USN later in 2014, after final fitting out. Austal adds that:

“Three JHSVs and four LCSs are currently under construction in Austal’s Mobile, Alabama shipyard. Austal will begin production of one more ship in each program before the end of January.”

Sources: Austal, “Austal Launches USNS Fall River (JHSV 4)” and “USNS Fall River (JHSV 4) Christened – One of seven Navy vessels currently under construction at Austal USA”.

Jan 16/14: JHSV 1 deploys. Operational use of the JHSV fleet begins with USNS Spearhead’s deployment from NAB Little Creek. She’ll head to “the US 6th Fleet Area of Responsibility” (Africa) until May 2014, then on to the 4th Fleet AOR (Central & South America) until December 2014. Sources: USN, “USNS Spearhead departs on Maiden Deployment”.

1st deployment

Jan 9/14: JHSV 3. USNS Millinocket successfully completes Navy Acceptance Trials in the Gulf of Mexico. Formal delivery is expected in late January. Sources: MarineLog, “JHSV 3 completes Acceptance Trials”.

Oct 8/13: JHSV 1. USNS Spearhead has successfully completed initial operational testing and evaluation with the US Navy. Sources: Austal, “JHSV 1 successfully completes US Navy operational testing”.

FY 2013

JHSV 10 bought, but Navy wants to cancel it over sequestration; JHSV 1 & 2 delivered; JHSV 3 launched; Keel-laying for JHSV 4; Aerostat experiment.

JHSV 2 Launch
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July 31 – Aug 6/13: Testing. USS Spearhead completes Initial Operational Test and Evaluation and Total Ship Survivability Trials, thanks to about 280 Marines from 1st Battalion/ 2nd Marine Regiment/ 2nd Light Armored Reconnaissance Battalion, and 2nd Assault Amphibian Battalion. The Marines embarked Spearhead with their weapons, gear and vehicles and traveled from Morehead City, NC, to Mayport Naval Station, FL and back, while participating in various tests. Sources: US MSC Sealift magazine, October 2013.

June 6/13: Naming. The Secretary of the Navy names the last 3 JHSV ships under contract.

The future USNS Yuma (JHSV 8) honors the city in Arizona near the USMC’s big testing range, and will be the 4th ship to bear this name. JHSV 9 USNS Bismarck is named in honor of North Dakota’s capital city. As one might imagine, it’s a first for the US Navy. JHSV 10 USNS Burlington is also a first, named for the largest city in Vermont. US DoD.

June 6/13: JHSV 2. USNS Choctaw County is accepted into service, after completing acceptance trials in May. Delivery just 6 months after the 1st ship in the class is a very fast pace. US Navy | Austal.

USNS Choctaw County

June 5/13: JHSV 3. Millinocket is launched from the Austal USA shipyard in Mobile, AL. It’s not done, just entering the final phase of construction, test, and activation, followed by preparation for sea trials late in 2013. US NAVSEA | Austal.

May 23/13: JHSV 4. The keel is formally laid for Fall River. Austal.

May 3/13: JHSV 2. USNS Choctaw County successfully completes USN Acceptance Trials. Sources: Austal, “Joint High Speed Vessel USNS Choctaw County (JHSV 2) completes Acceptance Trials”.

April 27/13: Aerostat experiment. The Miami Herald reports that the chartered catamaran HSV 2 Swift is currently testing an interesting combination for the US Navy. An aerostat (tethered blimp) mooring system has been attached to the starboard rear at the helicopter deck, and sailors are deploying hand-launched Aerovironment Puma mini-UAVs to investigate targets cued by the aerostat’s radar and optical sensors. When fully deployed to 2,000 feet, Raven Inc’s TIF-25K gives Swift a sea surveillance radius of 50 miles at almost zero operating cost, roughly doubling a warship’s surveillance radius, and increasing Swift’s by 10x.

The JHSV ships and Hawaii Superferries (esp. USNS Puerto Rico) are natural fits for this configuration, given their similarity to HSV 2. If weight and other issues can be worked out, the USA’s Littoral Combat Ships like the trimaran Independence Class could also be an option, and so could amphibious LSD and LPD ships. Still, Swift needs to work out a coherent concept of operations in these trials, including the question of barrier vs. mobile surveillance approaches.

If all goes well with the operational tests, the US Navy will consult with drug enforcement agencies, including the Key West, FL Joint Interagency Task Force South (JIATF) that oversees Operation Martillo in the Caribbean. If the system is deployed, the biggest losers would probably be expensive-to-operate P-3 quad-turboprop sea control planes. US personnel have also begun promoting the concept to other nations, including Colombia, though those countries would almost certainly use their own ships.

April 20/13: JHSV 3 christened. The Millinocket is christened at Austal’s Alabama shipyard, named after 2 Maine towns. No word on negotiations concerning JHSV 10, though Austal’s release does make a point of noting 10 JHSV vessels under contract. US MSC | Austal.

April 12/13: Naming. 3 JHSV ships are among the 7 named by Secretary of the Navy Ray Mabus, who actually stuck to class naming conventions this time instead of veering into political partisanship.

JHSV 5 will become USNS Trenton, after New Jersey’s capital city. JHSV 6 will become USNS Brunswick, after the seaport in Georgia. JHSV 7 will become USNS Carson City, after Nevada’s capital city. Pentagon, “Secretary of the Navy Names Multiple Ships”.

April 5/13: LCS Council. The CNO adds the JHSV program to the portfolio of the Littoral Combat Ship (LCS) Council, which was set up to manage the logistics, support, training, and concept of operations involved in making LCS a useful part of the fleet. Sources: Gannett’s Navy Times, “LCS council adds new member”.

Added to LCS Council

March 15/13: JHSV 2. Choctaw County completes builder’s trials, reaching speeds of more than 41 knots. Delivery is expected this summer. Austal.

March 2/13: JHSV 10. The US Navy’s guidance regarding sequestration budget cuts involves negotiations to cancel JHSV 10’s contract. They have to hold negotiations, because the contract is already live. The question will be cancellation costs.

Dec 20/12: JHSV 10. Austal USA in Mobile, AL receives a $166.9 million contract modification, exercising the construction option for JHSV 10. All contract funds are committed immediately.

Work will be performed in Mobile, AL (48%); Pittsfield, MA (9%); Franklin, MA (3%); Philadelphia, PA (3%); Henderson, Western Australia (3%); Atlanta, GA (2%); Chicago, IL (2%); Gulfport, MS (2%); Slidell, LA (1%); Iron Mountain, MI (1%); Houston, TX (1%); Dallas, TX (1%); Chesapeake, VA (1%); Milwaukee, WI (1%); Brookfield, WI (1%), and various sites inside and outside the United States each below 1% (21% tl.), and is expected to be complete by June 2017. US Naval Sea Systems Command in Washington, DC manages the contract (N00024-08-C-2217).

JHSV 10 bought

Dec 5/12: #1 delivered. US Military Sealift Command accepts delivery of USNS Spearhead [JHSV 1] at Austal Shipyard in Mobile, AL.

Following delivery to the Navy, Spearhead will participate in operational testing before sailing to its layberth in Little Creek, VA. The Navy says that it expects the ship to begin conducting missions in Q1 of FY 2013. Which is to say, by Dec 31/12. US MSC | US Navy | Austal.

USNS Spearhead

Oct 1/12: JHSV 2 launch. Choctaw County is launched in Mobile, AL.

FY 2011 – 2012

JHSV becomes Navy-only; JHSVs 4-9 bought; 2 Superferries bought, re-named; JHSV program to end at 10; JHSV 1 christening, trials; Corrosion controversy.

Austal JHSV concept
(click to view full)

Sept 15/12: JHSV 2 christened. USNS Choctaw County is christened during a ceremony at Austal USA in Mobile, AL. US MSC | Pentagon.

May 30/12: Secretary of the Navy Ray Mabus announces that the next JHSV will be named the USNS Millinocket. Pentagon.

May 8/12: The US Navy re-names the Hawaiian Superferries, which will becomes USNS Guam and USNS Puerto Rico.

They do not say, but it’s likely that the larger Huakai, tabbed to replace the Westpac Express and move Marines to and from Okinawa and Guam, is the future USNS Guam. The smaller Alakai was being considered for missions in Latin America and/or Africa, so it’s likely that she’ll become USNS Puerto Rico.US DoD.

April 25/12: The first of 43 modules for JHSV 3 have been successfully transported from the Module Manufacturing Facility (MMF), and erected in the final assembly bay on the waterfront, in preparation for the May 3/12 keel-laying ceremony. The 46 tonne, 20.4m x 8.3m x 9.4m module will be part of one of the catamaran akas. Austal.

April 19/12: JHSV-1 trials. The future USNS Spearhead completes builder’s trials of the ship’s propulsion plant, communication and navigational systems, ride control systems, pollution control systems; and first-of-class maneuverability and stability trials. The ship reached speeds of more than 35 knots, exceeding the program’s requirements.

Next steps include INSURV inspection, and commissioning. US Navy acceptance is scheduled by the end of 2012. USN PEO Ships | Austal.

Feb 24/12:JHSV 8-9. Austal USA in Mobile, AL receives a $321.7 million contract modification, exercising construction options for JHSV 8 and JHSV 9.

Work will be performed in Mobile, AL (48%); Pittsfield, MA (9%); Franklin, MA (3%); Philadelphia, PA (3%); Atlanta, GA (2%); Chicago, IL (2%); Gulfport, MS (2%); Slidell, LA (1%); Iron Mountain, MI (1%); Houston, TX (1%); Dallas, TX (1%); Chesapeake, VA (1%); Milwaukee, WI (1%); Brookfield, WI (1%); various sites throughout the United States (5%); and various sites outside of the United States (19%). Work is expected to be complete by April 2016 (N00024-08-C-2217).

Austal’s release offers a snapshot of current progress. USNS Spearhead is scheduled for builder’s sea trials in early March 2012. JHSV 2 is taking shape in Austal’s final assembly bay. Modules for JHSV 3 are being built, and the ship’s official keel laying is scheduled for April 12/12.

JHSV 8 & 9 bought

Jan 26/12: JHSV cut. The Pentagon issues initial guidance for its FY 2013 budget, and next plans. They include lowering planned JHSV buys by 8 ships, leaving only the 10 in the current contract. Pentagon release | “Defense Budget Priorities and Choices” [PDF] | Alabama Press-Register.

Just 10

Jan 20/12: Superferry supplement bought. Inside the Navy reports that the cost for the 2 Hawaii Superferries, plus required modifications, is actually $70 million. The superferries were seen as a better option to move 880 Marines, because JHSV wasn’t designed for maximum passenger seating. Read “Hawaii Superferry’s Bankruptcy = US Navy Opportunity” for full coverage.

Dec 19/11: Superferries. The Defense Authorization Act of 2012, which will soon become law, looks set to buy both of the Austal-built Hawaii Superferries out of the firm’s bankruptcy, then send them to US MSC, alongside the future JHSV vessels. Read “Hawaii Superferry’s Bankruptcy = US Navy Opportunity” for full coverage.

Superferry supplements bought

Oct 10/11: JHSV 3 begun. Austal announces the official beginning of fabrication for JHSV 3 Fortitude. Austal USA President and COO, Joe Rella:

“The race is on… The world is about to learn just how much value Austal’s investments in modular ship fabrication offers our Navy and Military Sealift Command customers. We challenge ourselves every day to build each ship faster and more efficiently than the one before.”

Oct 7/11: JHSV 6 named. Secretary of the Navy Ray Mabus names JHSV 6 as USNS Choctaw County. He grew up in that Mississippi county, though there are also Choctaw counties in Alabama and Oklahoma. Ray Mabus said that “I chose to name JHSV after Choctaw County to honor those men and women who represent rural America.”

The name eventually migrates to JHSV 2. US MSC.

Sept 10/11: JHSV 1 christened. JHSV-1 Spearhead is launched at Austal USA’s yard in Mobile, AL. The formal christening ceremony is held on Sept 17/11. The ship is reported to be slightly over budget, but not badly so – a welcome departure for a USN first ship of class. US MSC | Austal | Alabama Press-Register | Maritime Executive.

June 30/11: JHSV 6-7. Austal USA in Mobile, AL receives a $312.9 million contract modification, exercising options for JHSVs 6 and 7. Note, as usual, that this is not the full price of a ready to serve ship. On the other hand, JHSVs have much lower amounts of “government furnished equipment” beyond the base seaframe and installed gear, so the figure will be much closer than it would for a warship.

Options remain for another 3 ships under the current FY 2009-2013 contract, though the program of record tops out at 18 ships. Spearhead [JHSV 1] is scheduled for launch in August 2011, and delivery in December 2011, with other ships currently in various stages of assembly.

Work will be performed in Mobile, AL (48%); Pittsfield, MA (9%); Franklin, MA (3%); Philadelphia, PA (3%); Henderson, WA (3%); Atlanta, GA (2%); Chicago, IL (2%); Gulfport, MS (2%); Slidell, LA (1%); Iron Mountain, MI (1%); Houston, TX (1%); Dallas, TX (1%); Chesapeake, VA (1%); Milwaukee, WI (1%); and Brookfield, WI (1%), with other efforts performed at various sites throughout the United States (5%) and outside the United States (16%). Work is expected to be complete by June 2014. US Naval Sea Systems Command in Washington, DC manages the contract (N00024-08-C-2217). See also US NAVSEA | Austal.

JHSV 10 bought

June 20-22/11: Corrosion issues? After USS Independence [LCS-2] corrosion reports hit Austal’s share price, a company release addresses the issue. It notes the complete lack of such problems on all of Austal’s commercial and military ships to date, and suggests that the US Navy may have failed to follow basic procedures. Information Dissemination has a different take, and wonders if Austal’s JHSV, which may not have a cathodic protection system either, could also be at risk due to the military’s added electronics:

“In the case of LCS-2, the problem was apparently accelerated by stray currents in the hull from the electrical distribution system problems the ship has been having since it was turned over to the Navy. LCS-4 doesn’t have [a cathodic protection system] either, but apparently CPS is part of the lessons learned process and was included in the fixed-price contracts for Austal versions of the LCS beginning with LCS-6. LCS-2 will have the CPS installed at the next drydock period, while Austal has said a CPS will be added to LCS-4 before the ship is turned over to the Navy. The question everyone seems to be asking is whether the JHSV could suffer the same issue… I’d be curious to know if Westpac Express has a CPS installed, or some other form of prevention is used at all.”

MarineLog’s report says that yes, cathodic protection is used on Westpac Express. See: Austal | Alabama Press-Register | Information Dissemination | MarineLog | WIRED Danger Room.

June 17/11: Corrosion issues? The US Navy has told Congressional appropriations committees that “aggressive” corrosion was found in the propulsion areas of the Littoral Combat Ship USS Independence, which rely on Wartsila waterjets. The ship has been given temporary repairs, but permanent repairs will require dry-docking and removal of the water-jet propulsion system. The strong Australian dollar has hurt Austal’s commercial exports, so this blow to its defense business has added impetus. Bloomberg | Alabama Press-Register | Sydney Morning Herald.

Corrosion in new ships isn’t unheard of, though it’s never a good sign. Norway’s Fridtjof Nansen Class AEGIS frigates had this problem, for instance. The Independence Class runs some risks that are specific to its all-aluminum construction, however, as key subsystems with different metals create risks of galvanic corrosion.

Corrosion controversy

June 11/11: Industrial accident. A 50-ton block from JHSV Vigilant, containing the ship’s service diesel generators, breaks loose while the module is being lifted and repositioned for further work. One source reported that pad eyes tore loose from the module, causing it to fall about 3 feet and tip over.

The extent of the damage to the module, and the cost of repairs, are still being assessed. The good news is that modular construction ensures less schedule impact. Defense News.

Accident

June 9/11: Inside the Navy reports that a June 14/11 Defense Acquisition Board meeting will determine the Navy’s readiness to procure JHSV ships 6-10. Defense officials may opt to fast-track the decision as a “paper DAB,” granting approval without requiring a meeting.

June 2/11: Sub-contract. Taber Extrusions LLC announces contracts to supply extruded aluminum products for JHSV 3 Fortitude, and LCS 6 Jackson, from its facilities in Russellville, AR and Gulfport, MS. Some structural extrusions for both ships will also be manufactured by Taber and supplied to Austal through a contract with O’Neal Steel Corp.

Taber has an 8,600 ton extrusion press with a rectangular container and billet configuration. The firm says that compared with smaller presses and round containers, their tool gives superior metal flow patterns with much tighter tolerances for flatness, straightness and twist; and better assurance of critical thickness dimensions. The resulting wide multi-void extrusions are friction stir welded into panels, and tight tolerances improve productivity while reducing downstream scrap. When finished, they make up some of the ship’s decking, superstructure and bulkheads.

May 2/11: Army Out. The US Army signs a memorandum of agreement to transfer custody of all 5 of its JHSVs to US Military Sealift Command. Army watercraft personnel who had been training to operate the ships have been reassigned. Instead, JHSVs will be operated by the US Navy’s Military Sealift Command, and crewed by civil service (JHSV 1-4) or civilian contract (JHSV 5-10) sailors. The transfer was approved in principle in December 2010, during Army-Navy talks.

MSC has been slated to operate the Navy JHSVs since August 2008, and in May 2010, MSC announced that the vessels would each have a core crew of 21 mariners (vid. May 13/10 entry). That template will now apply to all ships of class, which will carry a USNS designation instead of the Navy’s USS. US DoD | US MSC | Gannett’s Navy Times.

Navy-only now

Oct 12/10: #4 & 5 bought. Austal USA in Mobile, AL receives a $204.7 million contract modification, exercising options to build JHSV 4 and 5. Work will be performed in Mobile, AL, and is expected to be complete by December 2013. US Naval Sea Systems Command in Washington, DC manages the contract (N00024-08-C-2217).

The $204.7 million is on top of the earlier $99.6 million long-lead materials contract, bringing the total so far to $304.3 million for the 2 ships. See also Austal.

JHSV 4 & 5 bought

FY 2009 – 2010

Program baseline set; Austal wins; JHSVs #1-3 bought; Long-lead items for #4-5; JHSV 1 keel-laying; Austal opens new manufacturing facility; Hawaii Superferries in Haiti; JHSV program to reach 23 ships?

JHSV 1 construction
(click to view full)

Sept 28/10: JHSV 2 begins. Austal announces that they’ve begun construction of JHSV 2 Vigilant for Maritime Sealift Command. A subsequent release fixes the start date at Sept 13/10.

July 22/10: JHSV 1 keel-laying. Keel-laying for the first JHSV ship, Spearhead, at Austal’s Mobile, AL facility. Austal | Press-Register advance report.

June 3/10: #4-5 lead-in. Austal USA in Mobile, AL receives a $99.6 million modification to a previously awarded contract (N00024-08-C-2217) for JHSV 4 and 5 long lead time materials, including main propulsion engines, aluminum, waterjets, reduction gears, generators and other components, beginning in fall 2010.

Work will be performed in Detroit, MI (38%); Chesapeake, VA (18%); Henderson, Australia (13%); Gulfport, MS (10%); Ravenswood, WVA (9%); Ft. Lauderdale, FL (4%); Mobile, AL (3%); Auburn, IN (2.6%); Winter Haven, FL (1%); Gardena, CA (1%); and Davenport, IA (0.4%), and is expected to be complete by December 2011. The Naval Sea Systems Command in Washington, DC manages this contract. See also Austal release.

May 26/10: Sub-contract. Kongsberg Maritime has successfully delivered the first JHSV Helicopter Operations Surveillance System (HOSS) to General Dynamics Advanced Information Systems. The sub-contract was awarded in November 2009.

The JHSV HOSS system will provide comprehensive flight deck coverage for helicopter operations, even in very low light conditions, on a MIL-S-901D shock qualified 19″ SXGA liquid crystal display (LCD) monitor in the JHSV control room. The monitor’s Night Vision Device (NVD) optical filter makes it suitable for night operations in ship compartments directly overlooking the flight deck. defpro.

March 25/10: JHSV 4 named. US Navy Secretary Ray Mabus officially names the 2nd US Navy ship under the JHSV program: USNS Fall River [JHSV 4]. US Navy | Gannett’s Navy Times.

March 16/10: Support. Reuters reports on a recent US Navy SBIR research solicitation, aimed at more quickly and cheaply diagnosing cracking in aluminum ship structures. From US Navy SBIR N10A-T041: “Fracture Evaluation and Design Tool for Welded Aluminum Ship Structures Subjected to Impulsive Dynamic Loading” :

“A new analysis tool combined with an experimental validation protocol is needed to accurately characterize the dynamic response and fracture behavior of welded aluminum ship structures subjected to extreme loading events. The goal of this effort is to develop an explicit dynamic failure prediction toolkit for fracture assessment of welded thin-walled aluminum structures. To efficiently characterize a large size ship structure, innovative modeling techniques using fractured shell elements are needed along with a mesh independent crack insertion and propagation capability. In addition to innovative crack simulation in a shell structure, advanced constitutive models have to be implemented in the toolkit to capture the rate dependence and anisotropy in strength, plastic flow and ductility. Developing and demonstrating novel damage simulation and fracture prediction methods has significant potential impact on design and operation of current and future Navy welded aluminum, ship structural systems.”

US Navy Commander Victor Chen reiterated the Navy’s confidence in the JHSV and Littoral Combat Ships; the JHSV is aluminum construction, as is the LCS-2 Independence Class, and the LCS-1 Freedom Class uses an aluminum superstructure on a steel hull. He adds that:

“We already have a level of confidence in how to work with aluminum. The Office of Naval Research is trying to expand the knowledge base and build on what we already know.”

May 13/10: Crewing plans. The US Navy and Military Sealift Command announce the crewing plan for USN JHSVs (even numbers, JHSVs 2-10). Because the ships are new and could conduct a wide variety of missions, MSC determined that the best course of action is to institute a pilot program where JHSV 2 Vigilant and JHSV 4 Fall River will be crewed by 21 civil service mariners each, in order to create a base of experience and knowledge. Delivery as USNS Vigilant is scheduled for FY 2013, but the crews arrive beforehand; while USNS Fall River’s delivery is scheduled for FY 2014. JHSVs 6, 8 and 10 will be crewed with 21 civilian contract mariners each, with specifications developed based on experience with the first 2 ships.

The Army Transportation Corps officers have apparently won their argument to crew the Army’s JHSVs as USAV ships, involving larger crews of soldiers. Within a year, however, that victory would be undone. US MSC.

April 2/10: SAR baseline. The Pentagon adds [PDF] the JHSV program to its Selected Acquisition Reports. The program’s baseline is $3.9355 billion, and subsequent SARs set the number of ships at 18. The program is listed under the US Navy.

Baseline

Feb 11/10: Superferries. The former Hawaii superferries Huakai and Alakai are pressed into service by the USA’s Maritime Administration (MARAD), in the wake of the disaster in Haiti. The ships are managed by Hornblower Marine Services (HMS), and the deployment is seen as an earl concept test of the similar JHSV design’s operations. Haiti’s lack of port infrastructure has not, to date, been a major problem for these ships.

Maritime Executive magazine has the full report, and see also July 30/08 entry.

Feb 3/10: JHSV Boost? Defense News reports that the JHSV program may be about to get a very big boost. Navy Undersecretary Bob Work:

“There was a big debate within the [Navy] department on patrol craft, PCs… People said these are very good for irregular warfare. But when we looked at it we said we wanted to have self-deployable platforms that have a lot of payload space that you can take to the fight whatever you need – SEALs, Marines, riverine squadrons. So we decided to increase the Joint High Speed Vessel program.” Work said the Navy now envisions buying up to 23 of the ships for its own use, in addition to five being built for the Army. “We like their self-deployability aspects,” Work said. “They can be a sea base, they can be an Africa Partnership Station, they’re extremely flexible.”

Jan 28/10: JHSV 2 & 3. Austal USA in Mobile AL receives a $204.2 million modification to a previously awarded contract (N00024-08-C-2217), exercising options for JHSV ships 2 and 3. Work will be performed in Mobile, AL, and is expected to be complete by July 2012. The Naval Sea Systems Command in Washington, DC issued the contract. See also the June 19/09 entry for related advance materials purchases.

The accompanying Austal release, adds that the similar (ex-)Hawaii Superferry ships, “Alakai” and “Huakai,” have been mobilized by the US Maritime Administration, and are currently supporting the ongoing relief operation in Haiti.

JHSV 2 & 3 bought

Dec 18/09: Industrial. Austal announces success in the US Navy’s Production Readiness Review (PRR), which allows their Mobile, AL facility to immediately begin construction of Fortitude [JHSV 1]. US Navy Program Manager George Sutton referred in part to Austal’s recently-competed Module Manufacturing Facility (MMF) when he said that:

“Considerable investments in the Austal shipyard coupled with the implementation of proven commercial technology gives me high levels of confidence in the shipyard’s ability to execute the program.”

Nov 10/09: Industrial. Austal officially opens its new $88 million state-of-the-art Modular Manufacturing Facility (MMF) in Mobile, AL, equipping its US shipyard with the ability to build up to three 100 metre-plus vessels each year. Phase 1 facility boasts 35,000 m2 of manufacturing space under one roof, including a 7,900 m2 warehouse, as well as paved parking for more than 2,000 vehicles.

The MMF will increase Austal USA’s capacity to assemble and outfit unit modules before consolidating them into the full vessel, automating component manufacture, including pipe runs, from a 3D model. This approach is widely used in advanced European and Asian shipyards, but is less common in the USA. Austal’s MMF is equipped with routers for the precise cutting of aluminum plate, as well as automated pipe and plate benders. Test constructions are currently underway at the new facility, with work on the first 103 meter JHSV scheduled to commence before the end of 2009. The facility will also build LCS-2 Independence class trimarans for the Littoral Combat Ship program. Austal release.

July 17/09: Ship names 1-3. The Pentagon announces names for the first 3 JHSV ships. The Army will field Fortitude [JHSV 1] and Spearhead [JHSV 3], while the Navy’s first JHSV will be named Vigilant [JHSV 2]. The names for JHSV 2 and 3 eventually change.

Spearhead would later become the name for JHSV 1 instead. US Navy Team Ships | MarineLog.

June 19/09: #2-3 lead in. Austal USA in Mobile AL receives a $99.6 million modification to their JHSV contract (N00024-08-C-2217), covering long lead time materials needed for JHSV 2 and JHSV 3. These materials include items like aluminum for the hulls, main propulsion engines, waterjets, reduction gears, generators, and other components that need to be on hand before construction begins in June 2010.

Work will be performed in Detroit, MI (38%); Chesapeake, VA (18%); Henderson, Australia, (13%); Gulfport, MS (10%); Ravenswood, WVA (9%); and Ft. Lauderdale, FL (4%); Mobile, AL (3%); Auburn, IN (2.6%); Winter Haven, FL (1%); Gardena, CA (1%); and Davenport, IA (0.4%), and is expected to be complete by July 2013. US Naval Sea Systems Command manages the contract

Once construction contracts are awarded for the 2 ships later in FY 2009, these materials will be moved with their associated costs into their respective ship construction line items.

April 6/09: US Secretary of Defense Robert M. Gates takes the unusual but approved step of making his FY 2010 defense budget recommendations public. They include another 2 high speed ship charters from 2009-2011, until JHSV ships begin arriving.

Nov 13/08: Austal wins. Austal USA in Mobile AL received a $185.4 million Phase II modification to previously awarded contract (N00024-08-C-2217) for 1 (one) JHSV, and for associated shore-based spares. The firm also has options for up to 9 additional ships by 2013, which could raise the contract’s total value to about $1.6 billion. The Naval Sea Systems Command, in Washington Navy Yard, DC manages this contract, which eliminates fellow Phase I winners Bollinger/Incat and General Dynamics Bath Iron Works. The 103m JHSV design appears to be based on Austal’s Westpac Express catamaran, which is currently under long term charter to the US Marines.

Work on this initial contract will be performed at the firm’s American facility in Mobile, AL and is expected to be complete by November 2010. Austal is teamed with General Dynamics Advanced Information Systems, who will design, integrate, and test the JHSV’s electronic systems, including an Open Architecture Computing Infrastructure, internal and external communications, electronic navigation, aviation, and armament systems.

Austal already produces ships in Mobile, AL, which has about 1,000 employees and will now grow to about 1,500 employees. Ships produced at this location include some similar civilian designs like the Hawaii Superferry, as well as the Independence Class trimaran Littoral Combat Ship produced in partnership with General Dynamics Bath Iron Works. Austal USA is growing the Alabama facility, and phase one of what will ultimately be a $170 million expansion should be complete by summer 2009. The assembly-line style manufacturing building will allow construction of 3 LCS/ JHSV/ Hawaii superferry scale vessels per year, rising to a capacity of 6 ships per year at full build out. Austal | General Dynamics | Marinelog | Alabama Press-Register | Biloxi-Gulfport Sun-Herald | Western Australia Today | Maine’s Brunswick Times-Record re: union lobbying in Congress to scrutinize the deal.

Austal Wins! JHSV 1 bought

FY 2005 – 2008

From initial requirements draft, to 3-team preliminary design contracts, to final RFP submissions.

Westpac express,
loading in Australia
(click to view full)

July 30/08: Austal announces its final Phase II JHSV submission to the US Navy, following an extensive detailed design and review process. The firm expects that a single Phase II contract for up to 10 JHSV ships will be awarded in late 2008.

Austal’s release adds the interesting tidbit that the firm was recently awarded a new contract to provide additional features and equipment on Hawaii Superferry’s second commercial 107 meter catamaran, in order to allow its use by the military if required.

Jan 31/08: Preliminary design. The US Department of Defense awards a trio of $3 million Phase I preliminary design contracts for the JHSV. Winners include:

Team Austal: Austal USA, Austal Ships (Australia), and General Dynamics Advanced Information Systems (GDAIS). This is sort of the same Austal/GD core team building the trimaran LCS 2 Independence design for the USA’s Littoral Combat Ship competition – but note competitor #3…

Team Incat: Louisiana-based Bollinger Shipyards, Inc., Incat of Australia, and its design arm Revolution Design, Nichols Brothers Boat Builders and Kvichak Marine in Washington State, and Gladding-Hearn (Duclos Corp) in Massachusetts. Their design will be based on Incat’s 112 meter wave-piercing catamaran, currently in commercial service. Consortium source.

General Dynamics’ Bath Iron Works. No information.

See: US NAVSEA release [PDF] | Incat Australia release | Austal release | UPI re: Bath Iron Works | Springbored’s blog commentary re: Austal-GD dynamics.

Preliminary design contracts

April 23-27/07: Representatives of the US Army, Navy, Marine Corps and the shipbuilding industry meet at at Quantico Marine Corps Base, VA, to discuss the JHSV’s current status of the Joint High Speed Vessel and update prospective contractors on the vessel’s design requirements. US Army release.

November 2005: Initial Draft. The JHSV program office’s Initial Capability Document received approval from the Department of Defense Joint Requirements Oversight Council in early November. All four military services concurred with the decision. The Analysis of Alternatives for this program is scheduled to report out before the end of the 2005 calendar year, and procurement of the lead ship is planned for FY 2008. NAVSEA release

Appendix A: The US Military’s HSV/TSV Experience

Westpac Express
(click to view full)

Instead of arising from a drawing board or a notional requirements sheet, the JHSV’s requirements were based on 7 years of experience operating similar leased vessels, from 2001-2008. The core concept is based on an Australian innovation: fast catamaran ferries from Austal and Incat that are in widespread civilian use. Each ship has a carrying capacity equal to about 20 C-17 heavy airlifters, and their waterjets can power these aluminum catamarans through the water at a consistent 35-40 knots in calm seas. Robert Kaplan, in “Hog Pilot and Blue Water Grunts“:

“Who thought up the idea of using car ferries to get Marines to a combat zone and then link up with pre-positioning ships?” I asked a Marine chief warrant officer. “No-one at the Pentagon. Just a bunch of guys brainstorming here,” the chief replied.”

It was more than just brainstorming. Incat’s HMAS Jervis Bay had been used very effectively by Australia during East Timor’s 1999 independence referendum and subsequent operations, and its demonstrated capabilities attracted American interest.

The chartered vessels quickly lived up to their billing. Normal transit for a Marine battalion from Okinawa, Japan to South Korea aboard ferry or amphibious shipping is about 2-3 days, and moving it by air would take 14-17 “lifts” from C-17 aircraft, a process that might require several trips unless that many planes were available. The same deployment could be carried out by Austal’s chartered WestPac Express catamaran in 24-30 hours; which is to say, at about half the time of conventional naval options, and at about 25% of airlift’s costs. One ship can carry a complete battalion of up to 970 Marines, along with 663 tons of vehicles and equipment. If the Marines must deploy from Guam, where many are being moved from Okinawa, the added distance makes JHSV an even more timely and cost efficient option.

“I Serve With HSV-2!”
(click to view full)

Austal’s ships weren’t the only high speed vessels in operation. The Army operated Incat’s HSVX-1 Joint Venture in conjunction with the Navy, and TSV-1X Spearhead was under sole Army control until its 2005 return to commercial service. Both ships saw extensive Army use in operations Enduring Freedom and Iraqi Freedom, as well as supporting operations in the Pacific, Atlantic, Mediterranean, Horn of Africa, Persian Gulf and Southeast Asia.

In one operation, TSV-1X Spearhead moved the 101st Airborne Division’s military police and their equipment from Djibouti, Africa to Kuwait in the Persian Gulf. The fast catamaran made the 2,000 mile trip in just 2.5 days. Its naval LSV predecessor would have needed 10 days to make the voyage, and would only have carried the equipment, forcing the troops to fly separately.

HSVX-1 Joint Venture was even used by Special Operations Command as a proof-of-concept platform for a special operations force afloat in the western Pacific. Its modifications included a helicopter landing deck and hangar, along with a small military command, control and communications suite. Modifications to its complement also included ScanEagle UAVs, letting US Navy experiment with UAVs, blimps and related vehicles in a persistent surveillance role. The combination of high speed transport, persistent surveillance, and advanced communications may prove to be very complementary.

A 3rd Incat ship, the 112m HSV-2 Swift, was contracted to serve as an interim Mine Warfare Command and Support Ship (MCS), supporting R&D into new mine warfare modular payloads. From 2004 onward, its scope of use became far broader, and Swift’s geographic range expanded to include Africa, Asia, and recovery efforts in the USA after Hurricane Katrina. It remains in American service as of 2013, and continues to trial new approaches like aerostats and UAVs.

If HSVX-1 and HSV-2’s experiences sound a lot like the USA’s forthcoming Littoral Combat Ships, the similarity is no accident. Experience with these high-speed catamarans has played an important role in developing the LCS concept of operations, though the US Navy may not have taken the experiments to their logical conclusion. Given the emergence of naval unmanned vehicles, some observers believe that JHSV’s size and lower cost make it a better choice than the smaller LCS as a “robotic swarm mothership”.

Additional Readings & Sources

Thanks to DID reader and long-serving US MSC vet Lee Wahler for his assistance with this article.

JHSV and its Relatives

• US Navy Fact File – Joint High-Speed Vessel – JHSV

• US Navy PEO Ships PMS-325 – Joint High-Speed Vessel (JHSV). 2007 snapshot.

• US Navy NWDC – Naval Concept Development – High Speed Vessel. 2007 snapshot.

• JHSV Program – Joint High Speed Vessel Program Overview: SNAME SD-5 & IHS. Sept 28/06 presentation.

• DID – Hawaii Superferry’s Bankruptcy = US Navy Opportunity. Became USNS Guam and USNS Puerto Rico, based on vessels similar to the JHSV.

• DID – U.S. Marines Extend Westpac Express TSV Ship Charter.

• US Military Sealift Command – WESTPAC EXPRESS, MV.

• US Military Sealift Command – HSV SWIFT. December 2013 snapshot. No longer leased.

Ancillary Equipment

• DID – Ruin on Rails: The US Navy’s Railgun Project. JHSV 3 will serve as a testbed.

• DID – From Dolphins to Destroyers: The ScanEagle UAV. USNS Swift was a testbed, and JHSVs can be expected to operate this and Insitu’s follow-on RQ-21 Blackjack UAV in future.

News & Views

• Soldiers Magazine, via The Free Library (August 2007) – Launching the JHSV.

• US Army (April 30/07) – Services Chart Course for New Vessel.

• Inside the Navy via Military.com (July 13/06) – Joint High-Speed Vessel Taking Shape.

• Seapower Magazine (May 2006) – In the Shallows: The Joint High-Speed Vessel will bring a new dimension to U.S. forces.

• National Defense Magazine (November 2005) – Navy’s High-Speed Vessel Aids Relief Effort.

• US Armed Forces Press Service (Oct 21/02) – “Joint Venture” Craft Cruises to the Future .

Before: M109 & M992
(click to view full)

The USA’s 155mm M109 self-propelled howitzers (SPH) were first introduced in 1962, as a form of armored mobile artillery that could stand up to the massed fire tactics of Soviet heavy artillery and rockets. They and their companion M992 Armored Ammunition Resupply Vehicles (AARV) have been rebuilt and upgraded several times, most recently via the M109A6 Paladin upgrade.

In the meantime, the Army has re-learned a few home truths. Artillery arrives in seconds rather than minutes or hours, is never unavailable due to bad weather, and cheaply delivers a volume of explosive destruction that would otherwise require hundreds of millions of dollars worth of bombers and precision weapons. Most combat casualties in the gunpowder age have come from artillery fire, and the US Army will need its mobile fleet for some time to come. So, too, will the many countries that have bought the M109 and still use it, unless BAE wishes to cede that market to South Korea’s modern K9/K10 system, or new concept candidates like the KMW/GDLS DONAR. What to do? Enter the Paladin PIM program.

PIM Program: A New M109A7/ M992A3 Paladin

M109 Limitations & the M109A6 Paladin

M109A6 Paladin, fired
(click to view full)

While the M109 was technically mobile, in practice it was only semi-mobile. The need to string communications wire in order to physically connect the battery’s howitzers and their fire-control center fixed the vehicles in position. Surveyors were used to calculate the battery’s location as part of this process, and the entire emplacement and readying procedure could easily take 15-20 minutes. So, too, could the process of taking this setup down so the battery could move to another location. It didn’t take a genius to figure out that spending so much time outside of any protective armor was going to get a lot of people killed in any serious conflict involving tools like attack helicopters, massed artillery and rocket fire, and nifty toys like artillery-locating radars that backtrack the origin point of incoming shells.

The M109A6 Paladin addressed these issues via computerization and communications upgrades. Secure SINCGARS radios replaced the wires. Inertial navigation systems and sensors attached to the gun automatically tell the crew where they are, and where their shells are likely to land. Finally, automatic gun-laying translates the fire co-ordinates to a specific gun position. No aiming circles. No surveyed fire points. No wire lines. Just move into the assigned position area somewhere, calculate data, receive orders from the platoon operations center, use FBCB2 (aka “Blue Force Tracker”) to verify the location of “friendlies,” use the automatic PDFCS (Paladin Digital Fire Control System) to aim the gun and send the shell on its way. Once the fire mission is over, the vehicle can move off, receive another target, then quickly lay and fire again.

Improved armor added even more protection to the new system, and an upgraded engine and transmission made the M109A6 speedier. On-board prognostics and diagnostics were installed to improve the vehicles’ readiness and maintainability. Finally, ammunition stowage was made safer, and the load was increased from 36 rounds to 39 rounds of 155mm shells. Some of which can be M982 Excalibur GPS-guided shells.

The M992 Field Artillery Ammunition Support Vehicle (FAASV) vehicle is the M019’s companion. The M992A2 is also referred to as “Carrier Ammunition Tracked” by the US Army, which is an apt name because it holds up to 90 shells on 2 racks (up to 12,000 pounds total), plus an hydraulic conveyor belt to help with loading the M109. In practice, the duo’s crews often handle that task manually. The Paladin PIM program will enhance the FAASV/CAT to M992A3.

M109A7 PIM: The Weapon

M109, firing
(click to view full)

The Paladin Integrated Management partnership builds on the A6’s advances, but there are so many changes that it’s almost a new-build program.

The BAE/Army partnership will re-use the turret structure and the main 155/39 mm gun. As such, additional range and accuracy depends on using new projectiles like the rocket-boosted & GPS-guided M982 Excalibur, or ATK’s non-boosted PGK screw-in guidance system. Both are explicitly contemplated in the Paladin PIM’s loading systems. Maximum rate of fire also remains unchanged, because tube structure and temperature remain the limiting factor for sustained rates of fire.

The Paladin Digital Fire Control System is somewhere between old and new. The system has continued to receive upgrades, and is being produced by BAE and Northrop Grumman. GPS is currently provided via older PLGR systems, with data sent to the Dynamic Reference Unit – Hybrid (DRU-H inertial navigator), but the obsolescence of electronic components within this box means that DRU-H and possibly PLGR are on the future replacement list.

M109A7 PIM
(click to view full)

What will be new? Two big advances:

Chassis. Previous M109 upgrades hadn’t altered the M109’s 1950s configuration. The new chassis are being fabricated & assembled with components from the M2/M3 Bradley IFV (e.g. engine, transmission, final drives, etc.), in order to create more commonality across America’s Heavy Brigade Combat teams. BAE Systems expects a growth in overall weight of less than 5%, but the combined effects of the new chassis and more robust drive components give Paladin PIM the ability to operate at higher weights than its current GVW maximum of about 39 tons/ 35.4 tonnes. That will be tested, given the expected weight of the T2 add-on armor and separate underbelly armor add-on kits.

All-Electric. The M109A7 PIM also incorporates select technologies from the Future Combat Systems 155mm NLOS-C (Non-Line-of-Sight Cannon), including modern electric gun drive systems to replace the current 1960s-era hydraulically-operated elevation and azimuth drives. The removal of the hydraulic systems saves the crew a tremendous amount of maintenance, and they retain manual backups for gun laying just in case.

The shift to an electric turret included a major redesign of the vehicle’s power system, converting the 600 hp engine’s work into up to 70 kW of 600 volt/ 28 volt direct current for use by various on-board systems. The power system’s modularity means that if any one of the motors inside fails, it can be replaced in the field within less than 15 minutes, using the same single part type. In concrete terms, it means the howitzer crew can handle the problem themselves and continue the mission, instead of withdrawing for repairs.

Paladin PIM: The Program

Adam Zarfoss, BAE Systems’ director of artillery programs:

“Artillery is playing an important role in operations in Iraq, with the Paladin providing critical fire support with both standard and precision munitions… The M109A6-PIM is the next step in Paladin development to ensure this essential fire support system remains ready and sustainable for soldiers in the HBCT [Heavy Brigade Combat Teams] through its projected life beyond the year 2050.”

Even with the previous-generation Paladin’s computerization and fast, safe set-up and take-down, a noticeable capability gap existed between the M109A6 used in Iraq, and newer self-propelled guns. At the same time, America’s comparable XM2001 Crusader/ XM2002 ARRV was canceled as an $11 billion Cold War relic in 2002, and the light 155mm NLOS-C died with the 2009 removal of the Future Combat Systems ground vehicle program.

The Paladin Integrated Management Program is designed to handle America’s future needs in the absence of Crusader and NLOS-C, and close some of the M109A6’s technological gaps. The initial goal was 600 M109A7 / M992A3 vehicle sets, but that has been lowered slightly to 558.

BAE Systems and the U.S. Army have signed a 2007 memorandum of understanding (MoU), establishing a Public-Private Partnership (P3) to develop and sustain the Army’s M109A6 vehicles throughout their life cycle. The establishment of a P3 will capitalize on the strengths and capabilities of each organization to ensure the cost-effective and on-time reset of the current fleet of M109A6 Paladin self-propelled howitzers (SPHs) and M992A2 Field Artillery Ammunition Supply Vehicles (FAASV), as well as the planned production of the M109A7/M992A3 Paladin Integrated Management (PIM) systems.

PIM prototypes were originally slated to be delivered to the US Army for test and evaluation in 2009, but changes to the program meant that the prototype contract wasn’t even issued until October 2009. That moved prototype delivery back to May 2011.

By January 2012, BAE had completed Phase I of the Army’s formal Developmental Test Program, with 5 vehicles returning for refurbishment, and 2 remaining at Aberdeen Proving Grounds for further tests. Full testing of all vehicles was set to resume in June 2012, and the Milestone C approval to proceed with Low-Rate-Initial-Production (LRIP) was scheduled for June 2013. In practice LRIP approval by the Defense Acquisition Board slipped to October 2013, and formal induction didn’t take place until May 2014.

Industrial Team

M992 cutaway
(click to view full)

Parties to the memorandum signing include BAE Systems leaders, US Army TACOM (Tank, automotive & Armaments COMmand), The Army’s PEO-GCS (Program Executive Office for Ground Combat Systems), the Army’s PKM-HBCT (Project Manager – Heavy Brigade Combat Team), and the Anniston Army Depot in Alabama. The MoU was signed during the AUSA 2007 conference in Washington, DC.

BAE Systems has significant experience with public-private partnerships thanks to Britain’s “future contracting for availability” innovations. In the USA, meanwhile, it has a long standing and successful partnership with the Red River Army Depot in Texas to remanufacture and upgrade the USA’s M2/M3 Bradley fighting vehicles.

The Army’s PM-HBCT will manage the M109 RESET activities. Anniston Army Depot will retain labor and lead the majority of the program, including the M109A6-PIM production process, through the public-private partnership. They will be integrated into the PIM Integrated Product Development Teams (IPDTs) structure during the design phase, and will support the manufacture of the prototype vehicles.

During the production phase, Anniston Army Depot will be responsible for induction of vehicles, overhaul of critical components like the gun system, and modification/ upgrade of the cab structure. BAE Systems will be responsible for materials management. The partially assembled cabs, along with overhauled components, will be provided to BAE Systems for integration with the new M109A7 PIM chassis. Areas involved in production will include York, PA; Aiken, SC; and Elgin, OK where final assembly will take place.

Export Potential

PzH-2000

A total of 975 M109A6 Paladins were produced for the US Army, and another 225 or so were produced for Taiwan. Full rate production ceased in 1999. BAE built a small final batch to fill out an Army National Guard request, which finished in 2001.

Most other countries who use the M109 (Belgium, Brazil, Chile, Denmark, Egypt, Greece, Israel, Kuwait, Morocco, Norway, Oman, Pakistan, Portugal, Saudi Arabia, South Korea, Spain, Thailand, Tunisia, Iran on its own, soon Iraq with US support) employ previous versions, ranging from M109A1s to M109A5s.

That’s a lot of potential upgrades.

So far, the most popular upgrade abroad is the M109A5+, which adds independent position location via GPS/INS, and radio transmission of co-ordinates. It’s a budget-conscious upgrade that omits the M109A6’s automatic gun-laying, which would require a tear-down and rebuild of the turret. It also omits the PIM upgrades, which make very substantial changes to every part of the vehicle.

On the other hand, countries that do decide to field fully modern armored artillery systems will find that Paladin PIM is still generally cheaper than buying new heavy systems. That’s enough to succeed in America. What about the rest of the world?

Abroad, Paladin PIM will be competing against options like KMW’s PzH-2000, Denel’s G6, and Samsung’s K9/K10 on the heavy side, some of which offer more advanced features. It will also have to deal with substitution threats from lightly-armored truck-mounted 155mm artillery like BAE/Saab’s Archer, Elbit’s Atmos, and Nexter’s Caesar. It’s still early days, but the M109A7 Paladin PIM system has yet to find an export customer.

Contracts and Key Events

Unless otherwise noted, US Army TACOM in Warren, MI issues the contracts to BAE Systems Land & Armaments’ Ground Systems Division in York, PA.

FY 2018

 

At Fort Sill

October 24/18: Tracks Contitech is being tapped to provide the US Army with vehicle tracks for its M109 Paladin artillery system. The firm-fixed-price contract is valued at $20.1 million and will run through July 8, 2021. The M109 family of systems has been in service since 1962. The latest variant is the BAE produced Paladin M109A7 next-generation artillery system. The new variant incorporates upgrades to hull, turret, engine, and suspension systems that offer increased reliability, survivability and performance over its predecessor. The 155 mm cannon is mounted on the chassis structure common to the Bradley tracked fighting vehicle. Work will be performed at Contitech’s factory in Fairlawn, Ohio.

FY 2016

August 11/16: Howitzers in the Paladin Integrated Management (PIM) program are being questioned over deficiencies with the weapon’s maximum rate of fire and problems with the automatic fire extinguisher that could potentially endanger the crew. The DoD’s inspector general raised the queries in a report released last week. 2012 and 2013 tests saw the howitzer fail the test for maximum rate of fire which led to a redesign of hardware, software and firing procedures but still failed a total of four out of eight attempts following the fixes “under non-stressful firing conditions.”

November 2/15: The Army announced on Friday that they have awarded a $245.3 million contract modification for 30 M109A7 Paladin self-propelled howitzers, along with 30 M992A3 Armored Ammunition Resupply Vehicles. This low rate initial production-2 (LRIP-2) modification (Option 2) follows a similar award (Option 1) in October 2014 for 18 of each vehicle, with the two options scheduled for deliveries by February 2017 and June 2018 respectively.

FY 2015

 

Oct 31/14: LRIP-2. A $141.8 million fixed-price-incentive contract modification exercises Option 1 for 18 M109A7 Self-Propelled Howitzers and 18 M992A3 Carrier Ammunition Tracked vehicles. All funds are committed immediately, using FY 2014 and 2015 Army budgets. This raises the contract’s total value (q.v. Oct 30/13) to $386.7 million so far.

Estimated completion date is Feb 28/17. Work will be performed in Elgin, OK (18%), and York, PA (82%) (W56HZV-14-C-0002, PO 0011).

LRIP-2 order: 18 SPH, 18 CAT

FY 2014

Milestone C approval; LRIP contract; GAO and DOT&E reports highlight remaining issues.

M109A7: Fire!
(click to view full)

July 18/14: EMD. An $88.3 million modification to contract to extend the existing M109A7 and M992A3 engineering and manufacturing development contract to incorporate low rate initial production test support. $14.1 million in FY 2013 and 2014 US Army RDT&E funding is committed immediately.

This raises announced Paladin PIM EMD contracts (q.v. Jan 17/12) to $401.6 million. Estimated completion date is March 31/17. Work will be performed in York, PA (W56HZV-09-C-0550, PO 0081).

May 19/14: Inducted. The US Army formally inducts the Paladin PIM system, and gives the systems new designations. It’s now the M109A7 self-propelled howitzer, with its companion M992A3 ammunition carrier. Low-rate initial production will begin in summer 2014, as M109A6s and M992A2s are shipped the Anniston Army Depot for disassembly. Some of those parts, especially the cab and cannon assembly, will be used along with new components like the chassis, engine, transmission, suspension, steering system, and power system.

US Army PM self-propelled howitzer systems Lt. Col. Michael Zahuranic is especially pleased by the fact that the upgrade creates more space, saves weight, and improves power and cooling, making it much easier to add new capabilities until its planned phase-out in 2050. BAE Systems VP and GM Mark Signorelli was also happy today, both for the milestone it represents for his company and because he had commanded a M109A3 when he was in the US Army. Sources: US Army, “Army inducts self-propelled howitzer into low-rate initial production”.

Inducted as M109A7 / M992A3

May 14/14: Engines. BAE Systems Land & Armaments LP in York, PA receives a $16.1 million contract modification for an advance buy of V903 engines, to equip PIM low rate initial production vehicles.

All funds are committed immediately, using FY 2014 budgets. Work will be performed in Columbus, IN (77%), and York, PA (23%), with an estimated completion date of Dec 31/18. US Army Contracting Command-Tank and Automotive in Warren, MI manages the contract (W56HZV-14-C-0002, PO 0003).

March 31/14: GAO Report. The US GAO tables its “Assessments of Selected Weapon Programs“. Which is actually a review for 2013, plus time to compile and publish. For the PIM program, its design is mature. So are its 2 critical new technologies: power pack integration, and the ceramic bearing of the generator assembly. On the other hand, weight limits are a concern, and testing had better go right, because the program’s schedule leaves very little time for fixes if tests show problems.

The largest single technology risk involves the current contractor for the engine and transmission, who may cease production due to lack of orders. That could force a vendor switch and even a redesign of the engine compartment, raising costs between $32 – $100 million and adding a “significant” schedule delay.

The Milestone C delay from June – October 2013 was staff-driven due to sequestration. Other delays to the start of developmental testing stemmed from changes to protection and survivability requirements, which led to a new ballistic hull and turret and new armor kits.

Jan 28/14: DOT&E Testing Report. The Pentagon releases the FY 2013 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). The revised program schedule reduces the program’s planned low-rate (LRIP) production run from 72 sets – 66 sets, while cutting the LRIP period from 4 years – 3 years.

The new M109A6 PIM has done well in tests with GPS-guided shells, with a CEP of less than 10m for rocket-boosted M982 Ia-2 Excalibur shells out to 35 miles, and average CEP of 24m out to 15 miles for ATK’s screw-in Precision Guidance Kit. The bad news is that ordinary shells are a problem. In 2012 Limited User Tests, the PIM failed to meet accuracy requirements at short (4-6 km) ranges, offered a timeliness downgrade from M109A6 standards by meeting less than 20% of fire mission time standards, and displayed deformation and jamming of the M82 primer when firing when firing M232A1 Modular Artillery Charge System (MACS) Charge 5 propellant.

The Army has begun using some very innovative approaches in its effort to fix the defects (q.v. July 30/12), and in January 2013, the program began installing and testing a series of Corrective Actions, Producibility, and Obsolescence (CPO) changes for the SPH and CAT. The Army intends to fix the timeliness problem using hardware and software changes, and there have been some positive indicators in subsequent tests. Meanwhile, they intend to continue testing upgraded suspension and transmission components in light of increased weight from the underbelly and T2 up-armoring kits.

A special research team is looking at the MACS problems. They’re considering a wide range of options: propellant changes, breech & firing mechanism redesigns, alternative ignition systems, or even restricting the PIM to 4 MACS charges and taking the range penalty.

Oct 30/13: LRIP. BAE Systems Land & Armaments LP in York, PA receives a $195.4 million fixed-price-plus-incentive contract for Low-Rate Initial Production of 19 Paladin PIM self-propelled Howitzers (SPH), 13 SPH Threshold 2 (T2) armor kits as up-armoring options, 18 Carrier Ammunition Tracked (CAT, formerly FAASV reloader) vehicles, 11 CAT T2 armor kits, and 37 lots of basic issue items. All funds are committed immediately, using FY 2013 RDT&E ($14.6 million) and “other” ($180.8 million) budgets.

Work will be performed at York, PA; Elgin, OK; and 24 locations throughout the United States until Feb 29/16. One bid was solicited and one received by US Army TACOM in Warren, MI.

The 1st production vehicle is expected to roll out of the depot in mid-2015. BAE says that this contract could rise to $688 million for about 66 vehicle sets (likely 67 SPH and 66 CAT), plus spares, kits and technical documentation (W56HZV-14-C-0002). Note that this is slightly less than envisioned before (q.v. Dec 6/12). See also: BAE, Oct 31/13 release.

LRIP-1 order: 19 SPH, 18 CAT

October 2013. The Defense Acquisition Board green-lights the Paladin Integrated Management program for low rate initial production. To that effect, the FY 2014 budget submitted by the Army in April 2013 asked for $260.2 million in base procurement to field a lot of 18 SPHs and CATs (Carrier Ammunition, Tracked) at a unit cost of about $14.45 million. A LRIP award is expected soon so that production can begin next year.

The Initial Operational Test & Evaluation (IOT&E) milestone had been scheduled for Q4 FY2016, back when Milestone C was expected in June 2013. Meeting that deadline will depend on whether corrective actions to address deficiencies found in tests (q.v. December 2012) can be made fast enough.

LRIP decision / Milestone C

FY 2012 – 2013

EMD contract finalized; Production moves to Elgin, OK; What videogames have to teach the PIM program.

PIM LUT

December 2012: Test results. The Pentagon’s Operational Test & Evaluation Office publishes its 1st report [PDF] on PIM. The Test and Evaluation Master Plan (TEMP) was approved in March 2012, and prototypes refurbished in June 2012 had gone through Phase II development testing by October 2012, following Phase I tests a year earlier.

Vehicle discrepancies after repeated gun shock were higher than with legacy subsystems, including PDFCS. A software issue between the Muzzle Velocity Radar System (MVRS) and PDFCS led to frequent failures. The SPH also failed to meet its climbing requirement, though DOTE doesn’t say whether that’s a problem with meeting a paper spec or a more serious mobility issue.

The report notes that the program’s tight schedule means corrective actions will have to wait until the LRIP phase. This leads DOTE to conclude that “the schedule for development, test, and implementation of those [corrective action, producibility, and obsolescence (CPO)] changes is high-risk and challenging.”

Dec 6/12: BAE Systems announces that they’ve picked the Elgin, OK facility in the Fort Sill Industrial Park for M109A6 Paladin PIM Low Rate Initial Production. This will move those jobs to Elgin about 2-3 years sooner than the original plan. BAE, in turn, wants to be next to the Army’s Artillery Center of Excellence and its experienced personnel.

The PIM LRIP award is expected in Q3 2013, and will involve just 72 PIM systems. Key components of the PIM production vehicles, including the chassis, will be sent to the Elgin facility from BAE Systems manufacturing facilities and suppliers. As part of final assembly and checkout, BAE Systems will use Fort Sill for mobility and firing verification.

July 30/12: Videogames & Telemetry. David Musgrave is the Army’s project lead for fire control software development on the M109A6 PIM, and he’s having a problem:

“We were encountering some problems with firing tests. I started asking questions looking for objective use data. How often does subsystem X fail? When it does fail, what was the user trying to do at the time? How often does a user perform Y task? The truth was I couldn’t get any decent answers. I was frustrated that there was a very limited information channel from our system back to us while it was being used.”

He thinks the solution might involve taking a tip from the videogame industry, which uses “telemetry” to track how people are interacting with the games, and what they’re using or not using. A presentation from BioWare’s Georg Zoller was especially inspirational, and Musgrave has a good head on his shoulders when it comes to the reality of implementation in the Army. He sees huge potential benefits for program managers, units, and soldiers alike, but only if the system doesn’t interfere with the weapon in any way, and the program doesn’t try to do too much. The biggest technical challenge will be finding a reasonable method to reliably get the tracking data back to a central server. See also US Army Article | Full RDECOM PowerPoint Presentation [PDF].

Jan 17/12: EMD. A $313.1 million cost-plus-incentive-fee contract modification for PIM engineering design, logistics and test and evaluation services, which will complete the Engineering, Manufacturing & Design phase. Work will be performed in York, PA, with an estimated completion date of Jan 31/15. One bid was solicited, with 1 bid received (W56HZV-09-C-0550). Additional EMD contracts bring the total to $401.6 million, and include:

• $88.5 million adds LRIP test support (July 18/14)

In discussions, BAE representatives added that the 7 prototype PIM vehicles (5 howitzers, 2 resupply vehicles) delivered in May 2011 have logged over 7,500 miles, fired over 2,600 rounds, and come through extreme temperature testing to complete Phase I of the Army’s Reliability, Availability and Maintainability (RAM) tests. Testing will resume in June 2012, and the next step after that is a June 2013 Milestone C decision, which would begin low-rate initial production. BAE release.

EMD Contract

Oct 24/11: EMD. A $9 million cost-plus-fixed-fee contract to provide refurbishment and analysis services for the PIM Bridge 3 effort. Work will be performed in York, PA, with an estimated completion date of Nov 30/12. One bid was solicited, with one bid received (W56HZV-09-C-0550).

Oct 5/11: EMD. A $9.8 million cost-plus-fixed-fee contract for the PIM Bridge 1 effort. Work will be performed in York, PA, with an estimated completion date of Nov 30/11. One bid was solicited, with 1 bid received by the U.S. Army Contracting Command in Warren, MI (W56HZV-09-C-0550).

Oct 5/11: T2. A $7.9 million cost-plus-fixed-fee contract to buy the PIM’s T-2 Armor Kits. Work will be performed in York, PA, with an estimated completion date of Sept 30/12. One bid was solicited, with 1 bid received by the U.S. Army Contracting Command in Warren, MI (W56HZV-09-C-0550).

Oct 5/11: Transmission. L3 Communications Corp. in Muskegon, MI receives a $7.9 million firm-fixed-price and cost-plus-fixed-fee contract, to develop a common transmission for the Bradley Family IFV/CFVs, and the Paladin Integrated Management vehicles. Work will be performed in Muskegon, MI, with an estimated completion date of Nov 15/13. One bid was solicited, with one bid received by the U.S. Army Contracting Command in Warren, MI (W56HZV-09-C-0098).

FY 2007 – 2011

From MoU to delivery on initial prototypes.

M109A6 PIM
(click to view full)

June 7/11: An $11.6 million cost-plus-fixed-fee contract modification, to buy PIM ballistic hulls and turrets. Recall that the new PIM chassis are being fabricated & assembled with Bradley common components.

Work will be performed in York, PA, with an estimated completion date of April 30/12. One bid was solicited, with one bid received (W56HZV-09-C-0550).

May 2011: Delivery. The 7 PIM prototypes are delivered to the U.S. Army, on schedule. Source.

Prototypes delivered

Oct 28/10: BAE Systems announces that they are on track to deliver 7 Paladin/FAASV Integrated Management (PIM) prototype vehicles to the U.S. Army on schedule, under the $63.9 million August 2009 research and development contract, announced in October 2009 (5 M109s, 2 FAASVs).

The initial PIM vehicles are conducting contractor testing in Yuma, AZ and Aberdeen, MD before they are delivered for government testing in January 2011.

June 15/10: An $8.7 million cost-plus-fixed-fee contract, for Paladin PIM line replaceable units. Work is to be performed in York, PA, with an estimated completion date of June 30/12. One bid was solicited with one bid received (W56HZV-09-0550).

Jan 20/10: Rollout. BAE Systems unveils its upgraded PIM (Paladin Integrated Management) vehicle to military customers, Congressional representatives, community leaders and employees at a ceremony held at its York facility. This is the 1st vehicle built under the Oct 5/09 contract. BAE Systems release.

Oct 5/09: Prototypes. BAE Systems announces a $63.9 million contract from the U.S. Army Tank Automotive & Armaments Command for 5 prototype M109A6 PIM self-propelled howitzer vehicles, and 2 prototype M992A2 Field Artillery Ammunition Support Vehicles (FAASV).

Development contract

Nov 4/08: PDFCS. BAE systems announces a $20 million contract from the US Army’s TACOM Life Cycle Management Command, to purchase and deliver 140 Paladin Digital Fire Control Systems (PDFCS) kits, and more than 60 spare components to support the system. They will be added to the 450 or so kits that have already been ordered under this contract.

Some of the kits under this contract will be installed on vehicles at fielding sites across the world, while others will be shipped to an Army Depot where they will be used on the Paladin reset line. Work will be performed by the existing workforce at BAE Systems facilities in York, PA; Sterling Heights, MI; and Anniston, AL beginning in September 2009. Deliveries are scheduled to be complete by January 2010.

Oct 9/07: MoU. BAE Systems and the US Army sign a memorandum of understanding (MoU), establishing a Public-Private Partnership to develop and sustain the Army’s M109 Family of Vehicles throughout their life cycle. BAE Systems release.

Oct 8/07: BAE Systems unveils the M109A6-PIM Paladin upgrade at the AUSA 2007 show in Washington DC. BAE Systems release.

Unveiling & Partnership

Additional Readings

Readers with corrections, comments, or information to contribute are encouraged to contact DID’s Founding Editor, Joe Katzman. We understand the industry – you will only be publicly recognized if you tell us that it’s OK to do so.

Background: Artillery & Shells

• US Army – M109 Family of Vehicles [PDF].

• BAE Systems – Paladin Integrated Management (M109A6 PIM).

• GlobalSecurity.com – M109 155mm SP Howitzer. The M109A6 Paladin has a separate, subsidiary entry.

• Wikipedia – M109 Howitzer. Good list of purchasing countries.

• Maine Military Authority – Capabilities: M-109 Howitzer. “Maine Military Authority stores M-109 Howitzers for the United States Army Security Assistance Center (USASAC). These Howitzers are available for sale to foreign militaries. Maine Military Authority has the capability to rebuild M-109 Howitzers and return them to fully Mission Capable (FMC) status. MMA has rebuilt 72 Howitzers to date for USASAC.”

• DID – GPS-Guided Shells: The New Excaliburs. Block Ib and Excalibur-S are relevant to the M109A7.

• DID – New Frontiers for Raytheon’s Excalibur GPS Guided Shells. From June 2013.

• DID – ATK’s PGK: Turning Shells into Precision Artillery. Less accurate and less range than Excalibur, but cheaper.

News & Views

• US Army (May 19/14) – Army inducts self-propelled howitzer into low-rate initial production.

• US Army (Sept 1/11) – Army developing new self-propelled howitzer.

• US Army (April 15/11) – Army harvests technology from canceled programs. Paladin PIM benefited from NLOS-C.

• NDIA National Defense Magazine (May 2010) – Army Resuscitates Mobile Artillery Program. Some NLOS-C technologies will move to the M109 Paladin PIM.

Adm. Gorshkov: Before.
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This free-to-view DID Spotlight article offers an in-depth look at India’s troubled attempt to convert and field a full-size aircraft carrier, before time and wear force it to retire its existing naval aviation and ships.

India faced 2 major challenges. One was slipping timelines, which risked leaving them with no aircraft carriers at all. The other challenge involved Vikramaditya’s 3-fold cost increase, as Russia demanded a re-negotiated contract once India was deeper into the commitment trap. The carrier purchase has now become the subject of high level diplomacy, involving a shipyard that can’t even execute on commercial contracts. A revised deal was finally signed in March 2010, even as deliveries of India’s new MiG-29K naval fighters got underway – but now Russia still has to make good. This article tracks the changes India is making to its new aircraft carrier, key characteristics, and a full history of contracts and events affecting this carrier and its planned aircraft contingent.

INS Vikramaditya: India’s New Carrier

After: INS R33
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Russian naval doctrine saw the 45,000t Admiral Gorshkov as a missile cruiser with a complement of aircraft. India wanted a full-fledged aircraft carrier. Getting there required extensive modifications.

The cruiser-carrier’s guns, anti-shipping and air defense missile launchers on the front deck were removed. In their place, India installed a full runway and ski jump, widened the deck in numerous places, and installed a bigger and stronger rear aircraft elevator.

Core ship systems were also slated for modernization. New boilers were installed to run on diesel fuel, for instance, and communications were improved. One nasty surprise that might have been expected was the need to replace most of the ship’s old wiring. Adding more reliable, higher capacity wiring will help make Gorshkov a fully modern ship, but it has been very labor intensive and expensive.

INS Vikramaditya’s weakness will be defensive. An official Indian CAG report says that INS Vikramadirya will have no aerial defenses until 2017. When it does, those weapons will need to integrate with the Russian LESORUB-E combat system, which means that weapon installation won’t take place until the carrier’s initial refit. The Navy would like to field the Barak-8/ MR-SAM missile for medium-long range defense, but integration could be challenging. They also want a close-in weapon system or 2, and intend to hold a competition rather than adopting the gun/missile Kashtan CIWS system carried by Russia’s own Admiral Kuznetsov carrier, or buying Russia’s lower-end 30mm AK-630.

Anti-submarine defenses are equally concerning. The Indian Navy only has 10 Ka-28s, and only 4 of those are operational. That deficit, plus a Sea King fleet that is small, old, and needs improvements, makes anti-submarine defense a big concern. India may end up outfitting its own Dhruv light helicopter with 1st-generation locally-designed ASW gear, and basing some on the carrier. That’s a fine stopgap solution, but a questionable medium-term option for defending their fleet flagship. A global tender for larger and more advanced ASW helicopters has been delayed since 2008.

Failure to add a modern towed sonar to its surface combatant ships juts makes things worse. Anti-submarine defenses will have to be improved within the fleet as a whole, if India intends to field a viable carrier force.

Gorshkov-Vikramaditya: Aerial Complement

Ka-31 AEW
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Many of Gorshkov’s key modifications are aircraft-related, including the new arrester gear and ski jump. That’s just the down-payment on the final cost of an operational carrier, because the aircraft are bought separately.

The original cruiser-carrier’s complement was 12 Yak-38 Forger V/STOL(Vertical/Short Take Off and Landing) fighters, 12 Ka-28 helicopters, and 2 Ka-31 airborne early warning helicopters. The removal of the Gorshkov’s forward missiles, addition of the ski ramp, and other modifications will improve the ship’s air complement, but the nature of its original design means that INS Vikramaditya will still fall short of comparably-sized western counterparts. Carriage ranges given for the refitted Vikramaditya seem to converge around 16-24 fighters, and 10 compact Ka-28/31 or Dhruv helicopters.

In contrast, the 43,000t FNS Charles de Gaulle nuclear-powered aircraft carrier is about the same size, with a 40-plane complement that leans heavily to fighter jets. The FS Charles de Gaulle will also have an advantage in surveillance coverage, thanks to catapults that let her operate E-2C Hawkeye 2000 airborne early warning planes. INS Vikramaditya won’t have that option, because it doesn’t have a launch catapult.

The carrier’s AEW complement, if any, is almost certain to use India’s Ka-31 helicopters instead. That means a smaller radar, on a slower platform, offering much less coverage.

MiG-29K 3-view
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Vikramaditya’s fighters will also be Russian. Its air wing will draw on a fleet of 45 Indian MiG-29Ks, thanks to about $1.95 billion in contracts. The initial $740 million contract for 16 MiG-29K (12 MiG-29K, 4 two-seat MiG-29KUB) aircraft plus training and maintenance was confirmed on Dec 22/04. The contract’s option for another 29 planes, rumored to be worth another $1.2 billion, was signed in March 2010. The MiGs would be operated in STOBAR (Short Take-Off via the ski ramp, But Assisted Recovery via arresting wires) mode.

MiG’s design was reportedly selected over the larger and more-capable SU-33 naval fighter for several reasons. One is that India already operates a large fleet of MiG-29s, and has been improving its ability to maintain them in country. Another reason is that India also wants to operate naval fighters from its locally-built 37,500t – 40,000t “Project-71 Air Defence Ship” (Vikrant Class) STOBAR carriers. The SU-33s wouldn’t be an ideal choice for a carrier that size, Britain hadn’t yet put its Harrier feet up for sale, and India’s own Tejas Naval fighter project remained a high-risk option. That left the MiG-29K as India’s only rational choice, and Russia followed with an order to equip their own carrier.

Waiting for Gorshkov – A History

On Jan 20/04 India and Russia signed a $947 million deal to refurbish and convert the Soviet/Russian Admiral Gorshkov into a full carrier, to be re-named INS Vikramaditya. The announced delivery date for INS Vikramaditya was August 2008 – an ambitious schedule, but one that would allow the carrier to enter service in 2009, around the time as their 29,000t light carrier INS Viraat (formerly HMS Hermes, last of the Centaur class) was scheduled to retire. The new carrier would berth at the new Indian Navy facility in Karwar, on India’s west coast.

That was the plan. Unfortunately, the Vikramaditya story is sadly typical of both Indian defense procurement, and of Russia’s defense industry.

Denial, Delay & Disagreement

Now what?
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Initial reports of delays sparked controversy and denials in India, but subsequent events more than justified them. Slow negotiations and steadily-lengthening delivery times quickly pushed delivery of the Gorshkov back to 2010, and then to 2012 or later, even as Russia’s asking price more than doubled. India’s sunk construction costs, Russian possession of the Gorshkov, the difficulty in finding a substitute carrier to replace the Gorshkov sooner than 2013, and the Chinese push with the Varyag, have all combined to give the Russians substantial leverage in their negotiations.

They exploited that leverage to the fullest. Cost estimates and reports concerning the Gorshkov’s final total now hover in the $2.9 billion range, following the revised project agreement of March 2010.

As is customary with Indian defense procurement, transparency arrived only after all other alternatives had been exhausted.

When reports first surfaced that this delivery date would not be met, India’s Ministry of Defence initially tried to deflect the issue with denials and obfuscation. In May 2007, Chief of Naval Staff Admiral Sureesh Mehta said the ships will be delivered:

“…by late 2008 or early 2009… Our officials, who are stationed at the spot, have said that the work is going on as per schedule and we can have a month long delay once the work is completed as that part of Russia is frozen for a long time.”

Later comments on this issue included this May 1/07 quote:

“The work is only three to four months behind schedule and we can expect the aircraft carrier to be delivered by late 2008 or early 2009”

Neither assessment turned out to be true, and subsequent updates proved the critics to be correct. After the delivery delays could no longer be denied, the initial approach was to minimize their length. February 2008 news reports, however, began to give figures of up to 3-4 years before refurbishment and testing could allow the ship to enter service. Subsequent reports by Indian and Russian sources stressed 2012, or even later.

Those estimates, at least, turned out to be true. The carrier didn’t see operational service of any kind until May 2014, and it will take even longer before it’s fully ready to fight.

India’s Carrier Collapses

INS Viraat
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The delays have left India’s Navy with a serious scheduling problem, and created periods with no significant carrier force.

INS Viraat’s retirement was scheduled for 2009, but Vikramaditya’s delays forced India into another refit, leaving the country without a carrier for 18 months until August 2009. Even with the refit, Viraat is nearing the limits of her mechanical life, and shortages of flyable Sea Harrier fighters are creating issues of their own. Subsequent refits and overhauls will try to keep the carrier, whose keel was laid in 1944, running until 2018. When she did return after an unexpectedly long refit, she had just 11 flyable Sea Harrier fighters available.

India’s other option was the locally-built Vikrant Class “Air Defence Ship” escort carrier project, which received formal government approval in January 2003. It was supposed to field a 37,500t – 40,000t carrier by 2013-2014; instead, Vikrant’s operational acceptance into the fleet slipped to 2018, then 2019.

To the east, China bought the engineless hulk of the 58,000t ex-Russian carrier Varyag in 1998, towed her to China, and worked hard to refurbish her. The ship began trials in 2012. By September 2012, reports surfaced that the ship had been re-named “Liaoning,” in honor of the province where it was retrofitted. She began sailing before the end of the 2012, and the ship has launched and recovered J-15 (SU-33 derivative) naval fighters. In May 2013, China declared an official naval aviation capability. Reports have China aiming for 4 carriers in the medium term.

Contracts & Key Events 2014 – 2018

Arrival in India; Competition for air defense systems; Maintenance agreement with Russia.

Two again 2018

October 24/18: Sea trials India’s sole operational aircraft carrier will start sea trials by the start of next week. The INS Vikramaditya recently completed its second refitment at Cochin Shipyard, a process which cost close to $96 million. Captain Puruvir Das, the carrier’s commanding officer, told the New Indian Express “soon, we will start the sea trials, which will take place off the Kochi and Goa coasts. We are hopeful of returning to the Western Naval Command without delay.” During the refitment major work was carried out, including an extensive hull survey and repainting, as well as some large scale repair of the ship’s shaft system. “The refitment will enhance the operations of Vikramaditya. It will be ready for sea operations once the trials are completed,” added Captain Das. The Kiev-class former Russian Navy aircraft carrier has been in service since 2013 and upgrade of its infrastructure were started in September 2016.

July 12/18: India’s plan to build and commission its second indigenous aircraft carrier has been postponed again. Steadily declining budgets, technological hurdles and prolonged delays by the Ministry of Defense in approving the program make it very unlikely that the Vishal will enter service by 2030-2032. The proposed 65,000–70,000 ton conventionally powered ‘flat top’ carrier would be capable of embarking 50–60 fixed- and rotary-wing platforms and cruise at 30 knots, but it would also cost between $12 – 13 billion. India’s Navy has currently one carrier in operation the refurbished Soviet-era Kiev-class Vikramaditya. By 2018–19, Vikramaditya was to have been supplemented by INS Vikrant, the 37,000-tonne Project 71 carrier with a short take-off but arrested recovery (STOBAR) configuration that has been under construction since 2009 at Cochin Shipyard Limited, southern India. At this point the Vikrant is scheduled to enter service by October 2020. The Indian Navy plans to field three carrier battle groups under its Maritime Capability Perspective Plan.

2015

December 10/15: The INS Vikramaditya is set to get its first overhaul, the Indian Navy has announced. The Kiev-class former Russian Navy aircraft carrier has been in service since 2013 and upgrade of its infrastructure is set to be under way by September 2016. Works will be undertaken by Cochin Shipyards (CSL), who recently released India’s first indigenously built aircraft carrier, the INS Vikrant, to the Navy. CSL will no doubt be utilizing the experiences learned during the Vikrant’s construction during the refit.

December 8/15: India’s first indigenous aircraft carrier will be delivered to the Indian Navy by December 2018. The INS Vikrant was undocked in June by Cochin Shipyard (CSL) who are anxious to start construction of a second vessel, although no formal agreements have been made. Some minor delays have been experienced due to lack of availability of warship grade steel, and delays in Russian approval over designs and equipment supply. When commissioned, the INS Vikrant will become the third aircraft carrier in service in the Indian Navy, which has been increasing its fleet size to boost India’s presence in the Indian Ocean.

July 16/15: India’s INS Vikramaditya is scheduled to leave Karwar next week after a recent refit. As per previous reports, the carrier has been updated with new air defense systems, including the Barak-1 missile system and the Russian AK-630 close-in weapon system (CIWS). The Indian Navy carried out feasibility studies for the integration of the two systems in June 2014, with the original plan being to fit the vessel with the Barak-8 missile system, jointly developed with Israel; however, development delays led to the carrier being fitted with the older Barak-1 system.

Dec 4/14: Vikrant Schedule. Vice Admiral Anil Chopra, Commander-in-Chief of the Western Naval Command since last June and the 2nd most senior officer in India’s navy, tells reporters that INS Vikrant is now to be commissioned in 2019, months later than the previous already-postponed deadline. Plans to build a second carrier in the class will be “initiated soon.” Source: Free Press Journal.

Aug 25/14: Infrastructure. Defense World claims that India is preparing to field a 2nd MiG-29K squadron in the east, as part of a major upgrade that will grow INS Dega in Vishakapatnam from 1100 to 1500 acres. An initial outlay of INR 4.5 billion (about $75 million) was reportedly approved this month to build MiG-29 fighter and Hawk trainer support and infrastructure there, in preparation for MiG-29K arrival some time in 2015. The Navy is also looking at reactivating Bobilli, a disused, World War II airfield about 45 nautical miles away, as a secondary divert base. The Business Standard:

“The volume of naval aviation that the airbase is slated to handle will bring it almost at par with the largest naval airbase INS Hansa [on the western coast, in Goa]. The workload will include accommodating the full squadron of MiG29K/KUBs as well as the [Navy’s] Advanced Jet Trainer (AJT) Hawks, nine of which are already operational and eight more will arrive by June 2016, along with their required infrastructure and support set up. INS Dega will also field a large chunk of aircraft which form a part of future acquisitions like Multi Role Helicopter (MRH), 56 Naval Utility Helicopters, Naval Multi Role Helicopters (NMRH) as well as Unmanned Aerial Vehicles (UAVs).”

Some reports characterize this move as preparation for the new Vikrant Class carriers under construction. INS Dega will eventually be used that way, but the carriers aren’t going to arrive before 2019. Until then, INS Vikramaditya will have squadrons available on 2 coasts. A parallel ‘Project Varsha’ program would add a major new naval base near Rambilli, 50 km south-west of Visakhapatnam, which will be able to house aircraft carriers and nuclear submarines. Indian history strongly suggests that Project Varsha won’t be ready in time to welcome INS Vikrant. Sources: India Today, “EXCLUSIVE: Navy initiates ‘Look East’ for lethal MiG29K” | Economic Times, “Navy to deploy MiG 29Ks in Vishakhapatnam; move aimed to strengthen eastern coast” | Business Standard, “New naval base coming up near Visakhapatnam”.

June 16/14: Dhruv ASW? India is reportedly looking to outfit their locally-designed HAL Dhruv helicopter with some anti-submarine equipment from the state’s DRDO research agency:

“The Hindustan Aeronautics Limited-built ALH Dhruv is undergoing trials for carrying out role of detecting hostile submarines using systems developed by the DRDO, Defence officials said…. The system was put under trial at Vishakhapatnam and would be tried further before any final decision is taken on deploying the twin-engine chopper on board the carrier, they said.”

The Dhruv is in the same size and weight class as AgustaWestland’s Lynx, but the final result of this program is likely to fall rather short of capabilities possessed by the AW159 Wildcat, or of larger machines like the NH90 NFH or MH-60R Seahawk. On the one hand, adapting an existing HAL platform circumvents India’s broken foreign procurement system, creating a second-rate but deployable near-term solution for their astonishing weakness in this area (q.v. March 31/14). It also creates a platform that can be improved over time, which is good for India and its industry.

On the other hand, providing sub-standard protection to the flagship of one’s naval force is a terrible idea if it’s the only proposed solution. The question is whether the long-discussed foreign tender (q.v. Feb 25/14) for helicopters like the NH90 will also go forward, in order to equip platforms like India’s high-end destroyers (q.v. Oct 15/13) and add a higher tier of shipborne ASW protection for key assets. Sources: IBD Live, “Dhruv chopper likely to be deployed on-board INS Vikramaditya”.

June 4/14: “Slammer”. Welcome to the world of assisted carrier landings. A 2-seat MiG-29KUB pilot just found out the hard way, after flying in from INS Hansa’s shore base. He was going to miss R33’s first 2 arrester wires, but as he throttled up for a bolter takeoff, his jet caught the 3rd wire with the arrester hook. The MiG’s nose reportedly pointed skyward before slamming back to the deck.

Everyone is fine, but the nose wheel is going to need repair or replacement, and the pilot may wind up with a new nickname. We recommend “Slammer,” in the long and proud tradition of handles that sounds cool but refer to something embarrassing.

There will be more incidents like this, as Indian aviators become more familiar with this new landing mode. Sea Harriers will absolutely kill you for a misstep during vertical landings, so it isn’t like this is some new frontier of required professionalism. It’s just that a full-speed trap is a very different animal, with its own skills and dangers. Sources: Calcutta Telegraph, “Safety scare on Gorshkov”.

May 16/14: ASW weakness. Ajai Shulka says the reason that operational safety was the reason that Vikramaditya was joined by an armada of Indian warships for the last leg of its journey to Karwar. The problem is the lack of an effective towed sonar on Indian surface combatants, due to obstruction by the defense bureaucracy. Coming as it does on top of the MoD derelict performance with respect to anti-submarine helicopters, it creates a huge naval weakness that would doom India’s carriers in a shooting war. Read “Anti-Submarine Weakness: India Has a Problem” for full coverage.

ASW weakness

May 7/14: Navy chief Admiral Robin Dhowan says that:

“The navy has inducted aircraft carrier INS Vikramaditya which is now operationally deployed with MiG 29K aircraft embarked and being flown by Indian naval pilots…”

Looks like India has made real progress since the 1st all-Indian flight (q.v. Feb 7/14), and reports also indicate that the carrier has taken part in a recent war game with India’s Western Navy. INS Vikramaditya will remain India’s core carrier option for some time, as Vikrant isn’t expected to be ready until the end of 2018. Sources: India’s Business Standard, “INS Vikramaditya is operationally deployed with MiG- 29K aircraft: Navy Chief”.

Accepted into fleet

March 31/14: ASW weakness. Not only will India’s carrier sail without onboard air defenses, it and its escorts can’t field an effective set of anti-submarine helicopters.

“The Navy is today being asked to make do with four Ka28 helicopters that have the technology of mid-80s for training pilots, doing ASW roles against modern submarines for the five Rajput Class destroyers as well as the aircraft carrier Vikramaditya,” said a source.”

The other 6 Ka-28s have been mothballed for spares, while a mid-life upgrade that would restore the 10 to flying condition and give them modern sensors has been trying to get underway since 2008. Bids were finally opened in 2012, and a combination of Russia’s Kamov and Italy’s Finmeccanica won the INR 20 billion project. Contracts are set, and both the Cabinet Committee of Security and India’s CBI investigators cleared the deal. Defence Minister Antony’s office has been sitting on that for over a month, however, while playing extreme hardball with AgustaWestland over the VVIP helicopter deal.

Meanwhile, the Sea King fleet has problems of its own, and a proposal to buy up to 16 modern naval helicopters from foreign sources remains stalled (q.v. Feb 25/14, Oct 15/13, Aug 17/12). Sources: Daily Mail India, “Navy left ‘defenceless’ after being forced to ‘make do’ with outdated Soviet hardware”.

ASW weakness

March 13/14: Support. India has decided to stick with Sevmash shipyard in Russia’s northern Arkhangelsk region for long-term post-warranty servicing of INS Vikramaditya. The relevant protocol was signed in Goa on Wednesday, March 12, at the 23rd Indo-Russian Inter Governmental Commission on Military Technical Cooperation’s (IRIGC-MTC) naval subgroup meeting. The full 20-year contract is expected in May 2014.

Sevmash engineers and specialists are already providing warranty maintenance services for the 1st year of operation, and there was no question that India would have to extend the relationship. Even an aggressive indigenization program would take a few years to gear up and provide adequate service. Still, 20 years is a puzzle. Given India’s past problems with Sevmash specifically, and with Russian maintenance and support generally, their flagship aircraft carrier appears to be an odd exception to the government’s recent indigenization push. Sources: India & Russia Report, “Sevmash chosen for INS Vikramaditya post-warranty servicing”.

Nyet, Spassiba

March 12/14: Weapons. India reportedly rejected Russian offers to mount their Kashtan gun/missile close-in air defense system on INS Vikramaditya, which were reportedly made during a recent meeting of the India-Russia Inter-Governmental Commission on Military Technical Cooperation. It’s not a final rejection, but their experience with Russian maintenance is reportedly pushing them to hold an open competition. That could be a fine opportunity for a range of systems. KBP’s Kashtan would be eligible to bid, but so would bolt-on, independently-operated options like Raytheon’s SeaRAM missiles or Phalanx 20mm gun, or systems like MBDA’s Mistral-based Simbad/Tetral.

INS Vikramaditya is eventually supposed to use the medium range LR-SAM/ Barak-8 as its main air defense weapon. A close-in defensive option will be needed until India tests and fields it, and it will remain a good idea even after LR-SAM has been installed. Sources: Defense Radar, “Indian Navy To Open Search for Carrier Air Defense System.”

Feb 25/14: Helicopters. India’s Ministry of Defence clears a whole series of defense projects: upgrades for 37 airbases, modernization of 5 ordnance depots, 4,000 hand-held thermal imagers for soldiers, 5,000 thermal imaging sights for tanks and infantry combat vehicles, 44,000 light-machine guns, 702 light armoured multi-purpose vehicles, and 250 RAFAEL Spice IIR/GPS guided smart bombs. The deal’s not done?

A program to buy M777 howitzers, 56 transport aircraft to replace the ageing Avro fleet, produce 4 amphibious LPDs – and 16 naval multi-role helicopters to restore an effective anti-submarine capability. With elections looming, it will take some time before any of them are restarted. Sources: Times of India, “Decision on four key defence deals put off”.

Feb 7/14: Indian landing. A MIG-29KUB fighter lands on Vikramaditya. That has happened before, but it’s the 1st time with an Indian naval officer at the controls. Indian naval aviation has relied on Sea Harrier vertical-landing jets for decades, which makes this arrested landing a milestone for the Navy as a whole, as well as for the ship.

While the 303 Sqn. Black Panthers were commissioned in 2013, the ship will take another 3-4 months before they’re fully ready. It might even take longer, but reports of troubles on the ship’s journeys are probably exaggerated. The complaints amount to postponing refueling with INS Deepak in rough seas off of Portugal, and a reported boiler breakdown. The first complaint is trivial, but the boiler issue could be a problem, given past issues with that machinery. Even India’s Navy won’t know how big an issue this is, until debriefings are done and the report is in.

As the local beachgoers already know (q.v. Jan 14/14), a team of Russian specialists have arrived on board, and will stay in India for a year as technical backup. Itar-Tass, “First Indian-piloted MiG safely lands on Vikramaditya aircraft carrier” | RIA Novosti, “First Indian MiG-29 Fighter Jet Lands on Vikramaditya” | Hindustan Times, “Choppy first ride home for INS Vikramaditya”.

Black Panthers MiG-29KUB lands

Jan 21/14: The UK’s Daily Mail reports that Karwar’s new shore-based test facility (SBTF) replica of Vikramaditya’s flight deck on the ground has now become fully operational, adding that Indian pilots will begin flying operations from the ship very soon. Landings will take place at the SBTF, before working up to full ship-based operations. Sources: “Navy gets ready to start Vikramaditya flying ops”

Jan 14/14: Culture shock. Some Russian support personnel who are in town to help keep INS Vikramaditya ship-shape end up having a close encounter with the local police, after they leave the ship to have a few drinks and spend time on the beach. Public nakedness and carriage of alcohol doesn’t go over very well in Karwar, apparently, though a local resident suggests that Goa might be more into that sort of thing. Good to know. Indian Express, “Vikramaditya Brings Russian Culture to Karwar, Irks Locals”.

Jan 5/14: Arrival. INS Vikramaditya arrives in the Indian Navy’s Area of Operation in the Arabian Sea, marking the 1st time in over 20 years that India has 2 carriers at sea. The ship quickly gains an escort flotilla that includes the existing carrier INS Viraat, 2 Delhi Class destroyers, 3 Trishul Class frigates, a Godavari Class frigate, and “a couple of offshore [patrol] vessels.”

The carrier pulls into Karwar by Jan 8/14. Sources: Economic Times photo page, “INS Vikramaditya arrives: Navy operates two aircraft carriers after 20 years” NDTV, “INS Vikramaditya, India’s biggest warship, finally arrives” | Defense Update, “India’s Largest Carrier INS Vikramaditya Arrives at Karwar Home Port”.

2013

1st MiG-29K squadron commissioned; INS vikramaditya handed over and begins her long sail home.

MiG-29KUB on carrier
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Nov 27/13: Sailing home. INS Vikramaditya sets sail for India under the command of Captain Suraj Berry, without any operational aircraft on board. After bunkering and completing customs papers, India’s new carrier will head for the Russian port of Murmansk 215 km away, to join the frigate INS Trikhand and fleet tanker INS Deepak. The flotilla is expected to reach India by the end of January 2014, where it will homeport at the new Karwar base. Even then, the Indian Navy admitted that the ship would take at least 2 years to be ready for full-scale operational deployment – without weapons.

India is still finalizing the proposed weapon fit-out. The Navy would like to field the Barak-8/ MR-SAM missile for medium-long range defense, along with a close-in weapon system or 2. Russia’s Kashtan, which equips Russia’s own Admiral Kuznetsov, would be a high-end gun/missile CIWS option. The AK-630/ A-213-Vympel-A would offer a lower-end, gun-only option. Those weapons will need to integrate with the Russian combat system, and the priority placed on fighter pilot qualification means that weapon installation won’t take place until the carrier’s initial refit. Which is to say, around 2017 at the earliest.

A team of Sevmash specialists remain on board the ship to help with the voyage, and the shipyard hopes to sign a 20-40 year support contract with India after the initial 1-year guarantee period is done. Sources: The Hindu, “INS Vikramaditya sets sail for India” | RIA Novosti, “Refitted Aircraft Carrier Sails Out From Russia to India”.

Nov 16/13: Handover. INS Vikramaditya is handed over to the Indian Navy at Sevmash shipyard, in Russia. That was supposed to happen in 2008. Sources: Indian Navy, “Navy’s largest ship ‘INS Vikramaditya’ Commissioned” | RIA Novosti, “Russia Passes Refitted Aircraft Carrier to India After 5-Year Delay”.

Ship transferred and sets sail for Karwar

Nov 7/13: MiG-29K. India will soon move its 2nd MiG-29K squadron to Naval Air Station INS Dega, on the eastern seaboard in Vishakhapatnam. The Indian Navy’s Hawk Mk.132 advanced jet trainers are already based there, and so is the Maritime Naval Academy. India’s semi-indigenous Vikrant Class carrier will homeport in Vishakhapatnam once it’s complete, but that isn’t expected until at least 2017. Source: Times of India, “MiG 29K squadron base at Vizag soon, says Navy chief Joshi”.

Oct 15/13: Helicopters. India’s anti-submarine issues continue to surface, which is a serious weakness for a fleet air arm and for a carrier. How serious is it?

“The Navy has given an insight into how it is placed during its ongoing exercise with the Royal Navy off the Goa coast. The Royal Navy’s HMS Westminster – a type-23 frigate known for its advanced anti-submarine capability – is taking part in the exercise Konkan. The frigate is equipped with Merlin helicopters – the maritime version of triple-engine AgustaWestland EH-101 that is used extensively by the Royal Navy… The Indian Navy has pitched a Delhi class destroyer, which is a formidable platform, but it carries only one helicopter although it is capable of operating two. The only helicopter on the destroyer is Chetak, which has a limited role in search, rescue and communication. It cannot carry out advanced anti-submarine or anti-surface operation.”

That isn’t what you want defending your carrier. Sources: Daily Mail India, “Chopper shortage rattles Indian Navy during joint exercise with British fleet”.

Oct 14/13: Delays. After the September 2012 blowout (q.v. Sept 17/12), the program expected a handover delay until October 2013. Russian media report that Vikramaditya’s handover to India will take place on Nov 15/13, and the ship will sail out of Russian waters by Nov 30/13.

Russian Deputy Prime Minister Dmitry Rogozin says that: “The problems revealed during sea trials last year have been fixed.” Assuming that he’s correct, and that no new problems surface, the ship is now expected to arrive in Mumbai sometime in February 2014.

Aug 1/13: INS Viraat. Livefist reports that India has decided to keep the 1950s-era INS Viraat in service until 2018. Viraat isn’t really equipped for MiG-29Ks, and there’s some question whether its Sea Harrier contingent will last that long.

May 11/13: MiG-29K. India formally commissions the MiG-29K into the Indian Navy, beginning with the 303 Black Panthers Squadron at INS Hansa, near Goa. The squadron has 16 fighters and full on site training infrastructure now, as opposed to the 4 planes on hand when the MiG-29K was inducted for trials in February 2010.

The announcement comes 1 day after the Chinese formally announced the beginning of their own carrier aviation capability, on May 10. The Chinese fly larger and longer-range J-15 fighters, which are based on Sukhoi’s SU-33 design. The Diplomat | Business Standard | Economic Times | Hindustan Times | Times of India.

MiG-29K inducted

2012

Sea trials – and boiler blowout; Delivery delayed another year; 1st MiG-29K operations from the carrier deck; Russia adds itself to the MiG-29K customer list.

Sea trials begin
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Dec 24/12: The 2012 Russian-Indian summit in New Delhi features a number of military and civilian deals, but problems with the Vikramaditya also force their way onto the agenda. The statement itself doesn’t mean much; the meaning is contained in the fact that this statement was included at all. Over $4 billion in defense purchases weren’t specifically mentioned in paragraph 21 of their joint statement, which did find time to say that:

“Both sides discussed measures required to ensure expeditious delivery of the aircraft carrier «Vikramaditya» to India. The Russian side assured that requisite measures would be taken in this regard.”

Nov 3/12: INS Viraat. India’s lone aircraft carrier arrives for a refit at the Cochin Shipyard (CSL). The work is expected to last at least 3 months, and by March 2013, the projection for its return to service is July 2013 (9 months) – or later. India won’t have an operational carrier while the refit takes place, and at the end, they’re left with the carrier and just 11 Sea Harrier fighters. The Hindu | Economic Times | NDTV | Rediff | CDR Salamander.

Oct 10/12: Penalties? Russian Defence Minister Anatoly Serdyukov confirms a 1-year delivery delay, as he arrives in New Delhi for high level talks.

Under the contract, India can impose a penalty of up to 5%, and Ministry of Defence officials have been quoted using a figure of Rs 600 crore (currently about $113.8 million). Russia’s argument is that India didn’t impose a penalty on DCNS for the 3-year delay in delivering Scorpene submarines, but India has acknowledged that its own industry was largely at fault in that case. Unless Russia successfully pushes India into citing required ship design changes as a similar “fault,” the 2 situations are distinct. India Today | Zee News.

Sept 17/12: Blowout. The Vikramadiya has to take 7 of its 8 boilers offline when it tries to go to maximum speed of 30 knots in trials. This is an important ability for a carrier, which needs to generate airflow under its aircraft wings during launch. What the heck happened? Well, India didn’t want to use asbestos as heat protection for the boilers. It’s a definite safety hazard to crews. Instead, the boilers’ designer had to use firebrick ceramics. Which, as we see, didn’t work so well. Especially on a ship that Russia put up for sale in 1994, after a boiler room explosion.

They’ll have to cut the ship open to replace the boilers, which can’t happen until spring. Specialists from the Baltisky Shipyard and boiler design bureau are already at Sevmash shipyard, and the worst case would be damage to the pipes carrying steam from the boilers. The pipes are made from a special steel which is no longer made in Russia, and would need to be bought from the Ukraine. Meanwhile, reports are conflicting. Some say that Vikramaditya can still operate at reduced power, which could allow MiG-29K and systems testing when the weather cooperates, until the ship has to go in for repairs.

The operation is expected to cost Sevmash at least $30 million, and it will be interesting to see if they try to pass the cost on to India, on the grounds that Indian specifications caused the problem. That’s true, but asbestos isn’t a reasonable option, and another re-negotiation attempt isn’t likely to improve relations. The new date for a handover is October 2013, a 10-11 month delay. Business Standard | The Hindu | Livemint | Russia’s RIA Novosti.

Boiler blowout

Aug 17/12: Helicopters. India’s Mk.42B Sea King utility/ASW helicopters have readiness issues, which is a problem because India has a shortage of working anti-submarine helicopters. Upgrades have been delayed, and India is considering packages from AgustaWestland and an Israeli consortium. Upgrades to the 20 or so helicopters would include new avionics, electronic warfare suites, new communication kits, and an all-new weapons suite with anti-ship and anti-submarine ordnance. Sources: SP’s Naval Forces, “Indian Navy Sea Kings upgrade process soon”.

July 28/12: MiG-29K. The first carrier landings and takeoff take place on Vikramaditya, in a MiG-29KUB piloted by RAC MiG test pilots Mikhail Belyaev and Nikolai Diorditsa. RAC MiG.

1st Landing & Takeoff

July 16/12: ADS Watch. Vikramaditya and its air complement had better work well, and mesh swiftly, because there is no backup option. India’s Economic times reports that the 40,000 tonne Vikrant Class (aka. Indigenous Aircraft Carrier or Air Defense Ship project), being built at Cochin Shipyard has “slipped another three years.” The keel was laid in 2009, and it was prematurely floated out of drydock in December 2011, due to delays involving gearboxes and other systems. An anonymous MoD source is quoted as saying that:

“The fact is IAC will not be ready anytime before 2017. In a recent high-level meeting, the Cochin Shipyard was sharply pulled up for this huge delay… IAC is just about 14,000 tonnes at present [instead of the 25,000 tonnes it was supposed to be at launch].”

The original 2002-2003 period contract is already over its Rs 3,261 crore budget, and the follow-on contract to take it from “launch to completion” hasn’t been signed yet. The question isn’t whether the Navy will have 2 carrier strike groups by 2015, as planned; now it’s whether they’ll have that by 2020. Innovative thinking might be able to turn the existing INS Viraat into a useful helicopter and UAV carrier by 2015, if India moved swiftly – but that has never been the MoD’s forte. India’s Economic Times.

July 23/12: MiG-29K. A 2-seat MiG-29KUB naval fighter flown by Russian test pilots jet makes the 1st touch-and-go landings on Vikramaditya, during sea trials in the frigid Barents Sea. A touch-and-go isn’t really a landing, since the jet doesn’t stop. It comes in on approach, touches down on the flight deck, then revs the engines to full power and flies off the front. RIA Novosti.

June 8/12: Sea trials. Vikramaditya leaves the Sevmash shipyard, and heads out for naval trials in the White Sea. Defense News.

Sea trials

May 24/12: The Sevmash shipyard says they’ll have to postpone the Vikramaditya’s naval trials in the White Sea and Barents Sea. The date is now early June – or later, if the weather continues to be bad. That far north, poor conditions means more than just rain and waves. Times of India.

May 14/12: Project update. Minister of Defence Shri A.K. Antony’s written reply to Shri Purnmasi Ram in Lok Sabha, adds nothing new about India’s upgraded Sea Harriers, but says that India has now inducted 15 MiG-29Ks, and plans to induct INS Vikramaditya in December 2012.

Feb 29/12: MiG-29K. India won’t be the type’s only customer, now that Russia has ordered 24 planes for its own naval aviation squadrons.

2011

MiG-29K deliveries continue; Eurofighter MMRCA contender offers naval STOBAR option; Sea trials delayed.

Navalized Typhoon concept
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Oct 16/11: Indian media report that Vikramaditya’s sea trials will be delayed 5-6 months, to February or March 2012, because open sea trials aren’t possible from Severodvinsk in northern Russia during the winters. Instead, the ship will do everything they can in the harbor, then hold sea trials when the ice is out.

PTI was told by “senior Defence Ministry sources” said the change in trial plans will not affect the delivery schedule of the aircraft carrier – but then, they have been wrong and even misleading before. The more puzzling question is why it took until October 2011 to realize that conducting sea trials in northern Russia, in November, is unworkable. PTI | Voice of Russia.

Aug 3/11: MiG-29K. RAC MiG CEO Sergei Korotkov places the number of MiG-29Ks delivered to date at 11, with the initial order’s other 5 slated to arrive by the end of 2011. Work of the 2nd MiG-29K order of 29 planes is just beginning. AFP | domain-b | Hindustan Times | Voice of Russia.

Aug 2/11: The Indian MoD offers an official update of progress on the Vikramaditya – and its smaller cousins:

“Consequent to signing of Supplementary Agreements in March, 2010, the Russian side has increased the manpower and material resources considerably for the Project. A majority of the equipment/systems have been installed on board the ship. The delivery of ship is scheduled in December, 2012.

Regarding the ‘Air Defence Ship’ [DID: 35,000t carrier] being constructed at Cochin Shipyard Limited (CSL), 75% of hull work has been completed and is expected to be launched in December 2011, after which further works will be undertaken prior to commissioning… indigenous Aircraft Carrier-sized ships can [now] be built at CSL. Additionally, Indian-manufactures warship quality steel is now available, which will reduce dependence on foreign countries.”

June 23/11: MiG-29K. A prototype MiG-29KUB trainer crashes in Russia. The plane was a test aircraft belonging to RAC MiG, and the company advised the Indian Navy to temporarily suspend MiG-29K operations until the crash’s causes were known.

India asked for a detailed report, and according to the MoD, the crash wasn’t because of a structural failure in the air, engine failure, or avionics/ systems failure. By June 28/11, RAC MiG advised that MiG-29K flights could resume if India wished. India MoD.

MiG-29K crash

May 30/11: MiG-29K. RAC MiG announces that they delivered a new batch of 5 MiG-29K/KUB carrier-based fighters to the Indian Navy in May, along with a flight training simulator and other technical equipment. That’s on top of the first 4 aircraft, \r

• which officially entered service with the “Black Panthers” naval squadron in February 2010, and makes 9 of 12 delivered on the initial carrier/aircraft contract.

The March 2010 contract for 29 more MiG-29K Fulcrum-Ds won’t begin delivery until 2012. Economic Times of India.

April 4/11: The Admiral Gorshkov is expected is to reach Murmansk in November 2011, as it heads to Murmansk ship-repair yard # 35 from Sevmash. The carrier is expected to undergo further upgrades and performance testing. Barents Nova.

Feb 21/11: Naval Eurofighter? Aero India 2011 sees Eurofighter and BAE unveil an interesting wrinkle: an initial design for a navalized Eurofighter than can operate from aircraft carriers, based on an internally-funded set of studies and simulations. In a direct nod to potential Indian sales, they tout the plane as being able to take off from “ski jump” carriers without catapults – a design that describes all of India’s current and planned carriers, but not the French carriers that launch the Rafale fighter.

Eurofighter GmbH describes the goal as 95% commonality with land-based aircraft, and required changes as “limited… include a new, stronger landing gear, a modified arrestor hook and localised strengthening on some fuselage sections near the landing gear, as well as updates the EJ200 engines,” which could include thrust-vectoring in flight.

The Eurofighter and Rafale are later picked as India’s 2 finalists for its M-MRCA fighter competition. Eurofighter GmbH | India Defence.

2010

Carrier agreement raises refit costs to $2.33 billion; India inducts MiG-29K, orders 29 more; Russian affair by program chief.

MiG-29K flight test
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Aug 9/10: Scandal. Indian Commodore Sukhjinder Singh, who was a key person in the Gorshkov refit program from 2005-2009, has reportedly handed in his resignation after reports of his illicit affair with a Russian woman (vid. April 12/10 entry). The inquiry by Indian naval HQ established the relationship with the woman, but ruled out court martial as they couldn’t establish the woman’s status as an agent, or anything untoward beyond a romantic relationship.

The findings of the Board of Inquiry will have to be acted upon by chief of naval staff Admiral Nirmal Verma, who must also decide whether and how to accept the Commodore’s resignation. On the bright side, at least he didn’t hire Jodie Fisher. See: DNA India.

Aug 3/10: MiG-29K. A CAG (Indian comptroller and auditor general) report says that Indian naval aviation has suffered in recent years, and the current state of the Sea Harrier fleet makes it clear that on-time induction of MiG-29Ks into the fleet will be critical. Read “India’s Sea Harrier Shortage” for more.

April 12/10: Scandal. The inquiry against Commodore Sukhjinder Singh has established his ‘amorous relationship’ with a Russian woman, and India’s naval brass are considering punishments. Meanwhile, he has been relieved of his current posting in the defence ministry’s directorate-general of quality assurance.

Singh oversaw the Gorshkov refit project in Russia from 2005-2007, and was the project’s principal director in India from 2007-2009. That gave him no role in price negotiations, but there is more than casual concern that he may have been “honey trapped” by an FSB agent to give details of India’s negotiating position. Explicit photographs with this Russian woman surfaced recently in the media, and formed part of the “clinching evidence” in the just-concluded naval Board of Inquiry (BoI). Defence minister A K Antony said that:

“Nothing beyond [a romantic relationship] has been proved so far. I do not want to jump the gun. I have asked Navy to finish (the inquiry report) as quickly as possible. I do not want to draw any conclusions prematurely. Once the Navy completes everything, we will take a decision.”

See: Current Affairs (incl. Times Now video) | DNA India | India Server | India TV | Kalyugikalki | The Times of India | Hindustan Times.

Honey trap?

March 11-13/10: India’s Cabinet Committee on Security approves a new $2.33 billion price for the Gorshkov refit, a rise of over 140%.

Russian President Vladimir Putin is currently visiting India, and is expected to sign a number of defense contracts, including the revised Gorshkov pact, and a $1.2 billion contract for another 29 MiG-29Ks. The Gorshkov agreement is signed on March 13/10, and the carrier’s delivery date is now 2013. Indian Express | Russia’s RIA Novosti | Sify | Zee News || Putin visit: Calcutta Telegraph | DNA | Economic Times of India | Sify || Post-Signing: Indian government PIB release | DNA India | Times of India.

Revised agreement, 29 more MiG-29Ks

Feb 19/10: MiG-29K. India inducts its first 4 MiG-29Ks into service at INS Hansa in Goa, as an Intensive Flying and Trials Unit. The government also apologizes to Goa’s citizen’s for the unannounced sonic booms they’ve experienced over the past few days.

During the ceremony, Defence Minister Antony confirms India’s intent to buy another 29 fighters, raising the Navy’s MiG-29K fleet to 45. ANI | Economic Times of India | Indian Express | Sify | Times of India | NDTV video – note that aerial footage is of India’s Kiran trainers instead.

MiG-29K inducted

Feb 15/10: Russian deputy service director Alexander Fomin is quoted as saying that Russia and India will sign a supplementary agreement to finish upgrading the Admiral Gorshkov “in February-March this year.” Time will tell. RIA Novosti.

Jan 17/10: Reports surface that India will “soon” finalize a $1.2 billion deal with Russia to buy 29 more MiG-29K jets, which would bring India’s order total for the carrier capable STOBAR (Short Take-Off But Assisted Recovery) fighters to 45. Russia’s RIA Novosti | domain-b | India’s Economic Times | Press Trust of India | Times of India | UPI | Associated Press of Pakistan.

Jan 16/10: Admiral Nirmal Verma tells the media that there is still no final deal:

“I cannot speak anything about the final pricing till the government’s approval is announced. But, yes, for any of these major induction programs, we have a price negotiation committee, which has done its job and a mutually agreed price has been arrived at.”

See: Press Trust of India | Times of India | Barents Observer | China’s Xinhua.

2009

Scathing CAG program report; India adds a bridging payment, but still no deal; MiG-29 training & infrastructure; British CVF carrier as a Plan B?; INS Viraat is unavailable, and India’s ADS carriers won’t arrive until 2015.

MiG-29KUB: early flight
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Dec 5/09: Reports surface once again that India and Russia have reached an agreement on the Vikramaditya’s price. This time, they may even be true. Indian Foreign Secretary Nirupama Rao said that during summit-level talks between Indian Prime Minister Manmohan Singh and Russian President Dmitry Medvedev:

“Both the leaders discussed the [Vikramaditya] issue and noted excellent progress on negotiations on price and technical issues which have been brought to a successful conclusion.”

The actual price in question is not discussed, and that political rapprochement may not be shared by the Navy. Defence Minister AK Antony has publicly distanced the Government from Naval Chief Admiral Sureesh Mehta’s recent public hard line regarding the Gorshkov’s price, and suggestions that India reassess its defense ties with Russia owing to quality issues. Adm. Arum Prakash also issued a warning, saying that: “The long-term price that we pay for 25 years of mischief, of twisting our arm will be much more than what we pay now.”

See: domain-b | Economic Times | Hindustan Times | IANS re: Rao quote | IANS re: Adm. Verma || Naval Spat: IBN Live | IBN Live quotes Adm. Mehta & Prakash.

Dec 4/09: MiG-29K. Ending a year-long wait, the first batch of MiG-29K naval fighter jets, purchased from Russia for the Admiral Gorshkov aircraft carrier, arrive in Goa in a “knocked down condition” packed in containers on board an AN-124 cargo aircraft. Press Trust of India.

Nov 30/09: Defence Minister Shri AK Antony, in a written reply to the Lok Sabha (India’s Parliament):

“The Russian side had submitted a revised Master Schedule indicating delay and increase in prices for repair and re-equipping of aircraft carrier ex-Admiral Gorshkov. The Government has agreed to conduct negotiations for finalizing a revised Repair and Re-equipping contract. Negotiations are in progress with the Russian side. Details of final prices would be known only after completion of these negotiations.

An exhaustive list of equipment to be fitted on the ship was included in the original contract. The Aircraft Carrier is scheduled to be inducted in December, 2012.”

Nov 16/09: Plan B from the UK? Amidst rumors of major British defense budget cuts, The Guardian reports that India has expressed formal interest in the 65,000t CVF/Queen Elizabeth class carrier program. The UK MoD is desperately looking for long-term budget savings, but canceling either of its full-size carriers at this point would be rival the cost of finishing them:

“According to senior defence sources, Whitehall officials are examining the feasibility of selling one of the carriers. It is understood they are planning to put forward the option as part of the government’s strategic defence review, which will start early next year… “Selling a carrier is one very serious option,” a defence source said this weekend, although the government is a long way from committing to any sale. It could take between six and 12 months to reach a decision, he added.”

Each Queen Elizabeth carrier costs about $3.5 billion, and the negotiating difference around the Admiral Gorshkov is currently around $2.2+ billion. The question is whether India would be able to buy one of the CVF carriers for less than the UK paid, in order to offer the Treasury monies that it could not otherwise obtain from the CVF program. If a refund could be forthcoming from the Russians, and a deal done with the British, investing the Vikramaditya’s $3 billion could net India a completely new ship rather than an old and refurbished one, with double the Gorshkov’s aerial complement. Key questions include whether those deals could be secured, and whether India is prepared to wait until 2016 for the British carrier, as opposed to 2013 (and sliding…) for Gorshkov.

Then again, $2.2 – $2.5 billion could also secure India an America class light carrier from Northrop Grumman, with a similar tonnage and aerial complement to the Gorshkov, but markedly better electronics and defensive systems. If India begins to look beyond Russia for options, Britain’s CVF program is not its sole alternative.

Nov 1/09: INS Viraat Watch. The Times of India reports that INS Viraat is now on the verge of completing its sea-acceptance trials and work-up phase, after an 18-month-long comprehensive refit and upgrade program in Mumbai and Kochi. This will give India an aircraft carrier again. The 28,000-tonne carrier will complete its 50th year as an operational warship in November 2009, having serves as both HMS Hermes and INS Viraat.

Oct 23/09: A British BBC report explains some of the hurdles on the road to Vikramaditya’s delivery:

“In this hurry [on both sides to sign a deal], fine points including the ones relating to what was expected of Russia were overlooked… India agreed to buy and get a ship refurbished without Gorshkov’s design [presumably means a detail design blueprint]… When the ship was ripped open, it was found that the wiring was ageing and needed to be redone. A Japanese contractor awarded the rewiring contract found the job overwhelming – given the costs involved – and left. Now a new contractor has been found for the purpose. Gorshkov’s steel plates and machinery, too, needed to be pulled apart and new ones fitted… With Gorshkov’s induction delayed, the government decided to refit its only aircraft carrier, INS Viraat, but it will not be operational till 2015. That leaves the Indian navy with no aircraft carrier for some time.”

Oct 15/09: Despite prior reports that an agreement on the Vikramaditya’s final cost would be reached during Defence Minister A.K. Antony’s 2-day visit to Moscow, India and Russia have failed to reach agreement. Negotiations will continue. India MoD | Indo-Asian News Service.

Sept 24/09: MiG-29K. Russia’s Vedemosti newspaper reports that the Russian Navy may decide to replace its 19 larger and longer-range SU-33 fighters on its Admiral Kuznetsov carrier with 24 MiG-29Ks, when the SU-33’s must be retired in 2015. Caution is advised, since the article is based on a source who sees a contract as possible in 2 years; that’s not exactly a rock-solid basis for concluding that India will avoid the potential trap of being the MiG-29K’s only operator. Vedemosti [in Russian] | Barents Observer.

Sept 3/09: Indian media report that a deal to finish the Vikramaditya refit is expected by mid-October 2009. Some caution is advised, as past reports and predictions in this area have later been proven false by events. India’s Business Standard | The Hindu | Hindustan Times.

Aug 16/09: Bridging payment. Indian media report that the government has cleared a $122 million bridging payment for continued modification work on the Gorshkov, while negotiations continue. The payment was sanctioned in early August, following demands by Rosoboronexport. domain-b | Economic Times of India.

Bridging payment

July 31/09: India’s Business Standard conducts an interview with Russia’s outgoing ambassador to India, Vyacheslav Trubnikov. Excerpts:

“[VT] Not changing [the Gorshkov order], but the Indian Navy was eager to get the best, the most modern equipment [to insert into the hull].

[IBS] So the Navy’s appetite kept increasing, they wanted more and more..
[VT] Yes.

[BS] Reports are that it will cost around $2.2 billion?
[VT] It would be irresponsible of me to comment. Price negotiations are now entering the final stage. What is important for India is also the time of delivery. But the point is that if India wants additional equipment, the carrier will cost even more. So if both sides stop and decide, okay no request from India and no increase in price from our side, then we can finalise price and delivery.”

July 29/09: The CAG report begins to generate political opposition to the Gorshkov deal, as well as media op/ed calls for a re-think. In the course of one such op-ed, The Hindustan Times offers a report on the negotiating spread:

“The Russians now want $2.9 billion (Rs 14,500 crore) for the warship, while the defence ministry is bargaining for $2.2 billion (Rs 11,000 crore). [Defence Minister Antony said that] “The Russians have demanded a substantially huge amount. We are still negotiating the deal. No final decision has been taken.”

July 25/09: CAG Criticism. India’s Comptroller and Auditor General (CAG) issues a scathing report, saying that:

“The objective of inducting an aircraft carrier in time to fill the gap in the Indian Navy has not been achieved. The cost of acquisition has more than doubled [from $875 million] to $1.82 billion (Rs. 7,207 crore) in four years. At best, the Indian Navy would be acquiring, belatedly, a second-hand ship with a limited life span, by paying significantly more than what it would have paid for a new ship…”

The largest cost escalation is in sea trials, which have risen from $27 million to $500 million, and the CAG report sharply criticizes the Navy for poor project supervision practices. The report adds that planning failures will leave the warship with no air defense upon delivery, and only a Close-In Weapon System (CIWS) when one is retrofitted in 2017. Risks are also cited with respect to the aircraft arresting gear, which has not been finalized due to development problems. India CAG – they do not archive reports | DNA India | The Hindu | Indian Express | Rediff | Times of India | Agence France Presse.

CAG criticism

May 25/09: Indian media report that the government has decided to speed up renegotiation with Russia, after a recent Moscow trip undertaken by defence secretary Vijay Singh failed to break the long-standing deadlock. The government has reportedly scheduled 3 visits to Russia by Indian officials, in hopes of sealing the deal by the end of July 2009. During those visits, they will also discuss the larger subject of Indian-Russian defense relations.

Another senior official of the Controller of Warship Production and Acquisition will reportedly visit Russia in the middle of June 2009, to work out the warship’s hoped-for 2011 trials in Barents Sea. Assuming that a deal can in fact be reached this time. Times of India.

April 6/09: MiG-29K. India inaugurates the first phase of the MiG-29K maintenance and training facility at the INS Hansa naval base in Goa. Vice-Admiral J. J. Bedi, Commander-in-Chief of India’s Western Naval command, is quoted as saying that:

“This is the first time in my service career of 40 years that I witness construction and availability of major infrastructure project prior to the induction of hardware in the Indian Navy.”

He expects the first batch of 4 aircraft to be “with us by middle of this year.” The Hindu.

March 16/09: MiG-29K. Still no agreement on the Gorshkov refit. Meanwhile, The Times of India reports a Russian decision to ground its MiG-29 fleet, following accidents caused by the disintegration of the planes’ tail fins. It quoted an unidentified “senior officer,” who said that:

“We continue to fly our MiG-29s… Our checks are stringent since we operate our MiG-29s also from coastal airbases (Jamnagar) and Russian metallurgy is susceptible to salinity.”

That’s a somewhat worrying assertion, in light of the MiG-29K naval buy. India is scheduled to finish its MiG-29A upgrades to MiG-29SMT status in 2014, thanks to a contract signed in March 2008. That effort will not be delayed by the news from Russia, but the news will reportedly delay delivery of the new MiG-29Ks to the Indian Navy.

Feb 28/09: ADS Watch. The keel for India’s first “Project-71” 37.5t-40t indigenous carrier project is laid at the Cochin Shipyard in Kerala. The new carrier will be named INS Vikrant, after the 20,000t World War 2 era carrier HMS Herculaeus that was sold to the Indian Navy, and served as the Vikrant (from Sanskrit vikranta, “courageous/ victorious”) from 1961-1997. Ptoject-71 currently has a budget of INR 32.6 billion (currently about $650 million), but few observers believe that the final cost will remain on budget.

Delivery is scheduled for 2014-2015, and these carriers are expected to carry their own complement of MiG-29K fighters. Plans exist for a naval variant of India’s LCA Tejas lightweight fighters, but India’s history of extremely late and failed weapons projects suggests caution. Even a successful project is unlikely to induct a naval Tejas before 2016-2018, leaving both of India’s future carrier classes strongly dependent on Russian goodwill. The Hindu | Indian Express | Sindh Today.

Feb 23/09: Indian media report that Russia has demanded another $700 million, on top of their demand for an additional $1.2 billion which had been approved by India’s cabinet, on top of the original $947 million contract. The shipyard is also demanding $190 million immediately, in order to continue work. Delivery is still scheduled for 2012, but this assumes the schedule promises are kept, and that there are no work stoppages or other production delays owning to contract negotiations.

Assuming that this is in fact Russia’s final demand, it would bring the asking price for the Gorshkov to $2.85 billion. That figure could buy a similar 45.7t new-build America Class LHA-R medium carrier with funds left over, and might even buy one of Britain’s new 65t CVF Class carriers. Hindustan Times | Indian Express | Forecast International report/op-ed | Indian Express op-ed.

Feb 22/09: MiG-29K. The Hindu quotes UAC VP and RAC MiG Director-General Mikhail Aslanovich Pogosyan, who says that Indian naval pilots have been training in Russia since October 2008. The theory portion of the course is done, and:

“Indian pilots are already training to fly the MiG-29Ks from a shore-based facility. They have been doing even 15 sorties in a day during the winter. We expect the first four MiG-29Ks to arrive in India later this year, with the other 12 being delivered by 2010.”

So far, 4 certified MiG-29Ks have been transferred to the Indian project team in Russia, after Russian test pilots have conducted carrier landing check-outs. After the course is complete, India’s Navy hopes to continue their own pilots’ training by using a Shore-based Test Facility (SBTF), built with Russian help at INS Hansa in Goa.

Feb 12/09: RIA Novosti reports that Russia has delivered the first 4 MiG-29 naval fighters to India. Oddly, they use the designation “MiG-29 Fulcrum D,” which is the NATO reporting code and not Russian or RAC MiG nomenclature.

2008

Russia wants more money to complete the contract; Reality – delivery in 2012, maybe; Sevmash shipyard not exactly ship-shape; USA’s retiring CV-63 to India?

USS Vikramaditya?
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Dec 3/08: Indian Express reports that India’s Cabinet Committee on Security (CCS) on Tuesday “gave in to Moscow’s demands,” and will renegotiate the Vikramaditya upgrade on terms acceptable to Moscow.

Nov 22/08: Australia’s the Age newspaper reports that Russian President Dmitry Medvedev has cut his December 2008 India visit to a single day, a signal usually associated with a strained geo-strategic relationship. The visit will now take place on Dec 5/08.

Nov 13/08: As negotiations regarding the Gorshkov continue to drag on, pressure for timely resolution is building on the Russian side, as well. Sevmash (Severodvinsk Machine Building Enterprise) shipyard Deputy General-Director Sergey Novoselov tells RIA Novosti new agency that:

“We are essentially constructing a new aircraft carrier at the open assembly berth of Sevmash. In the last two years, work has only proceeded thanks to internal loans…”

That cannot continue indefinitely – but Sevmash is not backlogged with projects, which means it needs to hang on to the Admiral Gorshkov refit. So, what if India proves unwilling to pay? Novoselov pointed out that even at $2 billion, a refitted Gorshkov costs only 50-67% of the $3-4 billion involved in building a medium sized carrier. Novoselov would not be pinned down to any firm figure, of course, but some Russian defense planners are either taking him seriously, or willing to help him put added pressure on India. RIA Novosti, via Forecast International:

“If India won’t pay the money [over the agreed $617 million], we will keep the aircraft carrier ourselves. It will be very useful to us, because the situation in the world is complicated. Vessels like that are needed to patrol the waters of the Atlantic and the Mediterranean,” noted a Russian defense industry official.”

If Russia did make that move, India would need compensation for costs incurred to date – reportedly about $400 million.

Nov 11/08: Russia now says that the delivery of Admiral Gorshkov aircraft carrier to the Indian Navy will be delayed till 2012. The shipyard also claims that New Delhi has not made any payments since last year, although extra work to the tune of $1.7 billion has been done by the shipyard. ITAR-TASS reportedly quoted a shipyard representative as saying that:

“At this juncture, the completion of work in 2010 would be realistic. Two more years would be required to complete the vessel’s sailing trials, including testing its aircraft in the severe conditions of Barents Sea.”

DID isn’t quite sure why arctic operations would matter to India. India Defence.

Nov 2/08: India’s finance ministry has for the second time rejected a proposal from the MoD to approve an additional $1.2 billion in funds, in order to complete the INS Vikramaditya retrofit project. The article reports that India has already paid Russia about 67% of the original program cost, but has made no further payments since January 2007. The India Defence report adds, cryptically:

“The finance ministry’s latest decision also stemmed from a request to allocate $60 million to perform sea trials of the refurbished vessel during 2011.”

Oct 18/08: The Hindu newspaper quotes Sevmash Shipyard’s deputy director for foreign defence contracts Sergei Novosyolov, who says that Gorshkov will be taken out of dry dock by the end of the month.

“The ship’s hull has been fully done and painted and scaffolding will be dismantled by the end of October…”

Sept 21/08: Still no firm deal on the Gorshkov refit, but India’s Defence Acquisition Committee (DAC) has given approval in principle to add another 29 MiG-29Ks to the original 16-plane, $1.5 billion deal.

No price negotiations have taken place, but the contract is expected to be worth close to $2 billion when it is signed. The Navy is reported to have set its sights on a 3-squadron goal for its MiG-29K/KUB force. Indian Express report.

Sept 19/08: Indian Express reports that after Indian officials expressed concern over the slow progress in overhauling Gorshkov at the Sevmash shipyard in North Sea, Russian asked South Block to immediately pay the cash-strapped shipyard $200 million, “without prejudice to the on-going price negotiations,” in order to speed up work.

The report adds that Russian Defence Minister A Serdyukov’s visit to Delhi later in September 2008 is expected to result in a revised price for the Gorshkov refit, which must then receive political approval in India.

June 3/08: Press Trust of India reports that Russia’s Sevmash shipyard has promised readiness by 2012 – maybe. RIA Novosti quotes Sevmash officials as saying that:

“The successful solution of all the financial issues will enable the shipbuilders to sail the aircraft carrier out into the Barents Sea for trials. In the winter of 2012, the ship is expected to be finally refitted and trials will continue in the summer of that year… At the end of 2012, the aircraft carrier is expected to be fully prepared for its transfer to the Indian navy in accordance with the schedule approved by the Russian Navy.”

Negotiations and maneuvering around the contract’s final details continue, and Sevmash’s history of delivery, detailed below, must also be considered when evaluating such statements.

June 2/08: MiG-29K. Defense News reports that India’s MiG-29Ks will be based on land, because the country has no operational carriers. With INS Viraat unavailable due to upgrades and Vikramaditya badly behind schedule, the MiG-29Ks will go to the Naval Aviation Centre at INS Hansa in Goa instead. Hansa is the base used to train naval pilots. Deliveries of all 16 MiG-29Ks are expected to be complete by 2009.

May 30/08: USS Kitty Hawk? Reuters reports that American Secretary of Defense Robert Gates was asked about rumors that the USS Kitty Hawk might be sold to India at the at the Shangri-La Dialogue forum of regional analysts, defense and security officials. “I am aware of no such plans,” Gates replied.

May 9/08: ADS Watch. News Post India’s “Indian Navy To Order Another Aircraft Carrier” claims that the Indian Navy will supplement the Vikramaditya with 2 of its 37,500t indigenous “Air Defence Ship” carriers, instead of just one. The article also includes additional information about the Vikramaditya’s schedule and the potential risks.

April 9/08: Despite an agreement that was supposed to be finalized in March, Indian Defence Secretary Vijay Singh describes the parties as still “locked in intense negotiations over the price details,” adding that “technical assessment of the work needed on the carrier is still on…” The expected responses re: the deal being on track, and having a final price proposal to bring to the Cabinet “soon,” were also voiced. Zee News.

March 18/08: MiG-29KUB flies. During Chief of Naval Staff Sureesh Mehta’s visit to Russia, the first serially produced MiG-29KUB (tail number 113) performs its maiden flight at the RAC MiG test airfield in Lukhovitsy near Moscow. The MiG-29KUB is the 2-seat variant of the carrier-capable MiG-29K. RAC MiG release.

March 10/08: The Indian government’s DDI News reports that “India has reconciled to a price hike for procurement of Russian carrier Admiral Gorshkov and the government has constituted an experts committee to work out the increase.”

Naval Chief Sureesh Mehta, who had opposed additional payments under the contract, said that: “There will be some price hike. We need to pay extra amount and whatever amount is due as per contracts we will pay.” This does not sound like an encouraging report from ongoing negotiations.

March 3/08: India caves. India opts to pay Russia more, in hopes of getting the Gorshkov ready in time. Figures given vary between $500 million and $1.2 billion; exactly how much more India will agree to pay will reportedly be decided later in March 2008, after 2 more rounds of negotiations. India’s Defence Secretary Vijay Singh is quoted as saying that:

“It should be completed by mid-2010. After that, it will undergo 18 months of extensive sea trials by the Russian navy to ensure all systems are working properly.”

Retired Admiral Arun Prakash was head of the Indian Navy in 2004 when the original deal was “laboriously and painstakingly negotiated for 11 months, and the contract sealed and signed.” He told BusinessWeek that he is disappointed by Russia “reneging on the deal” and says Russia “gifted” the Gorshkov to India in exchange for a $1.5 billion contract to buy planes and helicopters and “revive their terminally ill shipbuilding and aircraft manufacturing industries.”

India will also reportedly send 500 shipyard workers, technicians and managers to Russia, to take direct charge of the work, cover Russia’s labor shortage, and keep an eye on quality control so that it’s caught immediately. Whether this will suffice, in the wake of Sevmash shipyard disasters like the Odfjell contract (q.v. Feb 21/08), remains to be seen.

What also remains to be seen at this point is whether India’s MiG-29K contract becomes the next bottleneck. India remains the only customer for this substantially different aircraft, and MiG will need to make production line changes that the existing contract may not adequately finance. Indian MoD, March 12/08 | Calcutta Telegraph | NDTV | Pravda | StrategyPage | Times of India

Meanwhile, BusinessWeek has its own speculation re: “Why India Talked Up A US Carrier Deal.” As an interesting second perspective on the larger Russia-India relationship, see also the Navhind Times March 4/08 article “India’s Defence: Looking Beyond Russia“.

March 3/08: Sea Harriers. India’s Defence Minister Shri A K Antony confesses that India’s Sea Harrier fleet has an availability problem, due to the rotation of aircraft through the current upgrade program.

“India’s Sea Harrier Shortage” looks at numbers and planned upgrades for India’s legacy naval aircraft, as the Navy prepares for future operations with MiG-29Ks. Given the amount of trouble the Harriers are in, it seems unlikely that they will be able to provide a Plan B if the MiGs have problems.

Feb 27/08: India’s Minister of Defence Shri A K Antony, asked about this issue, says:

“The overall progress of repair and re-equipping of the ship, ex-Admiral Gorshkov, in Russia is behind schedule. Execution of contract for construction of three ships of Project 1135.6 (follow-on-ships of Talwar Class) is on schedule. Russia has indicated an increase in price for repair and re-equipping of ex-Admiral Gorshkov. There is no proposal under the active consideration of the Government to contact some other country in this regard. The need for contacting other country does not arise as the existing contract with Russia is still valid.”

A fine politician’s reply. If another country contacted India instead, his denial would still be “true” in the strict sense of the term…

Feb 23/08: Progress on Gorshkov? According to the India Times’ Economic Times, Indian Defence Secretary Vijay Singh’s 5-day delegation visit to Sevmash Shipyard, and talks with Russian Energy and Industries Minister Viktor Khristenko, may have made progress. Russian senior officials reportedly assured Singh that the Russian government was making strenuous efforts to improve the situation.

F/A-18F over CV-63
(click to view full)

Feb 19-23/08: Crazy Sam’s Carrier Clearance Sale? As reports begin to suggest that Russia and India are too far apart to agree on the Gorshkov refit, speculation grows that the USA intends to solve India’s problem with a stunning offer during Defense Secretary Gates’ imminent visit to India. instead of retiring and decommissioning its last conventionally-powered carrier, the 81,800 ton/ 74,200t USS Kitty Hawk [CV-63, commissioned 1961], would be handed over to India when its current tour in Japan ends in 2008. The procedure would resemble the January 2007 “hot transfer” of the amphibious landing ship USS Trenton [LPD-14], which become INS Jalashva. The cost? This time, it would be free. As in, $0.

Naturally, there is a quid pro quo that accompanies these rumors. In return for an aircraft carrier that would be larger than its counterparts in every navy other than the US Navy, India would select at least 60 F/A-18 E/F Super Hornets in its MMRCA fighter competition, to serve as the carrier’s air wing. Unlike the Gorshkov, the Kitty Hawk is a purpose-built carrier whose full air complement is a whopping “75+” aircraft and helicopters. India has also expressed interest in the USA’s E-2 Hawkeye carrier AWACS aircraft, which would be a natural fit for its new ship.

As a number of sources point out, this is a multi-pronged move that would achieve several objectives at once. First, the offer removes all Russian negotiating leverage over India by removing the issues of sunk costs, foreign possession of the Vikramaditya, and any danger of being left without a carrier. The Indian Navy would be greatly strengthened, and its ability to police the Indian Ocean from the Straits of Malacca to South Africa would take a huge leap forward. Any additional work to upgrade or refurbish the carrier could be undertaken in India, providing jobs and expertise while maintaining full national control over the refit. The USA gains financial benefits of its own, as the Navy avoids the expensive task of steaming the Kitty Hawk home and decommissioning it. Americans would almost certainly receive maintenance contracts for the steam catapults, and possibly for some new electronics, but those economic benefits pale in comparison to the multi-billion dollar follow-on wins for Boeing (Super Hornet), Northrop Grumman (E-2 Hawkeye), and possibly even Lockheed Martin (F-16 E/F, F-35B). All of which works to cement a growing strategic alliance between the two countries, and creates deep defense industrial ties as well.

Then there’s the effect on Russia, whose relations with the USA currently border on outright hostility. With the MiG-29Ks no longer necessary for India, that contract would almost certainly be canceled. At which point, the commonality value of choosing the MiG-35 as a lower-cost secondary MMRCA buy drops sharply, opening the door for other MMRCA split-buy options that could include the Saab/BAE JAS-39 Gripen, or a complementary American offer of F-16E/Fs and/or F-35Bs. The combined effect of these blows would be a severe setback for Russia’s arms industry, though rising oil & gas revenues in Russia and other export opportunities may lead to less shrinkage and civilian re-purposing than publications like the Weekly Standard believe. The question now is: will this happen? Barents Observer | Weekly Standard | Information Dissemination: Feb 20th/ 23rd.

Feb 21/08: Sevmash screwups. “Galrahn” of the respected blog Information Dissemination passes a key tip along to DID. First, recall that the Sevmash shipyard in Severodvinsk, Archangel Oblast is responsible for the Gorshkov refit. Until recently, they also had a $544 million contract to build up to 12 tankers for the Norwegian shipping form Odfjell. When it was signed in 2004, it was promoted as “a historic deal in Norwegian-Russian industrial relations.”

Now it has been canceled, and Odfjell CEO Terje Storeng has used terms like “no will to try to understand that this is a commercial project,” “deliberately sabotaged and delayed the project” et. al. to Dagens Næringsliv. He adds:

“Following serious delays in the construction process, combined with demands for further price increases from the Yard, continuous cooperation problems as well as protracted negotiations, Odfjell decided today to serve formal notice of cancellation to Sevmash. The instalments already paid are covered by standard refund guarantees from international banks. Odfjell will further claim full compensation for its costs and losses caused, on account of wilful misconduct and massive contract breaches by the Yard. Unless the matter is solved amicably between the parties, the issue will be solved by arbitration in Sweden, as provided for in the contract.”

Note the Russian official’s comments in the Feb 7/08 entry. Closure may once again become a very real possibility for Sevmash. Worse, Odfjell’s experience has to give India serious pause re: the reliability of Russia’s new refit cost estimates, and the likelihood of further extortion to ‘adjust’ the deal down the road. Barents Observer | Dagens Naeringsliv report [Norwegian] | Odjfell.NO release

Sevmash has wider problems

Feb 7/08: Russia – Let’s Change a Deal! Zeenews quotes an unnamed “Russian official” with interesting and somewhat unsettling arguments, in advance of a high-level delegation’s arrival led by Indian Defence Secretary Vijay Singh:

“Moscow feels that the agreement for supply of the 45,000 tonne warship was signed at a time when the Russian ship-building company was in bad shape and India “used” the situation to sign the contract at lower price. The ship-building company was facing closure and was ready to sign any kind of contract when the contract was signed.”

Defense Industry Daily needs to look up the exact definitions to be certain, but we believe this process is known as “shrewd negotiation,” followed by “a deal.” Indian Naval Chief Admiral Sureesh Mehta appears to be using the same lexicon, and has publicly said that there should be no revision to the Goshkov contract. Still, India cannot receive the carrier she wants if the shipyard goes bankrupt, and Russia is holding the carrier. This gives the Russians considerable leverage in negotiations, unless India can find an alternate provider. There may be a way out, however:

“But Russia is willing to “compensate” for the cost of Gorshkov if it gets more military orders, which Moscow insists is not linked to 126 fighter planes that India is planning to buy but other defence purchases.”

2007

India’s navy and politicians in denial – but the carrier is late.

Ka-28
(click to view larger)

Nov 19/07: India’s MoD confirms delays in the Gorshkov’s delivery and slow progress, without really answering any questions. It acknowledges that the Russian side has submitted a revised Master Schedule, attributing the delays to “Growth of Work.” In response, an apex level Indian committee under the Defence Secretary, and a Steering Committee under a Vice Admiral, have been set up. A team has also been stationed at the shipyard.

No word on the timelines or costs suggested; indeed, these are likely to remain under negotiation. Indian MoD release.

Nov 6/07: A top-level Indian Navy delegation is heading for Moscow to discuss the delay and price escalation in the Admiral Gorshkov aircraft carrier deal. A detailed financial and technical plan outlining the specific justifications and amounts will be presented to the Indian side, who is there to listen rather than to negotiate.

The report pegs the original price quoted for refurbishing the carrier was just under $980 million, adding that the Russians are insisting on cost increases of at least $350 million. Indian officials reportedly fear that the final escalation may end up being much more once they are deep enough into the commitment trap of having paid for work. The report also adds that the Navy “had reconciled itself to the fact that the delivery of the ship would be delayed from the original deadline of August 2008 by a few years,” a surprising development given the limited service life of India’s remaining carrier. If the government is indeed prioritizing cost containment over delivery dates, reconciliation of the INS Viraat’s service life with Gorshkov’s entry may prove difficult. IDRW.

Oct 18/07: India’s MoD finally admits the obvious, as part of an announcement concerning an Indo-Russia fighter development deal. India MoD release:

“The Defence Minister described the Agreement on FGFA as a ‘major landmark’ and said that the Indo-Russian relationship is on a trajectory to reach new heights… Mr. Antony expressed satisfaction at the outcome of discussions on other important projects e.g., supply and licensed production of T-90 tanks, SU-30 MKI aircraft and other strategic issues. He admitted that there has been a delay in the delivery of the repaired and refurbished aircraft carrier Admiral Gorshkov [emphasis ours] along with supply of deck-based fighter aircraft MiG-29-K and said it was decided that some more studies by technical groups would be done to go through the details. He appreciated the efforts made by the Russian side to resolve issues relating to life cycle support of equipment of Russian origin.”

June 16/07: India Defence: High Level Indian Delegation In Russia To Re-Negotiate Defense Deals Pricing:

“With differences over prices delaying the delivery of upgraded Sukhoi multi-role fighters and Gorshkov aircraft carrier, India today rushed a high-level defence team to Russia with fresh proposals to break the logjam… The visit of the team assumes significance with Defence Minister AK Antony admitting that New Delhi was facing “problems” in acquisition of the carrier Gorshkov as well as in negotiating a new deal to buy 40 more upgraded Sukhoi-30 fighters for the Indian Air Force.”

May 17/07: India Defence: “No Delays in INS Vikramaditya Acquisition from Russia: Defence Minister.” With that said…

“However, sources from the Indian Navy had earlier confirmed reports being circulated in the Indian and Russian media regarding a possible two year delay in the acquisition of the Aircraft Carrier.”

Additional Readings

• Sevmash Shipyard

Equipment Profiles

• Indian Navy – About INS Vikramaditya – The newest & largest ship of Indian Navy

• Bharat Rakshak – INS Vikramaditya

• Naval Technology – Kuznetsov Class (Type 1143.5) Heavy Aircraft Carrying Cruiser, Russia

• RAC MiG – MiG-29K/ MiG-29KUB

• Bharat Rakshak – MiG-29K/KUB Fulcrum-D

• YouTube – Vikr. Russian report covers MiG-29K carrier landing trials in the Barents Sea.

• Air Force Technology – Ka-31 Radar Picket Naval Helicopter, Russia

• Bharat Rakshak – Kamov KA-31 Helix-B

• Air Force Technology – Ka-27/28 and Ka-29 Helix Naval Helicopters, Russia

• Bharat Rakshak – Kamov KA-28 Helix-A

Other Equipment

• Bharat Rakshak – INS Viraat (formerly HMS Hermes, last of the British Centaur Class). India’s current carrier.

• Bharat-Rakshak – Indian Aircraft Carrier (Project-71). The forthcoming Vikrant Class.

• US Navy, CV 63 Kitty Hawk official site – Kitty Hawk Statistics. Since decommissioned.

• Global Security – CV 63 Kitty Hawk

• DID FOCUS – India’s MMRCA Fighter Competition. This DII Q.V. entry is a public access article.

News & Views

• DID – Russia’s Military Spending Jumping – But Can Its Industry? Provides interesting figures for the industry, and a deeper look at some of the drivers behind the failed Gorshkov refit as well.

• Livefist (Feb 20/10) – Differences Between MiG-29 Of IAF & Navy. The IAF’s MiG-29Bs are being upgraded to MiG-29SMT/UPG status, which will even out many of the MiG-29K’s advantages.

• Asia Times, via WayBack (Dec 9/09) – India displays multi-vector diplomacy. Offers one take on the larger strategic background behind India’s ties with Russia. M K Bhadrakumar was a career diplomat in the Indian Foreign Service whose assignments included the Soviet Union, South Korea, Sri Lanka, Germany, Afghanistan, Pakistan, Uzbekistan, Kuwait and Turkey.

• BBC, via WayBack (Oct 23/09) – Crucial Indian defence deals delayed. These include the Navy’s submarine and aircraft carrier projects, advanced trainers for the air force, and coastal surveillance plans. “For its part, the government has been slow in responding to criticism – even from its auditing organisation. When it comes to defence issues in India, speed does not seem to be of paramount importance.”

• NewsMax, via WayBack (Dec 4/08) – Russian Military Misfires With Defects, Sales Lags. Points to RAC MiG as a firm with an especially problematic future, unless it can secure a big win very soon.

• DID (March 5/08) – India’s Sea Harrier Shortage. It isn’t just the Viraat that has to be maintained until a successor is ready…

• The Weekly Standard, via WayBack (Feb 22/08) – The Carrier Cold War. “The US tries to shut Russia out of India’s defense market.”

• Information Dissemination (Feb 20/08) – The Gorshkov Guessing Game and Feb 23/08 – Kitty Hawk To India Discussion Hits the US Media.

• Barents Observer, via WayBack (Feb 19/08) – India might not get its Russian aircraft carrier.

• Asia Times, via WayBack (Aug 21/07) – India’s blue water dreams may have to wait. The Gorshkov isn’t the only carrier project in trouble. This article mentions the Gorshkov’s difficulties, and also details both the current state of the INS Viraat and difficulties with India’s smaller 37,500t indigenous carrier, which is reportedly slipping its schedule badly and will only be ready by 2015 at the earliest, instead of 2012.

• India Defense, via WayBack (April 26/06) – INS Vikramaditya: Aircraft Carrier Acquisition from Russia Delayed, Cost Overruns Expected. Heatedly denied at the time by India’s military; subsequently confirmed as quite true.

• DID (June 30/05) – U.S. & India Sign 10-Year Defense Pact.

Americas

The US Air Force is procuring more updated Advanced Medium Range Air to Air Missiles (AMRAAMs) from Raytheon. The awarded cost-plus-incentive-fee option is valued at $62 million and provides for more missiles that integrate the Form, Fit, Function Refresh (F3R) of the AMRAAM guidance section. Friday’s contract involves foreign military sales to Norway, Turkey, Japan, Romania, and Australia. The Air Force’s AMRAAM F3R project is a comprehensive effort to mitigate the effects of parts obsolescence and diminishing manufacturing sources in the missile’s guidance section to extend the missile’s lifetime well into the 2020s. The F3R effort includes the substantial redesign of subsystems that include a new ASIC design, new hardware and a new signal processor. Work will be performed at Raytheon’s factory in Tucson, Arizona, and is expected to be completed by December 2020.

Honeywell International is being tapped to support the Air Force’s fleet of C-5M Super Galaxy transport aircraft. Under this $7.8 million firm-fixed-priced order the company will be responsible to upgrade 85 Versatile Integrated Avionics/Avionics Integrated Units (VIA/AIU) to the 905 configuration. The upgrades are part of the Galaxy’s Global Air Traffic Management (GATM) avionics program. The VIA software system has six primary “partitions” or applications that include flight management, com/nav/surveillance/identification (CNSI), communication management, display services and all-weather flight control. The C-5M VIA/AIU repair and upgrade effort is a key component to the overall Core Mission Computer/Weather Radar aircraft modification/installation kit that replaces the current mission computer, and replaces the weather radar with a commercial off-the-shelf color weather radar. Work will be perfumed at Honeywell’s location in Albuquerque, New Mexico, and is expected to be completed by June 14, 2020.

Ball Aerospace & Technologies Corp will support the Directed Energy Directorate with Solid State Laser Effects and Modeling efforts. The awarded cost-reimbursement type contract is priced at $36 million and allows the company to develop innovative diagnostic and test methods, increase the fidelity, realism and confidence of predictive models, measure and consolidate laser vulnerability data and support the general high energy laser system research environment. The Directorate focuses on four research areas: Laser Systems, High Power Electro magnetics, Weapons Modeling, Simulation and Analysis, and Directed Energy and Electro-Optics for Space Superiority. Among other things, the Directorate develops future offensive and defensive laser concepts, and models the synergy of directed energy and kinetic weapons at mission level. Work will be performed at Kirtland Air Force Base, New Mexico. Work under this contract is expected to be completed by October 2022.

Canada’s Surface Combatants program is picking up pace as Lockheed emerges as the preferred bidder to design the next fleet of Royal Canadian Navy ships. This brings Lockheed one step closer to land the potential contract worth more than $45 billion. The company pitched BAE’s Type 26 design to the government of Canada and Irving Shipbuilders, a Canadian firm that would actually build the ships. BAE and Lockheed are now set to negotiate the specific terms of the deal, which would cover the construction of 15 frigates and associated equipment and services. What follows now is a due diligence process, which includes negotiations with Lockheed on intellectual property rights, an assessment of combat systems performance an assessment of the company’s financial capability to deliver the project and verification of various other administrative matters. If all goes well the Canadian government could award the contract in 2019 with construction expected to be begin by the early 2020s.

Middle East & Africa

South Africa’s Denel Vehicle Systems is adding a new version of the RG31 Mk5 to its portfolio. The baseline of the 4 by 4 MRAP is usually used as an armoured personnel carrier (APC), the new version however integrates the Tactical Remote Turret 30 (TRT-30). The remodelled vehicle’s TRT-30 armament suite consists of a Russian 30 mm 2A42 dual-feed cannon and a 7.62 mm co-axial machine gun. The gunner can remotely control the weapons via a flat-screen man machine interface (MMI) and twin control handles. The TRT is also fitted with an automatic target tracker (ATT) that gives the gunner more accuracy while the vehicle os moving. Dubbed the Ibululu, the platform is equipped with a 205 kW Cummins engine that accelerates the 16 ton vehicle to speeds of up to 62 mph, and an Axle Tech 4000 (5G) suspension that allows for cross-country mobility.

Europe

Aero Vodochody is taking first orders for its new L-39NG jet trainers. Czech Defence Minister Lubomir Metnar recently announced that the country will buy six L-39NGs to replace its outdated fleet of L-39 Albatros aircraft. “The Ministry of Defence and the military are interested in these aircraft, negotiations are, of course, already taking place and we will acquire these aircraft,” Metnar told Ceska Televize. The NG is the latest multi-role, advanced jet trainer aircraft designed by the company and is intended to provide enhanced military flight training capabilities required for fourth and fifth-generation fighters. The company hopes to export the new platform to various global customers and estimates that it could deliver more than 100 L-39NGs over the next decade.

Asia-Pacific

The Indonesian government plans to renegotiate its partnership with South Korea in the K-FX development program. The agreement between the two countries was formalised in 2014, and outlined that Indonesia will contribute about $1.9 billion to the project which has an overall value of $7.9 billion. Indonesia’s coordinating minister for political, legal and security affairs is seeking to negotiate a way for Indonesia to pay its contribution, of which about $200 million is unpaid. Reuters says that “Indonesia’s request on the financial terms of the deal comes as it is trying to support the rupiah, which is trading near a 20-year-low, and to reduce the use of foreign exchange reserves.” The KF-X program will likely be South Korea’s largest defense acquisition program, that sees for the delivery of 120 jets for its own air force, and 80 to Indonesia.

Today’s Video

Watch: AUSA 2018 Association U.S. Army defense exhibition

C-5 Galaxy
(click to view full)

When it was introduced, back in 1970, the C-5 Galaxy was the largest plane in the world. It also has the highest operating cost of any US Air Force weapon system, owing to extremely high maintenance demands as well as poor fuel economy. Worse, availability rates routinely hover near 50%. To add insult to injury, the Russians not only built a bigger plane (the AN-124), they sold it off at the end of the Cold War to semi-private operators, turning it into a commercial success whose customer list now includes… NATO.

Meanwhile, the USA still needs long-range, heavy load airlift. The AN-124’s commercial success may get its production line restarted, but the C-5 has no such hope. Boeing’s smaller C-17s cost more than $200 million per plane. That’s about the cost of a 747-8 freighter, for much higher availability rates than the C-5, and a longer lifespan.

Sunrise? Sunset?
(click to view full)

What’s the right balance between new C-17s and existing C-5s? The US Air Force believes that the right balance involves keeping some of the larger C-5s, and thought they could save money by upgrading and renewing their avionics (AMP) and engines (RERP). Their hope was that this would eliminate the problems that keep so many C-5s in the hangar, cut down on future maintenance costs, and grow airlift capacity, without adding new planes. Unfortunately, the program experienced major cost growth. In response, the C-5M program wound up being both cut in size, and cut in 2. The C-5A and C-5B/C fleets are now slated for different treatment, which will deliver fewer of the hoped-for benefits, in exchange for lower costs and lower risk.

The C-5’s AMP-RERP The Problem: Less Than Reliable

C-5 Refuels from KC-135
KC-135 = 707 airliner!
(click to view full)

From Air Force Magazine:

“The Galaxy also has major problems, as was glaringly apparent during one particular C-5’s trip from Dover to Europe. As it readied for takeoff, an engine warning light appeared in the cockpit. The flight crew taxied the airplane back to the apron, the passengers got off, and maintenance crews investigated. After the problem was fixed and the passengers had reboarded, the aircraft headed out again, but another warning light came one – this time during the takeoff run.

Five more times, the C-5 attempted to leave, and each time there was a glitch.

Airborne at last, the heavily laden giant lumbered up to cruising altitude, but, some 100 miles out over the Atlantic, yet another warning light came on – this time, a landing gear door seemed ajar. The airplane returned to Dover for yet another repair. The C-5 finally reached its destination in Europe – but more than 18 hours late.”

Stories like this also help to explain why the C-5 has the highest operating cost of any Air Force weapon system. The programs designed to address these cost & reliability problems are called AMP (Avionic Modernization Program) and RERP (Reliability Enhancement & Re-Engining Program). To keep them straight in your head, think of AMP as amping up the Galaxy’s electronics for the modern era, and RERP as putting a bit more roar in its engines.

C-5s are currently assigned to:

• Dover Air Force Base, Delaware (USAF, C-5B)
  
• Travis AFB, California (USAF)
  
• Lackland AFB, Texas (USAF)
  
• Wright-Patterson AFB, Ohio (USAF)
  
• Martinsburg Air National Guard Base, West Virginia
  
• Memphis ANGB, Tennessee
  
• Stewart ANGB, New York; and
  
• Westover Air Reserve Base, Massachusetts

Changing the C-5: AMP

Before: C-5 cockpit
(click to view full)

AMP is the first step. Its main purpose is to equip the aircraft to fly in civil airspace by the most direct routes, at the most advantageous altitudes, with the most efficient fuel usage and cargo loads. The new avionics systems will allow the aircraft to comply with reduced vertical separation mandates, and also provides an architecture flexible enough to meet future communications, navigation, surveillance (CNS) and air traffic management (ATM) requirements. AMP is also trying to reduce the number of devices and wires in the planes, to reduce costs and improve reliability. All told, 12,000 wires are removed, and 4,000 are installed, during a C-5 AMP.

The program has displayed a philosophy of making its additions using as much commercial equipment as possible, rather than insisting on all-militarized systems. Riding on the development work spurred by changing commercial requirements, rather than funding development on its own, is a change for USAF procurement, but they get a very modern system that way. In addition to the substitution of digital “glass cockpit” computer screen displays, key Global Air Traffic Management avionics include:

• Future Air Navigation System (FANS) data link
  
• Aeronautical operational communications (AOC) data link
  
• VHF com, 8.33-KHz spacing
  
• Multimode receiver (MMR) with protected ILS, VOR, microwave landing system (MLS) and marker beacon
  
• Dual, embedded inertial navigation system (INS)/GPS
  
• Identification, friend or foe (IFF)/Mode S transponder
  
• Traffic alert collision avoidance system II (TCAS II), Version 7, (added earlier)
  
• Enhanced ground proximity warning system (EGPWS)
  
• Backup air traffic control (ATC) data link printer, and
  
• Versatile Integrated Avionics (VIA) software system, with six primary “partitions” or applications, such as: flight management, com/nav/surveillance/identification (CNSI), com management, display services and all-weather flight control.

Even after all these efforts, however, the AMP’s digital avionics offer only minor reliability improvements to the aircraft as a whole. What they will do, is allow the aircraft to operate with fewer restrictions in civil airspace.

They also lay the required foundation for the major improvements expected in the follow-on Reliability Enhancement and Re-engining Program (RERP). Many of the RERP phase’s improvements, which will make a much bigger difference to the C-5’s reliability rates, require the rewiring and improvements made during the AMP phase, in order to work properly. As USAF Mobility Division Chief for Global Reach Programs Colonel Brunderman notes:

“AMP puts a digital backbone into the aircraft. It replaces a lot of legacy analog dial systems that are no longer supportable and are getting unreliable and puts them into a digital format. AMP also allows the aircraft to interface with the digital controls on the new engines that come in the RERP phase.”

Changing the C-5: RERP

TF39 on C-5
(click to view full)

RERP’s core improvement is the addition of modern F138-GE-100 jet engines, derived from General Electric’s CF6-80C2s that power many Boeing 747s (including the President’s Air Force One), 767s, Airbus 300 and 310s, and other commercial aircraft. The full 2-part upgrade aims to lift the C-5’s mission capability rate from the present level of 55-60% to better than 75%. Lead contractor Lockheed Martin also claims the combined AMP and RERP upgrades will reduce the Air Force’s total ownership cost fleet-wide by 34% over the C-5M’s remaining life span.

These new CF6 engines deliver more than 50,000 pounds of thrust each, allowing the C-5Ms to carry more than 270,000 pounds, and to take off and land in distances as short as 5,000 feet. In comparative terms, they deliver 22% more takeoff thrust, achieve 30% shorter takeoff distances, enable 58% faster time-to-climb to cruising altitude (an important metric in dangerous environments, where getting above 15,000 feet makes you a lot safer), and have a 99.98% departure reliability rate in commercial service, providing a 10-fold improvement in reliability and maintainability over the C-5 fleet’s existing TF39 engines.

In 2002, Lockheed Martin awarded GE a $126 million contract to provide CF6-80C2 engines for the C-5M SDD phase. Following a successful SDD phase, the production phase could have called for upwards of 500 F-138 engines, plus service support, at a potential value of $2.6 billion to GE over the life of the multi-year program. In practice, the narrowing of the RERP program to just 42 aircraft means orders for about 170-190 F138 engines.

The C-5s’ RERP phase will also install full-authority digital engine controls (FADECs) that improve their performance and fuel efficiency, updated fault monitoring and recording systems, and much else. Work will cover hydraulic, fuel, fire suppression and pressurization subsystems as well as auxiliary power units, air conditioning systems, landing gear and the airframe.

After: C-5M cockpit
(click to view full)

After completing the entire modernization program, the C-5s will be renamed the C-5M Galaxy aircraft. The 2 new configurations (C-5 AMP, C-5M) will also create follow-on contracts to modify training devices, etc. to the new standards.

The first test C-5M flew on June 19/06, and the first production C-5M flew in September 2010. The production rate goal for C-5Ms is an 8-month turnaround on the modernization, which translates into 11 converted aircraft per year at peak production.

The Air Force planned to “RERP” 2 C-5Bs and 1 C-5A to verify the hoped-for performance and reliability boost. A production decision on the re-engining program was expected in FY 2007, but did not take place until February 2008. In the end, the C-5A fleet was excluded from the RERP phase altogether. Some were even excluded from the AMP phase, which means the overall C-5 fleet will shrink.

The C-5 AMP/RERP Program

Note that figures after 2015 involve fleet sustainment and modernization, which won’t really stop until the planes are retired from service.

C-5 Upgrade Programs: Budgets

Decisions, Decisions: The C-5 Gamble

C-5 over Atlantic City
(click to view full)

The initial C-5 program delivered 80 aircraft. A 2nd construction program in 1981-1986 delivered 50 more; 4 have been lost in crashes, for a total fleet of 126. Each C-5 aircraft can carry 265,000 pounds of cargo for 4,000 miles (roughly double that of the newer C-17A), or 125,000 pounds for 8,000 miles. Its hinged nose can even be raised to make loading or unloading easier, and the Galaxy’s ability to lift even the heaviest main battle tanks into theater made it a critical part of the trans-oceanic air bridge that would reinforce Europe or Korea in the event of an enemy attack. During the 2003 run-up to Operation Iraqi Freedom I, C-5s proved their worth again as they removed logistics bottlenecks in Europe.

If results and cost projections had been more positive, up to 112 total C-5A, C-5B and C-5C aircraft would have gone through the 2-phase AMP/RERP upgrade, which is currently scheduled to begin in 2008 and continue through to 2014. The C-5Ms would then be expected to serve until 2040. The key is that word “if”. As the US Air Force Association explains:

“The C-5 Reliability Enhancement and Re-engining Program, or RERP, has been the catch-22 of mobility for several years. If the upgrade works, USAF won’t need more new C-17s. If it waits and then the RERP doesn’t work, the C-17 line will be closed, leaving no strategic lift option.”

The twin questions facing the program remain cost, and effectiveness. USAF acquisition executive Sue Payton told a Senate committee in late 2007 that per-aircraft costs for C-5 AMP/RERP had ballooned to $146.7 million. In contrast, Lockheed Martin business ventures vice president Larry McQuien stood by the company’s $83 million price commitment, and said that even if additional Air Force costs like training, spare parts, support equipment, and unanticipated repairs were thrown in, the per-aircraft price would not exceed $118 million.

Officially, the Air Force won that argument. Per USAF estimates, Secretary of the Air Force Michael Wynne declared the C-5 program to be in breach of Nunn-McCurdy notification provisions. That law requires the US military to notify Congress if a program is more than 15% over its baseline budget, and rejustify it if the increase is over 25%.

The USAF estimate was significantly more than a 25% increase, and some senior officials began to have second thoughts.

If RERP’s stated objective is to boost the overall reliability of about 100 C-5s by 10 percentage points, goes the thinking, that equates to adding 10 aircraft to the fleet. If the cost to complete the program is $16-17 billion, that’s over $1.6 billion per extra plane. Of course, one reply may add, the 10% readiness increase happens now – but what if the real difference is that without AMP/RERP, readiness rates continue to get worse, or sudden structural issues surface? What if half-way through their remaining airframe life, worsening issues with engines, wires, maintenance etc. mean that only 20% of the unmodified C-5s can fly? That would create a much higher future readiness gain for the modernization program, but those cost-benefit scenarios become more complex to calculate, involving probability estimates, the value of having certainty, plus capacity tradeoffs and load pattern analysis. How many replacement aircraft would be required to replace lost C-5s, and what would that cost?

Heavy Metal

In the end, the USAF and Department of Defense separated the C-5s into 62 C-5 AMP-only aircraft, and 49 C-5M AMP/RERP aircraft. Further cuts appear to have reduced the C-5A+ AMP buy to just 79 planes total, leaving 27 C-5 AMPs and 52 C-5Ms.

The estimated cost of the new program drops to just $7.5 billion, but C-5A+ aircraft would be expected to show only minor readiness improvements, and maintenance of their engines will be a growing issue as the fleet ages. Lean Six Sigma initiatives and performance-based maintenance contracts will be used to try to address the readiness gap. Whether they will be successful remains an open question.

If not, studies were undertaken to see if the C-5 has a future as a civilian cargo aircraft, after all. With that low readiness rate, however, it’s unlikely.

Contracts & Key Events

Swiftly flow
the years…
(click to view full)

Unless otherwise noted, all contracts are issued to Lockheed Martin in Marietta, GA by the USAF’s Headquarters Aeronautical Systems Center at Wright-Patterson Air Force Base, OH. Note that the collection of entries becomes less complete before 2006.

FY 2014-2018

IOC achieved.

C-5M
(click to view full)

October 23/18: Upgrades Honeywell International is being tapped to support the Air Force’s fleet of C-5M Super Galaxy transport aircraft. Under this $7.8 million firm-fixed-priced order the company will be responsible to upgrade 85 Versatile Integrated Avionics/Avionics Integrated Units (VIA/AIU) to the 905 configuration. The upgrades are part of the Galaxy’s Global Air Traffic Management (GATM) avionics program. The VIA software system has six primary “partitions” or applications that include flight management, com/nav/surveillance/identification (CNSI), communication management, display services and all-weather flight control. The C-5M VIA/AIU repair and upgrade effort is a key component to the overall Core Mission Computer/Weather Radar aircraft modification/installation kit that replaces the current mission computer, and replaces the weather radar with a commercial off-the-shelf color weather radar. Work will be perfumed at Honeywell’s location in Albuquerque, New Mexico, and is expected to be completed by June 14, 2020.

August 7/18: Ready to Lift The Air Force is now in possession of a completely refurbished fleet of C-5M Super Galaxy transport planes. The US Air Force Air Mobility Command began a program to modernize the C-5s in 1998 after a study concluded the decades-old aircraft had 80% of their service life remaining. AMP is the first step. Its main purpose is to equip the aircraft to fly in civil airspace by the most direct routes, at the most advantageous altitudes, with the most efficient fuel usage and cargo loads. AMP is also trying to reduce the number of devices and wires in the planes, to reduce costs and improve reliability. RERP’s core improvement is the addition of modern F138-GE-100 jet engines, derived from General Electric’s CF6-80C2s that power many commercial airliners. The C-5 is capable of carrying two 78-ton M1A1 main battle tanks or helicopters and other large equipment intercontinental distances. Over the years Lockheed Martin upgraded a total of 52 C-5s with new engines, avionics and diagnostic systems, which will keep the airlifters flying until the 2040s.

October 25/17: Lockheed Martin has been awarded a $14.7 million US Air Force (USAF) contract to enhance the automatic dependent surveillance-broadcast out system, among other parts of the communications system on the C-5. Work to be undertaken include C-5 communications, navigation, surveillance/air traffic management engineering and manufacturing development program and incorporates the automatic dependent surveillance-broadcast out technology. Work will be completed at Marietta, Ga., and is expected to be completed by September 25, 2019. Lockheed’s C-4 Galaxy has been in service since 1970 and is one of the world’s largest transport aircraft.

July 16/14: #21 delivered. C-5M Super Galaxy #87-0044 leaves Marietta, GA as the 3rd C-5M destined for Travis AFB, CA. Sources: Lockheed Martin Code One Magazine, “Travis No. 3”.

June 30/14: #20 delivered. A C-5M Super Galaxy leaves Marietta, GA for Travis AFB, CA. Aircraft 85-0010 was delivered 28 days ahead of the contracted schedule. Sources: Lockheed Martin, “Another C-5M Goes West”.

June 18/14: RERP-6: Convert 11. A $222.9 million fixed-price C-5M RERP contract modification pays to modify a total of 11 C-5 aircraft, using the appropriate kits. This brings the Lot 6 total to $882.3 million for materials and installation (q.v. Oct 31/12, Oct 21/11)

All funds are committed immediately, using FY 2013 and FY 2014 USAF aircraft budgets. Work will be performed at Marietta, GA and is expected to be complete by Jan 10/17. USAF Life Cycle Management Center/WLSK at Wright-Patterson AFB, OH manages the contract (FA8625-07-C-6471, PO 0200).

May 8/14: RERP-7 kits. Lockheed Martin in Marietta, GA receives a $508.9 million fixed-price modification for C-5 RERP Lot 7 kits.

All funds are completed immediately, using USAF FY 2014 aircraft procurement funds. Work will be performed at Marietta, GA, and is expected to be complete by May 2018. The USAF Life Cycle Management Center/WLSK at Wright-Patterson AFB, OH manages the contract (FA8625-07-C-6471 P00201).

May 8/14: #19. C-5M Super Galaxy #87-0042 leaves Marietta, GA as the 1st C-5M destined for Travis AFB, CA. The C-5Ms will be flown by active duty crews from the 60th Air Mobility Wing, as well as crews from Air Force Reserve Command’s 349th AMW Associate unit at Travis AFB. Sources: Lockheed Martin Code One Magazine, “First Super Galaxy For Travis”.

April 26/14: Basing. The USAF announces that half of the 439th Airlift Wing’s C-5 fleet at Westover ARB, MA will be cut, with 8 of their C-5Bs transferred fto JB San Antonio-Lackland, TX beginning in 2015. Westover will receive 8 upgraded C-5M Super Galaxys, but they’ll still lose 59 full-time enlisted personnel and 275 drilling Reservists. Sources: Lockheed Martin Code One Magazine, “Westover Basing Decision”.

April 2/14: #18. USAF Lt. Gen. Brooks L. Bash, the vice commander of Air Mobility Command, personally flies C-5M #87-0040 from the Lockheed Martin facility in Marietta, GA, to Dover AFB, DE. It’s the last C-5M delivered to the base, which has been the type’s sole destination so far. Sources: Lockheed Martin Code One Magazine, “Last Super Galaxy To Dover”.

March 25/14: #17. C-5M Super Galaxy #87-0020 leaves Marietta, GA for Stewart ANGB, NY for internal paint and insulation blanket restoration. After getting the touch-up, the aircraft will be flown to Dover AFB, DE. Sources: Lockheed Martin Code One Magazine, “Super Galaxy Number 17”.

March 25/14: Avionics. Lockheed Martin Aeronautics Co. in Marietta, GA receives a sole-source $84.3 million cost-plus-incentive-fee contract. It funds the EMD development program for the C-5 fleet’s Core Mission Computer/Color Weather Radar program. These upgrades are envisaged as retrofits to the entire AMP/ RERP fleet.

$11.2 million in FY 2013 USAF aircraft budgets are committed immediately. Work will be performed at Marietta, GA, and is expected to be complete by March 31/17. The USAF Life Cycle Management Center/WLSK at Wright-Patterson AFB, OH manages the contract (FA8625-14-C-6596).

March 4-11/14: Budgets. The US military slowly files its budget documents, detailing planned spending from FY 2014 – 2019. The C-5 program gets the main C-5M budget zeroed out from FY 2016 – 2019. It’s not quite as big a change as it seemed, because some of the upgrades are being broken out as their own programs, but it’s still a total reduction of about $194.5 million from FY 2016 – 2019. See the charts above.

The C-5’s mission computer has to be replaced. It has reached capacity, and can’t even handle basic additions like the flight management system (FMS); weather radar; and basic requirements for using civil airspace past 2020: ADS-B Out, and identification, friend or foe (IFF) mode 5. The new mission computer will handle these and other upgrades.

A new color weather radar replaces the current AN/APS-133s, which have such serious problems with obsolete parts that they threaten to become unserviceable.

They also want to fix the bathrooms, but that isn’t just convenience. Not only is the current system unreliable, it leaks liquid sodium hypochlorite, causing severe corrosion and burnt wires in the landing gear control panels. Not a great outcome, so they’re going to replace them a commercial product using FY15 funding.

Feb 21/14: IOC. USAF AMC declares Initial Operational Capability for the C-5M. Lockheed Martin has delivered 16 planes, and the aircraft has passed its Qualification Test, Operational Test and Evaluation, stand-up of required spares and maintenance facilities at Dover AFB and other locations, and stand-up of enough trained aircrew and maintenance personnel.

The program is far enough along that the Pentagon’s DOT&E no longer features them in testing reports.

C-5M IOC

Dec 23/13: #16 delivered. Tail number 87-0036 is ferried to Dover Air Force Base, DE. It’s the 16th C-5M delivered, and the 6th delivered in 2013. Is it us, or did that recent set of rapid-fire deliveries seem a bit compressed? Sources: Lockheed Martin, “Sweet Sixteen”.

Dec 12/13: #15 delivered. The latest C-5M is off to Dover Air Force Base, DE. Lockheed Martin is still touting that the plane “exceeds a mission capable rate of 80 percent,” which is a big improvement if it’s true. Sources: Lockheed Martin, “Home for the Holidays”.

Dec 5/13: #14 delivered. Lockheed Martin flies its latest delivery to Stewart Air National Guard Base, NY for internal paint restoration, before C-5M #86-0017 heads to its permanent home at Dover AFB, DE. Sources: Lockheed Martin, “Another Super Galaxy Delivered” | Lockheed Martin Code One Magazine, “Super Galaxy Delivered”.

Nov 21/13: #13 delivered. Lockheed Martin delivers tail number 85-0004 to the 436th Airlift Wing at Dover Air Force Base, DE. Sources: Lockheed Martin, “Baker’s Dozen!”.

FY 2013

 

Lt. Col. Mike Semo,
C-5M Pilot
click to play video

Sept 19/13: #12 delivered. Lockheed Martin delivers C-5M #85-0003 to the USAF at its Marietta, GA plant. Maj. Gen. Wayne Schatz Jr., Director of Strategic Plans, Requirements, and Programs at Air Mobility Command headquarters, flies the aircraft to Stewart ANGB, New York, where it will undergo internal paint restoration before returning to its permanent home at Dover AFB, DE. This aircraft has recorded more than 19,000 flight hours.

Lockheed Martin says that they’re on track to deliver 52 C-5Ms by 2017. Sources: Lockheed Martin, “Make it a Dozen!” | Lockheed Martin Code One Magazine, “Super Galaxy No. 12”.

Sept 5/13: Training. A $21.3 million contract modification for a C-5M RERP aircraft maintenance system trainer and a flight control system trainer at Travis AFB, CA, plus associated spares. All funds are committed immediately, using FY 2012 procurement funds. The buy seems minor, but the 2012 report from the Pentagon’s testing department (q.v. Jan 17/13) cited a lack of dedicated training systems as a problem for the fleet.

Work will be performed in Marietta, GA, with an expected completion date of Aug 31/16. Fiscal 2012 aircraft procurement funds in the amount of $21,318,495 are being obligated at time of award. The Air Force Life Cycle Management Center at Wright Patterson AFB, OH manages the contract (FA8625-07-C-6471, PO 0224).

June 21/13: #11 delivered. The eleventh C-5M Super Galaxy leave Lockheed Martin’s Marietta, GA facility for Dover AFB, DE. Sources: Lockheed Martin, June 21/13 release.

June 18/13: Software. A $27.9 million indefinite-delivery /indefinite-quantity contract with cost-plus-fixed-fee, firm-fixed-price, and cost-reimbursement-no-fee portions. Lockheed Martin will support C-5 software and the software integration laboratory, offer engineering support, and provide an emergency operational flight plan.

$21 million in FY 2013-2016 Operations and Maintenance DPEM Software funds in the amount are committed for Task Orders 0001 and 0002. Work will be performed at Marietta, GA, and is expected to be complete by by June 20/16. This award is a result of an electronic solicitation with 1 bidder, from the USAF Life Cycle Management Center/C-5 Galaxy Center at Robins AFB, GA (FA8525-13-D-0004).

April 28/13: Waste. Congressionally-mandated waste continues. USAF training hours are cut and squadrons stop flying, in order to maintain aircraft that cannot fly and pay people in Congressional districts to do meaningless work. The USAF isn’t the only service with this problem, but it’s a sharp one for the C-5 fleet. From the New Hampshire Foster’s Daily Democrat:

“Parked around the airstrip at Joint Base San Antonio-Lackland are more than a dozen massive C-5A Galaxy transport planes. There is no money to fly them, repair them or put pilots in the cockpits, but Congress rejected the Air Force’s bid to retire them…. crews will tow the planes around the Texas tarmac a bit to make sure the tires don’t rot, then send them back into exile until they can finally get permission to commit the aging aircraft to the boneyard…. Fifteen of the C-5A Galaxy aircraft are at Lackland, where crews are getting in some flights now preparing for the retirement, while 11 are at Martinsburg, W.Va., and are flown [sic] by the Air National Guard there.”

April 25/13: Lockheed Martin Aeronautics Co., Marietta, Ga., was awarded a modification on contract for C-5M Reliability Enhancement and Re-engining Program (RERP). The value of this contract modification is $45.7 million, increasing the total contract value from $3.647 billion to $3.693 billion. The contract modification is for C-5M RERP Lots 3, 4, and 5 Rapid Repair and Response legacy repair efforts.

Work will be performed in Marietta, GA, and is expected to be complete by Oct 29/14. $14.8 million in FY 2011 through 2013 Aircraft Procurement funds are committed immediately by the USAF Life Cycle Management Center/WLSK at Wright-Patterson AFB, OH (FA8625-07-C-6471, PO 0182).

April 10/13: FY 2014 Budget. The President releases a proposed budget at last, the latest in modern memory. The Senate and House were already working on budgets in his absence, but the Pentagon’s submission is actually important to proceedings going forward. See ongoing DID coverage.

FY 2014 is the last major year of funding at $1.217 billion. That will drop to $334.7 million in FY 2015, when C-5M budgets will almost end completely. The last aircraft scheduled for delivery in Q1 FY 2017.

Jan 31/13: Support. A $16 million firm-fixed-price, cost-plus-fixed-fee and cost reimbursement contract for replenishment spares and repairs in support of the C-5’s AMP and RERP programs.

Work will be performed in Marietta, GA, and expected to be complete by Jan 31/14. The AFLCMC/WLKB at Robins AFB, GA manages this sole source acquisition, using FY 2013 dollars (FA8525-13-D-0001).

Jan 17/13: DOT&E report. The Pentagon releases the FY 2012 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). The C-5M is included, and it still isn’t “operationally suitable”. In fact, the office had recommended last year that C-5M wasn’t ready to proceed to IOT&E testing. It went anyway, and:

“The aircraft’s ability to conduct the strategic airlift mission is hindered by deficiencies in the Automatic Flight Control System, by problems with the Embedded Diagnostics System (EDS) and built-in test (BIT) functionality, by inadequate support equipment, and by a lack of dedicated training systems. Deficiencies in several aspects of C-5M support functions, identified before the 2010 OT&E began, had a significant effect on suitability, specifically the maintainability of the aircraft.”

As one might imagine, the USAF has an “extensive” correction action plan. Diagnostic false alarm rates remain “very high,” which risks sabotaging the entire mission availability rationale for the entire C-5M program. There’s also a problem with training, since C-5M specific aircrew and maintainer training devices are just becoming available, forcing the USAF to use 1 simulator, plus on-aircraft training when possible. That doesn’t help readiness, either, and the USAF plans to buy more training devices in FY 2013.

OFP 3.5 basic flight & operating software helped with some of the airspeed control issues, but the plane still isn’t reliable in critical situations like final approach, or “gusty or turbulent” conditions. The Air Force plans to begin operational testing of OFP 3.5.2 in August 2013. At least the thrust reversers got their heating blankets to prevent ice-up, then got strengthened gears to make sure they stayed retracted. It works, but they need to be inspected more often.

Nov 30/12: RERP. A $9 million contract modification for the C-5 RERP. Work will be performed in Marietta, GA until July 31/15 (FA8625-07-C-6471, PO 0184).

Nov 29/12: C-5A-M Support. A $56.7 million cost-plus-fixed-fee, cost-reimbursement- no-fee, firm-fixed-price, time and materials contract for the C-5 sustaining engineering and technical support services. It covers all C-5s in service, including the C-5Ms, which are becoming a significant enough presence to matter. Work will be performed in Marietta, GA until Nov 30/12 (FA8525-13-D-0003).

Nov 21/12: A $38.5 million contract modification for procurement of 2 optional C-5 RERP plus-up spare engines, and the engine kits effort. Work will be performed in Marietta, GA, and is expected to be complete by Dec 15/14 (FA8625-07-C-6471, PO 0161).

Note the purchase order number, this is similar to but distinct from the Nov 19/12 order.

Nov 19/12: RERP. A $38.3 million contract modification to buy 2 spare C-5 RERP RFI engines and RFI engine kits.

Work will be performed in Marietta, GA, and is expected to be complete by May 30/14. The AFLCMC/WLSK at Wright-Patterson Air Force Base, OH manages the contract (FA8625-07-C-6471, PO 0160).

Oct 31/12: RERP Lot 6. A $489.4 million contract modification for C-5 RERP Lot 6 kits. It’s added to the $160 million advance procurement (vid. Oct 21/11) for these 11 aircraft kits, and the installation and spares contracts are still pending beyond the current $659.4 million.

Work will be performed in Marietta, GA, and the contract will run until July 17/15 (FA8625-07-C-6471, PO 0140).

Oct 19/12: RERP Lot 5. Lockheed Martin Aeronautics in Marietta, GA receives a $221.8 million contract modification for the C-5 RERP Lot 5 Installation effort, involving 11 aircraft. That boosts the total cost of publicly-reported RERP-5 contracts to $1,000.5 million, or about $91 million per plane, including spares.

Work will be performed in Marietta, GA, and is expected to be complete by Oct 29/15 (FA8625-07-C-6471, PO 0166).

FY 2012

79th & last C-5 AMP delivered; All-C-5M fleet?; Cracks sapping fleet capacity; C-5M testing issues.

#5 departs
(click to view full)

July 20/12: #5 delivered. Lockheed Martin delivers the 5th production C-5M, and 8th overall, to Robins AFB, GA.

June 29/12: Un-cracked. Cracks at the C-5 cargo floor’s bulkhead end fittings had restricted its cargo carrying capabilities to a maximum of 80%, lowering its advantage over platforms like the C-17. In response, the US Air Force Research Laboratory (AFRL) developed a more stress and corrosion-resistant aluminum alloy, and a new die forging process, under the Durable C-5 Structural Improvements Program. Some C-5s are already being refitted at the Warner Robins Air Logistics Center, GA. US AFRL:

“The reshaped end fittings provide an optimised design that is less prone to cracks, and also offers multiple benefits for the revamped C-5 aircraft, which includes a 25% overall cost savings, an 80% reduction in fabrication time, and a 60% increase in service life of the fittings… methods employed earlier… insufficient, as the replacement fittings provided to the aircraft often cracked during the machining process, and also had a shorter lifespan than the original parts.”

April 30/12: Last C-5 AMP. Lockheed Martin announces that it has delivered the 79th and final C-5 AMP plane to the USAF. The planned program total had been cut from 111 to 80, but a C-5 crash dropped the number by one.

Last C-5 AMP delivered.

April 15/12: Link for savings. The USAF discusses its Mobility Mission Linking, or MML, program, which aims to make up for the inconvenient positioning of current C-5 wings in Texas and the USA’s east coast. When most missions are in Southwest Asia, it can mean up to 11 flight hours per mission with no cargo on-board. By linking multiple stops and eliminating the transit from Texas, MML expects to save 3.5 million gallons of fuel and $12 million between FY 2012- 2016. USAF.

April 12/12: All C-5Ms? A USAF story makes an interesting statement:

“The C-5 has long been known as the “Air Force’s largest airlifter.” In the future, Air Mobility Command officials say the goal is to have all C-5s become C-5Ms that would further strengthen the airframe’s worldwide airlift capabilities.”

There are 2 ways to do that. One way is to modernize the remaining 27 C-5 AMP aircraft at a later date, bringing the C-5M fleet to 59. the other way is to retire the lower-readiness, lower-capability, more expensive to operate C-5 AMPs early, leaving the USAF with just 52 C-5Ms as the entire fleet. In a coming era of budget cuts, which seems more likely?

April 7/12: Gannett’s Air Force times reports that Dover AFB will be the 1st base to convert to an all-C-5M fleet, after its last C-5B leaves for conversion in June 2012.

Feb 1/12: RERP #11 begins. Lockheed Martin inducts the 11th C-5 RERP aircraft to the Super Galaxy production line. Aircraft 86-0017 has accumulated more than 18,000 flight hours and more than 4,300 full-stop landings.

Jan 17/12: DOT&E test report. The Pentagon releases the FY 2011 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). The C-5M RERP is listed as 1 of just 3 USAF programs that met their reliability targets, though a subsequent March 2012 DoD DT&E and SE Annual Report lists C-5M reliability at just 66%, instead of the 75% target that must be met in FY 2016. In the interim, the C-5M is proceeding fairly well, but still has some issues to work on.

The 2010 operational test identified problems with engine thrust reversers (restricted use in flight makes emergency descents and some tactical patterns very difficult), autopilot (too aggressive in cruise operations & turbulence, doesn’t always maintain commanded airspeed), and the Environmental Control System (autopilot problems killing bleed air supply and dropping cabin temperature under 50F/ 10C). Operational testing of the fixes was scheduled to begin in January 2012, in conjunction with operational testing of the plane’s new Block 3.5 software set.

While the C-5M was deemed operationally effective, it wasn’t given an “operationally suitable” rating. That will require testing to eliminate a very high false alarm rate and poor fault diagnosis in the plane’s built-in-test equipment, and the delivery of C-5M aircrew and maintainer training devices. The C-5M is also susceptible to unspecified “information assurance” (data security) problems, but the risk was deemed to be low.

Nov 18/11: RERP Lot 5. Lockheed Martin Corp. in Marietta, GA receives a $13.4 million firm-fixed-fee contract modification for C-5 RERP FRP-5 items required to meet the field needs of its 11 C-5M aircraft. That’s on top of the $602.4 million in Oct 21/11 FRP-5 orders. One firm was solicited and one firm submitted a proposal to the ASC/WLSK at Wright-Patterson AFB, OH (FA8625-07-C-6471).

Oct 21/11: RERP Lots 4-6. Lockheed Martin Aeronautical Systems in Marietta, GA receives 4 C-5 RERP program contract modifications, worth around $890 million total. All are firm-fixed-price, with economic price adjustments if the cost of key metals etc. rises. They are:

For C-5 RERP Full Rate Production, Lot 4 (FRP-4, FY 2011), $126.7 million to finish C-5M conversion and install the 28 enhanced engines on FRP-4’s 7 aircraft (FA8625-07-C-6471, PO 0102). They’re Production Lot 4 RERP kits, but they’re installed in the same fiscal year that produces FRP-5.

For C-5 RERP FRP-5 (FY 2012), $518.9 million to build the FRP-5 RERP kits for 11 C-5s (FA8625-07-C-6471, PO 0107), and $83.5 million to buy initial spares for those planes (FA8625-07-C-6471, PO 0104).

For C-5 RERP FRP-6 (FY 2013), $160 million for advance procurement of items whose production lead time is more than 12 months, so they’ll be ready when the FRP-6 build contract for another 11 C-5 RERP kits is issued next year (FA8625-07-C-6471, PO 0103).

FY 2011

Civilian C-5s?

C-5 in RERP
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Sept 29/11: RERP #9P in. Lockheed Martin inducts the 9th C-5 for full C-5M conversion. Tail 0045 was the last C-5B produced for the USAF. It has accumulated nearly 18,000 flight hours, and more than 4,200 full-stop landings.

Sept 25-26/11: Non-stop. A C-5M Super Galaxy from the 436th Airlift Wing at Dover AFB, DE, flies direct to Bagram Airfield, Afghanistan, passing over the Atlantic and Europe en route. Traditionally, C-5s stop in Germany to refuel the plane and rest the crew, then finish the rest of the flight the next day. For this flight, a KC-135R aerial tanker based in Britain refueled the plane.

There’s a balance between proving out new routes, for use if needed, and using routes that don’t place a routine strain on resources. While the C-5M is capable of these missions, it remains to be seen whether they will become the norm. Another pathfinding example took place on June 5-6/11, as a C-5M crew flew an arctic route to Afghanistan over Canada, Russian, and Kazakhstan, with a KC-135R refueling over northern Canada. USAF AMC.

Aug 17/11: Training. Lockheed Martin announces a $5.8 million base contract from FlightSafety Services Corp. The scope of work includes managing hardware, software and courseware, maintaining simulator certifications to Air Force specifications, and overseeing the operations of the C-5 Aircrew Training System (ATS) program.

C-5 ATS helps train C-5 pilots, flight engineers, loadmasters and maintenance engine run personnel, and the contract will apply to all C-5 variants. Lockheed Martin will manage the Lackland AFB, TX C-5 Training Systems Support Center and formal training unit, and provide support for the other 6 training locations: Dover AFB, DE; Travis AFB, CA; Martinsburg ANG Base, WVA; Memphis ANG Base, TN; Stewart ANG Base, NY; and Westover Air Reserve Base, MA. The contract includes 4 more 1-year options, which could bring this contract up to 5 years and $30 million.

Aug 4/11: RERP #8P in. C-5B tail number 85-0003 becomes the 8th aircraft inducted into modernization production. That number is expected to rise to 10 by the end of 2011. Lockheed Martin.

July 18/11: RERP #3P flies. The 3rd production C-5M Super Galaxy takes its first flight at the Lockheed Martin facility in Marietta. Aircraft 0005 is assigned to Dover AFB, DE, and will be flown by both active duty and reserve airlift wings. Lockheed Martin.

April 27/11: Sub-contractors. Small business qualifier Thomas Instrument in Brookshire, TX receives a maximum $9 million firm-fixed-price, indefinite-delivery/ indefinite-quantity contract for C-5 aircraft gearbox assemblies.

The contract runs to March 2015 and is managed by the US Defense Logistics Agency Aviation at Robins Air Force Base, GA (SPRWA1-11-D-0009).

April 12/11: RERP #2P delivered. Lockheed Martin completes delivery of the 2nd production C-5M at Dobbins Air Reserve Base, Marietta, GA. The plane will undergo internal paint restoration at Stewart Air National Guard Base, NY, before traveling to its home base at Dover. Lockheed Martin.

Feb 15/11: An $8.9 million contract modification for the C-5 RERP Lot 4 readiness spares package, part 2, for Dover and Travis Air Force Bases. At this time, all funds have been committed (FA8625-07-C-6471; P00076). This contract and modification number was also announced on March 7/11, where it did not say that all funds had been committed.

Feb 14/11: FY 2012 Budget. The Pentagon releases its FY 2012 budget request, and the USAF details its major programs [PDF]. FY 2011 was the last year for C-5 AMP funding, at $627.7 million requested. In FY 2012, the C-5M RERP program would receive $851.9 million to convert 7 aircraft (up from 5 in FY 2011; note that conversions are done using the previous year’s production) and buy 11 equipment sets for installation in FY 2013, as well as $9.4 million to get USAF maintenance depots ready for C-5Ms, and $500,000 for an AMP/RERP compliant Aircrew Training System (ATS) and a Maintenance Training Device (MTD). Other USAF budget documents [PDF] add that:

“In FY 2012, the F-35, RQ-4 Global Hawk, and Light Cargo Aircraft have large initial spare requirements in preparation for fielding. Other initial spares programs with large requirements include MQ-9 Reaper, C-5 Airlift Squadrons, Light Cargo Aircraft, CV-22, and EC-130H COMPASS CALL aircraft. In FY2012 some programs, including Global Hawk, MQ-9, and C-5 began budgeting for initial spares in Budget Activity 06 instead of Budget Activities 01 through 05.”

The C-5 RERP is the largest of them all, with $116.175 million in spares. That’s not entirely surprising, given the number of new engines involved. The Pentagon doesn’t include the C-5 in its handout of costs by weapon system, but the C-5 AMP/RERP seems to add up to around $978 million in FY 2012.

Jan 28/11: A $20.6 million contract modification to provide interim contract support for the C-5 RERP Program. At this time, the entire amount has been committed (FA8625-09-D-6485 0008).

Jan 19/11: RERP #5P in. Lockheed Martin announces that the 5th C-5 aircraft has been inducted into the RERP process, to be transformed into a C-5M by the end of 2011.

Nov 30/10: An $8 million contract for C-5 fleet sustaining engineering efforts required to resolve technical, supportability, or efficiency issues. Money will be committed as needed by the WR-ALC/GRSKA at Robins Air Force Base, GA (FA8525-11-D-0003).

Nov 18/10: Training. A $23 million contract modification for Phase 3 of the C-5M RERP’s AMS (aircraft maintenance systems) trainer and flight trainer program. At this time, $14.3 million has been obligated (F33657-02-C-2000; P00227).

Nov 15/10: RERP #1P delivered. The 1st production C-5M leaves Stewart Air National Guard base in Newburgh, NY and arrives at its duty station of Dover AFB, DE. The C-5M planes flying to date have all been pre-production planes from the system development stage. defpro | Mid-Hudson News | NY State.

Nov 8/10: A maximum $29.2 million contract for C-5M AMP program sustainment support. Delivery orders will be issued as needs arise by the Warner-Robins Air Logistics Center at Robins Air Force Base, GA (FA8525-11-D-0001).

Oct 22/10: RERP Lot 4 k+s. A pair of C-5M RERP awards from the USAF, for current production, worth $387.9 million. See also Jan 11/10 entry.

A $326.9 million contract modification for C-5M RERP full-rate production Lot 4 materials and fabrication of material required to modify the 7 seven Lot 4 aircraft. At this time, all funds have been committed (FA8625-07-C-6471; P00041).

A $61 million contract modification for spare parts to cover the 7 C-5M aircraft from FRP Lot 4 production. At this time, all funds have been committed (FA8625-07-C-6471; P00058).

Oct 19/10: RERP Lot 3i/5a. A pair of C-5M RERP awards from the USAF, worth $278.6 million.

The first is a a $115.7 million contract modification for C-5M RERP low rate initial production Lot 3 installations. At this time, the entire amount has been committed (FA8625-07-C-6471).

The second is a $162.9 million contract which covers C-5M RERP full-rate production Lot 5 advance procurement of critical materials and equipment, such as aircraft engines. At this time, the entire amount has been committed (FA8625-07-C-6471).

Oct 4/10: Civil C-5s? Aviation Week reports that both Lockheed Martin and elements in the USAF are re-thinking the decision to terminate RERP for the C-5A fleet, if money allows – and even looking at placing some C-5s in the civilian market:

“Lockheed Martin says it needs long-lead funding in Fiscal 2014 to avoid a gap in the modification line after the last C-5B is upgraded, and to keep prices agreed upon with major suppliers… [including] General Electric for the new CF6-80C engines. “As the aircraft proves itself, we are talking to the Air Force about the benefits of a single fleet,” says Lorraine Martin, Lockheed Martin vice president for C-5 programs… The Air Force also operates 59 C-5As, but plans to retire 22 in 2011-12 because of excess strategic airlift capacity. Congress directed the Air Force to study the potential for placing the retired aircraft with the Civil Reserve Air Fleet (CRAF) or international coalition partners. A report will be submitted soon… A Defense Acquisition Board decision on full-rate production [of C-5M RERP planes] is set for Oct. 7.”

Barring some sort of government financing agreement that would tip the scales, C-5As and their $82+ million RERP upgrade costs would have to compete against new-build civilian BC-17s at about $225 million, in order to become a preferred option for would-be civilian carriers who wanted to compete with Antonov’s partners in the outsize cargo market.

Sept 20/10: Infrastructure. Soltek Pacific Construction Co. in San Diego, CA wins a $6.4 million firm-fixed-price task order under a multiple award construction contract (N62473-08-D-8615, #0014) to build a C-5 Squadron Aircraft Operations and Maintenance Facility at Travis Air Force Base, CA. The task order also contains one planned modification which if issued, would increase the cumulative task order value to $7.5 million.

Travis AFB is home to the 60th Aircraft Maintenance Squadron, which services and supports AMC C-5s. Work will be performed in Fairfield, CA, and is expected to be complete by October 2011. The Naval Facilities Engineering Command, Southwest in San Diego, CA received 4 proposals for this task order.

FY 2010

C-5 AMP cut from 112 – 92; C-5M RERP operational; RERP gets low-rate production approval

DSRV-1 loading
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Sept 19/10: RERP #1P flies. The first production C-5M takes off from Lockheed Martin’s Marietta, GA facility. It is slated for formal delivery on Sept 30/10, and will arrive at its new home Dover AFB, DE in November 2010.

Note that this is not the 1st C-5M, as there were 3 initial planes built in the system development phase, and they are already operational.

July 29/10: Training. CAE USA, Inc. in Tampa, FL receives $10.6 million contract to purchase 7 C-5 AMP training devices and 5 C-5M RERP program training devices for the C-5 aircrew training system. The simulators will be used by USAF Air Material Command, US Air National Guard, and USAF Reserve Command. CAE will begin by upgrading a C-5 WST(Weapon System Trainer) currently located at Stewart Air National Guard Base (ANGB) to the new C-5 AMP configuration. The other C-5 WST, located at Dover AFB, DE and already upgraded by CAE to the AMP configuration several years ago, will now be upgraded to the RERP configuration using new engine performance simulation software and a new aerodynamics model.

A month later, a CAE release says that the contract includes options to upgrade additional C-5 and C-5 cockpit procedures trainers, which could bring total value to more than $50 million. At this time, $10.6 million has been committed by the GHMKA at Hill Air Force Base, UT (F8223-10-R-3000/2).

June 8/10: RERP #3P in. Lockheed Martin inducts its 3rd C-5 Galaxy strategic airlifter into the RERP production line at Marietta, GA. The company has already delivered 3 initial C-5M aircraft, which Lockheed Martin says passed testing with “the highest rating possible.” The 1st production C-5M is scheduled for delivery to Dover AFB, DE later in 2010, and this 3rd production C-5M is expected to be ready in about a year (mid-2011).

Current Air Force plans call for Lockheed Martin to deliver 52 total C-5Ms (modification of 49 C-5Bs, 1 C-5Cs, and 1 C-5A) by 2016. Lockheed Martin.

June 7/10: A $5.7 million contract for C-5M RERP low rate initial production, and related expenses. At this time, the entire amount has been committed by the 716th AESG at Wright-Patterson Air Force Base, OH (FA8625-07-C-6471).

April 2/10: Training. FlightSafety Services Corporation of Centennial, CO received a $34.8 million contract for C-5 aircrew training system operation, maintenance, and support. At this time the entire amount has been obligated by the 508th ACSS/PK at Hill Air Force Base, UT (FA8223-10-C-0007).

April 1/10: SAR – C-5 AMP cut. The Pentagon releases its April 2010 Selected Acquisitions Report, covering major program changes up to December 2009. The first-stage C-5 AMP program is mentioned, confirming a cut from 112 aircraft to 92 aircraft:

“Program costs decreased $200.2 million (-14.3%) from $1,405.3 million to $1,205.1 million, due primarily to a quantity decrease of 20 aircraft from 112 to 92 aircraft (-$112.9 million), and decreases in other support costs and initial spares associated with the quantity decrease (-$73.3 million). There was also a decrease for prior year actuals for kit buys and installations (-$12.6 million).”

SAR change

The force mix would then become 20 unmodified C-5As, 42 C-5A+ AMP aircraft, and 59 C-5M AMP/RERP aircraft. Future disposition of the unmodified C-5As is not clear, but they could easily slip into the neverland of sitting in hangars at all times, eating maintenance dollars the whole time but not flying, while Congress refuses to allow the USAF to retire them. They would not be alone in this status.

March 30/10: GAO ASP. The US GAO audit office delivers its 8th annual “Defense Acquisitions: Assessments of Selected Weapon Programs report. It covers only the full C-5M RERP program, which it describes as mature, stable, and in production, albeit at 66% higher per-unit costs than the original baseline. The remaining program is not completely free of risk, however:

“While the Air Force is expected to spend $3.4 billion less under the restructured program, ultimately, less than one-half of the aircraft will be modernized at a much higher unit cost. Further changes to the program are possible based on whether the program exercises future contract options and the mobility capability study. Program officials have indicated that if options for lots [4] through [7] of the C-5 RERP production contract are not exercised by the dates required in the contract, the remaining lot four through seven negotiated not to exceed prices become invalid for all future options. Consequently, officials indicated that future work may need to be renegotiated and if so, it would lead to a substantial increase in the negotiated prices. In addition, DOD is currently studying its future mobility capabilities requirements with the results expected in December 2009. The study may or may not affect the number of C-5s that require the RERP modification.”

March 16/10: Infrastructure. Lockheed Martin Corp. in Marietta, GA receives a $6.2 million contract. Lockheed Representatives clarify that it will fund the data, support equipment, and spares needed to stand up 5 different Air Logistics Center C-5 AMP maintenance depots, for components manufactured and repaired by GE aviation.

At this time, the entire amount has been obligated. 716 AESG/PK, Wright-Patterson Air Force Base, Ohio, is the contracting activity (F33657-98-C-0006, P00231).

Feb 19/10: An $86.2 million contract which will provide for the C-5M RERP. At this time, $23.2 million has been committed by the 716th AESG/SYK at Wright-Patterson Air Force Base, OH (FA8625-09-D-6485).

Feb 9/10: C-5M operational. USAF Air Mobility Command announces that the C-5M Super Galaxy has completed 4 months and 1,300 hours of operational test and evaluation, releasing the aircraft for use in worldwide operations.

OT&E began on Oct 1/09, and required the cooperation of USAF Air Mobility command, Air Materiel Command, and the Air Reserve Command. Aircrews from the 436th and 512th Airlift Wings flew a mission that included cold weather operation testing at Eielson AFB, Alaska. They also flew nonstop flights from Dover AFB, DE, USA to Incirlik Air Base, Turkey, without refueling, bypassing traditional C-5B fuel stops at Rota Naval Air Station, Spain. USAF AMC announcement | Lockheed Martin release.

The USAF estimates that these direct flights saved more than 365 hours vs. the same mission with a C-5B (N.B. 289 of those are on the ground), and approximately 186,000 gallons of fuel.

Jan 11/10: RERP LRIP-1. Lockheed Martin announces $343.3 million in ongoing funding through a recently issued Acquisition Decision Memorandum (ADM), authorizing Low Rate Initial Production (LRIP) associated with the C-5 RERP program. That funding supports LRIP RERP production support for 15 aircraft, including installation on 3 aircraft, material and fabrication for 5 aircraft, and long-lead funding for 7 aircraft.

Production of the C-5M Super Galaxy began on Aug 18/09, and that first aircraft is slated for delivery to the USAF in September 2010. Three test C-5Ms have already been delivered to the USAF, and current USAF plans call for 52 fully-modernized C-5Ms by 2016.

Jan 5/10: Training. A $6.3 million contract to fund C-5 RERP engine maintenance training devices, integration efforts, and a contract change proposal. At this time, $3.9 million has been committed (33657-02-C-2000, P00207).

Nov 6/09: A $143.2 million contract that will provide C-5 AMP sustainment support. The 330 SW at Robins Air Force Base in Georgia manages the contract (FA8525-06-D-0001, P00013).

FY 2009

1st RERP begins; C-5A+ #50 delivered; GAO cites C-5 AMP shortfalls, risks.

C-5M takeoff
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Aug 18/09: RERP Production begins. Lockheed Martin has produced 3 C-5M test aircraft, but today the 1st C-5 Galaxy (USAF serial number 83-1285) flies into Marietta, GA from Dover AB, DE, for induction into the C-5M RERP production line. This aircraft was also the first C-5B to come off the original production line in 1985. RERP modernization is expected to take 13 months, eventually declining to 8 months for subsequent aircraft as production ramps up.

The 3 C-5Ms produced for the test program are already being put to work. Lockheed Martin cites a recent mission from Dover AFB, DE that flew non-stop and unrefueled from Dover to Incirlik, Turkey, while carrying 90,000 pounds of cargo on 36 standard military cargo pallets. The crew was able to complete the round trip in 2 days versus the normal 3, and saved 30,000 pounds of fuel by eliminating an en-route stop. Lockheed Martin release.

May 28/09: +6 AMP. A $7.3 million modification will install AMP kits and the consolidated load panel in 6 aircraft, under firm-fixed-price terms. Time-and-material charges will apply to rapid response and repair for potential aircraft issues that are discovered during kit installation. At this time, the entire amount has been committed (F33657-98-C-0006, P00223).

April 29/09: C-5A+ #50. Lockheed Martin announces the 50th C-5 AMP delivery, to Air Force Reserve Command’s 433rd Airlift Wing at Lackland AFB, TX, completing AMP modifications to the C-5B fleet.

The AMP installations are taking place at Dover AFB, DE and at Travis AFB, CA, and the fleet-wide AMP modifications are scheduled to be complete in the second quarter of 2014. Modification of the C-5A fleet continues at Travis AFB and at Dover AFB, DE. Current plans call for the entire 111-aircraft C-5 fleet to receive the AMP modifications. A majority of those aircraft will be C-5As, but they are not receiving the additional C-5M RERP modification, which is dependent on the AMP work being done first.

April 22/09: Loading practice. The US Air Force discusses cooperative efforts with the Marine Corps to figure out exactly how to load the newest UH-1Y Hueys and AH-1Z Viper attack helicopters into the C-5:

“…the Marines have been working with Air Force representatives for three months to find the best method of transporting their helicopters to the fight. According to John Buchanan, 60th APS cargo operations manager, they tried to use a C-17 Globemaster III first but found they had to strip too many parts off the helicopter. So the next logical step was to test the C-5 capability.”

The UH-1Y/AH-1Z’s 4-bladed rotor doesn’t fully fold, which makes even the C-5 has been a challenge. At one point in the loading process, clearance for the UH-1Y helicopter is down to 3 inches.

March 31/09: A $13.3 million modification to the indefinite-delivery/ indefinite-quantity RERP contract, to cover an undisclosed contract change. The entire amount has been committed (F33657-02-C-2000, #P00175).

March 30/09: GAO ASP. The US government’s GAO audit office issues GAO-09-326SP: “Defense Acquisitions: Assessments of Selected Weapon Programs.” The C-5 AMP and RERP sections describe the technologies as mature, but note that:

“The AMP was fielded with waivers to 14 specification requirements [that affect operational requirements]. The C-5 RERP will address 4… Other deficiencies and waivers may be addressed in a new modernization program slated for fiscal year 2010. The AMP is addressing some diminishing manufacturing source problems with the navigation system and backup integrated processor.

According to the Director of Operational Test and Evaluation, the AMP is partially mission capable, however, not operationally suitable. About 250 deficiencies, including software issues related to autopilot disconnects, were found during testing… A total of 37 deficiencies will be corrected in C-5 RERP and an additional 6 deficiencies will be fixed if the RERP Operational Flight Plan 3.4 software build is fielded. In addition, 73 more deficiency reports have been corrected or are being corrected as part of a sustainment contract software build that will be released in March 2009…

[RERP] Operational testing is expected to begin in August 2009. However, the Air Force does not plan to provide a low-rate initial production aircraft for operational testing… because one will not be available until September 2010… [There is a risk of] design changes, revised production processes, and rework…”

March 2/09: LAST SDD C-5M. Lockheed Martin delivers the 3rd fully modernized C-5M aircraft to the U.S. Air Force.

Feb 27/09: An $8.4 million contract modification for “the C-5 Reliability Enhancement and Re-engineering Program estimate at completion growth and cost overrun.” At this time $6.4 million has been obligated (F33657-02-C-2000, P00172).

Feb 9/09: SDD C-5M #2. Lockheed Martin delivers the 2nd of 3 fully modernized developmental test C-5M AMP-RERP aircraft to the U.S. Air Force. Following a brief ceremony at the company’s Marietta, GA facility, the C-5M flew to Dover AFB, DE.

To date, the company’s release says that it has also completed 40 out of 111 C-5A AMP aircraft.

Feb 6/09: RERP Lot 3. A $299.8 million fixed-price economic price adjustment contract, exercising options for Lot 3 of the C-5M RERP program. At this time $25.3 million has been committed. (FA8625-07-C-6471, #P00011). See also: Lockheed Martin release.

Feb 6/09: A maximum $86.2 million indefinite-delivery /indefinite-quantity contract for interim contractor support activities around the C-5 RERP program. This contract supports the Super Galaxy during familiarization and Operational Test and Evaluation (OT&E). At this time $25.3 million has been committed (FA8625-09-C-6485).

Dec 9/08: 1st SDD C-5M. Lockheed Martin delivers the first fully modernized C-5M to the U.S. Air Force at Warner Robins Air Logistics Center, Robins AFB, GA.

The aircraft is the first of 3 developmental test C-5Ms to be delivered, with the other 2 to be delivered to Dover AFB, Delaware, in February 2009. All three aircraft successfully completed developmental testing in August 2008. Current Air Force plans call for Lockheed Martin to deliver 52 modernized C-5Ms. Lockheed Martin.

1st C-5M

Nov 3/08: A firm fixed price contract modification for $6.1 million, exercising a USAF option for installation of 5 C-5 Avionics Modernization Program (AMP) Kits in its Aircraft. At this time all funds have been obligated (F33657-98-C-0006, Modification P00215).

FY 2008

RERP program cut from 112 to 49.

C-5 & CH-53E Heli
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Sept 24/08: Infrastructure. Kinsley Construction Company Inc in York, PA won a $26.8 million firm-fixed-price contract for a follow-on project, involving the 167th Airlift Wing’s Base conversion from C-130 to C-5 Aircraft. Work will be performed in Martinsburg, WVA, with an estimated completion date of April 2010. Proposals solicited were two-phase design build source selections, and 3 proposals were received by the National Guard Bureau in Buckhannon, WVA (W912L8-08-C-0016).

Sept 17/08: 1st C-5A into AMP. Lockheed Martin announces the induction of the first U.S. Air Force C-5A into the AMP program, adding that:

“There are 111 C-5s to be modified through AMP with 42 production airplanes completed to date. The AMP installations are taking place at Dover AFB and Travis AFB and are scheduled to be completed in second quarter 2014. The C-5 AMP fleet has flown more than 9,400 sorties and 40,000 operational flight hours.”

Some C-5Bs have already begun AMP work. The C-5A fleet was re-winged in the 1980s, extending its structural service life. Mission reliability rates, on the other hand, have remained low. AMP is expected to make only a partial dent in the C-5A’s readiness rates, but the new technologies will make a large difference to C-5A+ fleet’s ability to fly in civil airspace when they are operational.

Aug 18/08: C-5M testing done. Lockheed Martin announces that its team has successfully completed developmental testing of all 3 C-5M RERP test aircraft. Preparations now get underway to deliver the 3 test aircraft to the US Air Force in support of Operational Test and Evaluation scheduled to begin in the 3rd quarter of 2009.

< strong>Aug 18/08: SAR. The US military releases its latest round of Selected Acquisition Reports. The C-5 RERP is included, because its costs have reportedly decreased again. The C-5As will now be abandoned completely, and only the C-5B/C aircraft will be upgraded all the way to C-5Ms:

“The SAR was submitted to rebaseline from a Development to a Production estimate following approval of Low Rate Initial Production (Milestone C) and to reflect the Nunn-McCurdy certified restructured program. Since the last report, costs decreased -$3,436.8 million (-30.9 percent) from $11,130.9 to $7,694.1 million due primarily to a reduction in quantity of 59 aircraft from 108 to 49 (-$3.271.0 million) and associated schedule and estimating allocations (-$163.9 million)

• . In addition, there were reductions in support associated with the quantity decrease (-$401.0 million).”

The move would also have a significant effect on C-17 production, as it will change the number of new airlifters required by the US military.

SAR change

July 7/08: Lockheed Martin Aeronautical Systems in Marietta, GA received a maximum $17.4 million, unfinalized contract modification. It covers work under CCP 553 for Readiness Spares Package for the C-5M Reliability Enhancements and Re-engining Program (RERP). At this time $8.7 million has been committed (FA8625-07-C-6471, P00005).

June 19/08: Infrastructure. Kern Steel Fabrication, Inc of Bakersfield, CA received a firm fixed price contract for $13.6 million for the design and production of an Isochronal (ISO) Maintenance Stand for the C-5 aircraft. The award amount in item #3 above involves the design and one first production unit (albeit not exercised yet, Option I involves quantities of 1 to 3 maintenance stands). At this time $13.6 million has been obligated (FA8533-08-C-0004).

April 18/08: RERP Lot 1-2. A firm-fixed-price contract for $127.2 million. This contract modification is an Undefinitized Contract Action (UCA) for Lot 1 material/fabrication and initial spares, and Lot 2 advance procurement items, for the C-5M Reliability Enhancement and Re-engining Program (RERP). At this time the full amount has been obligated (FA8625-07-C-6471, P00003).

April 7/08: SAR – fewer RERP planes. The C-5 RERP program’s changes lead to a detailed cost change breakdown in the Pentagon’s Selected Acquisition Reports release:

“Program costs decreased $6,375.3 million (-36.4 percent) from $17,506.2 million to $11,130.9 million, due primarily to net reductions in the Air Force cost estimate for equipment (-$3,332.0 million), installation (-$1,602.2 million), engineering change order estimates (-$505.5 million), and Government Furnished Equipment (-$210.2 million). Additionally, program costs decreased due to the application of revised escalation indices (-$41.0 million), a decrease in advance procurement costs (-$192.1 million), and decreases in initial spares (-$414.2 million) and other support and training costs (-$417.6 million).”

Feb 15/08: Only 49 C-5Ms. In a confusingly-written release, the USAF states that:

“Air Force officials announced today that officials in the office of the under secretary of Defense for acquisition, technology and logistics have certified the C-5 Reliability Enhancement and Re-engining Program for 49 additional aircraft.”

Here’s what that actually means. The 62 C-5As that are still flying will all go through the AMP program, and will receive new avionics by 2014. These C-5A+ Galaxys will be flown by the US Air National Guard and Air Force Reserve. Only the 47 flying C-5B transports and 2 C-5Cs used by NASA will receive the full AMP/RERP upgrade, and become C-5Ms by 2014. According to Defense News, US Undersecretary of Defense for acquisition, technology and logistics John Young believes that program costs will drop to $7.7 billion, down from the September 2007 estimate of $17.5 billion. See also: Sen. Carper release [D-DE].

SAR change

February 2008: The US Air Force Association’s Washington Watch feature notes developments on the C-5/ C-17 fronts:

“Congress ordered an “objectivity/sufficiency” review of the RERP by the Institute for Defense Analyses, due March 1. A RAND review is also being done at the Air Force’s request…”

“Gen. Norton A. Schwartz, head of US Transportation Command, said he “cannot support” terminating C-17 production at this time, given the problems facing the C-5 upgrade program. He declared his belief that the minimum fleet now is 205 C-17s… at a briefing on Capitol Hill.”

At present, total American C-17 orders sit at just over 190 aircraft.

Nov 19/07: SAR – RERP critical cost breach.The Pentagon releases their latest Selected Acquisition Report, and offers their official view re: program costs.

“C-5 RERP (Reliability Enhancement and Reengining Program) – The SAR was submitted to report a unit cost increase of more than 25% to the current baseline estimate and more than 50% to the original baseline, which resulted in a “critical” Nunn-McCurdy breach. Program costs increased $6,168.3 million (+54.4%) from $11,337.9 million to $17,506.2 million, due primarily to a revised program estimate based on an analysis of prime contractor production proposal data, System Development and Demonstration (SDD) actuals, and commercial pricing data.”

A critical cost estimate breach forces re-justification of the entire program under the USA’s Nunn-McCurdy legislation, which covers weapons acquisition.

SAR change

Oct 17/07: Flight International reports that the USAF has asked Airbus for information about the A380F freighter version of its super-jumbo jet, and speculates that it may be connected with the C-5AMP/RERP’s rising costs. DID looks at the A380F, whose 150t (33,000 pound) capacity surpasses even the C-5. There may be a connection, but it may or may not be the connection Flight International thinks.

Are you pondering what we’re pondering? See: “USAF Talking to Airbus About A380 Air Force 1, C-5 Replacement?” for the full story and analysis.

FY 2007

RERP blows cost breach; Infrastructure build-out.

C-5 Galaxy
(click to view full)

Sept 27/07: US Air Force Secretary Michael Wynne declares Lockheed Martin’s C-5 Reliability Enhancement and Re-engining (RERP) program in violation of Nunn-McCurdy cost inflation triggers, which require the Pentagon to notify Congress when cost growth on a major acquisition program reaches 15%. If increases reach 25%, the Defense Department must re-justify the program. Lockheed and its supporters are contesting the Air Force’s cost estimates, arguing that the RERP’s costs will grow at rates below the Nunn-McCurdy threshold notification requirement. The notification comes amidst Congressional fights over spending to modernize Lockheed C-5s versus new Boeing C-17s. See the “Additional Readings” section below, and also Aviation Week:

“According to Congressional Research Service defense analyst Christopher Bolkcom, in “then-year” dollars, the Air Force believes the total RERP program will cost $16.1 billion, versus Lockheed’s projection of $11.7 billion and the most recent Selected Acquisition Report’s estimate of $11.3 billion. Another Capitol Hill source has said Air Force forecasts reach $17.8 billion.”

Sept 27/07: RERP Re-baselined. A contract modification for $133.3 million for C-5 Reliability Enhancement and Re-engineering Program (RERP) System Development Re-baseline Engineering Change Proposal. This contract is a modification to an existing contract. At this time, $16.3 million has been obligated (F33657-02-C-2000, P00139).

April 30/07: RERP Lot 1a. A $23 million fixed-price-incentive-firm contract for advance procurement of long lead/ advance buy items for Lot 1 of the Low Rate Initial Production for the C-5M Reliability Enhancements and Re-engining program (RERP). At this time, total funds have been obligated. Solicitations and negotiations were complete April 2007 (FA8625-07-C-6471).

March 26/07: Infrastructure. A DID reader writes:

“I enjoy your articles covering various military spending. I have been checking your aircraft transport listings and haven’t seen much about the C5A. My reason for asking here in Martinsburg, WVA the Air Guard (167th) is spending between 300 million and 400 million to completely rebuild the base that was used for C130H to C5A. The work they’re doing on the other side of the field is absolutely amazing, huge new hangars, new runways and taxiways, construction crews working day and night. I find the amount of money being spent to be simply unbelievable with all of the spare capacity at BRAC’ed air bases. I guess Sen Byrd is spending house ways and means money instead of DoD to get it through, but I was wondering what are you folks hearing? You really got to see it to believe it, and you hear next to nothing in the media. Can your organization tell me anything about the Air Forces plan for the C5A and whats up at the 167th — Big money being spent.”

April 9/07: SAR – more C-5 AMPs. The Pentagon releases its Selected Acquisition Reports for the December 2006 reporting period, and the C-5 AMP program is listed due to cost increases: C-5 AMP (Avionics Modernization Program) costs increased $551.2 million (+64.1%), from $859.3 million to $1,410.5 million. The primary reason is a quantity increase from 59 to 110 kits (+51 kits, +$291.4 million), and associated increases in initial spares, peculiar support equipment, and other weapon system costs (+229.1 million).

SAR change

March 22/07: AMP Lot 5k. A $23.4 million firm-fixed-price contract modification for C-5 AMP production Lot V kits and spares. At this time, total funds have been obligated and work will be complete May 2009 (F33657-98-C-0006/P00167).

Dec 22/06: a $16.7 million cost-plus-award fee contract modification. This is a modification to the C-5 Reliability Enhancement and Re-engining Program (RERP). This undefinitized contract action will correct 4 of the 14 Avionics Modernization Program (AMP) waivers, incorporate functionally from the AMP Block Cycle Change (BCC) Cycle Change 2006 software build, and address specific high priority issues. At this time, $8 million have been obligated, and work will be complete June 2007 (F33657-02-C-2000/P00119).

March 7/07: C-5 justification. In testimony before the House Armed Services Committee Air & Land Forces Subcommittee, Congressional Research Service defense specialist Christopher Bolkcom says [PDF]:

“Current estimates of the per-aircraft cost of AMP and RERP are expected to be approximately one-third that of a new C-17, and the C-5 will carry twice the C-17’s payload. The C-5 also has superior load/off load capabilities. The upgraded aircraft (called the C-5M), is also expected to have greatly improved mission capable rates. It may be noteworthy that during Operations Enduring Freedom and Iraqi Freedom, DoD leased Russian An-124 aircraft to carry outsize and oversize cargo because not enough C-5 aircraft were available. The An-124 Condor is a strategic lift aircraft larger than, but comparable to the C-5. As Figure 1 below illustrates, the Air Force has spent $170 million since FY2002 for An- 124 missions. It also appears that the number of An-124 missions is accelerating. FY07 figures already are on par with FY05 figures, and the fiscal year is not yet half over. While the C-5 may not be as modern as the C-17, or able to operate from as many runways, the fact that DOD has to outsource missions to Russian aircraft indicates that the C-5 still offers important capabilities that other U.S. aircraft may not be able to satisfy.”

DID will simply note the assumption that AN-124s were leased due to a shortage of C-5s, rather than a shortage of C-5s and C-17s. The testimony also includes program and operating cost data for both the C-5 and C-17 aircraft.

Dec 8/06: Process improvement. USAF Air Mobility Command officials announced Dover Air Force Base, DE as one of 3 central sites selected for future C-5 Galaxy isochronal inspections of the entire aircraft. Two additional C-5 ISO inspection sites, one at an Air National Guard base and another at an Air Force Reserve base, will be announced at a later date. During these ISO inspections, aircraft maintainers look for and repair problems in every system.

The US Air Force is reducing C-5 ISO inspection sites from 8 to 3 in order to centrally schedule the inspection from a fleet-wide perspective. Meanwhile, process improvements will aim to reduce “flow days” required to complete a C-5 ISO to a consistent number across the fleet, and reduce waiting time. If the system works, it would add an estimated average of 2.5 availability-days to every C-5 in the fleet, which equates to about 300 more sorties per year, or 10,000 pallets. USAF release.

Nov 30/06: Training. Flight Safety Services Corp. in Centennial, CO received an $18.1 million firm-fixed-price contract modification for C-5 Aircrew Training Systems Contract-Fund option 8. It covers students throughout and fixed operations, maintenance and support from Oct 1/06 through Sept 30/07. This work will be complete by September 2007. The Headquarters Ogden Air Logistics Center at Hill Air Force Base, UT issued the contract (F42630-99-C-0170/P00163).

Nov 17/06: C-5M #2 flies. The 2nd of 3 C-5M AMP/RERP aircraft that will comprise the new test set takes flight for the first time from Dobbins Air Reserve Base, GA. The first test aircraft first flew June 19/06 and has logged more than 51 flight hours to this point. C-5s that have completed only the AMP program, however, have logged more than 4,000 flight hours, many of which were flown in support of Operation Iraqi Freedom.

The first C-5M completed dynamic taxi testing at the Air Force Flight Test Center at Edwards Air Force Base, CA in August 2006. This latest aircraft will be used mostly for utilities and subsystem tests, airfield performance, and diagnostics testing. Both of these aircraft were originally C-5B models. A 3rd test aircraft to be brought up to C-5M standards, a C-5A, is currently in the final stages of modernization and is scheduled to fly later in 2006.
Nov 3/06: Air Force Operational Test and Evaluation Center commander Maj. Gen. Robin E. Scott signs the C-5 AMP Qualification Operational Test & Evaluation (QOT&E) report, which provided a progress update on the C-5M program for the low rate initial production decision. The test team recognized that the C-5 AMP “enhances existing strategic airlift,” but still has limitations. Source.

FY 2006

1st C-5M (RERP) done, flies.

C-5M test flight
(click to view full)

USAF story.

Aug 8/06: A $6.3 million cost-plus-award fee contract modification. This action provides for an expansion of supply support and development for C-5 RERP. At this time $411,000 has been obligated. This work will be completed by August 2008(F33657-02-C-2000/P00092).

July 26/06: C-5M OpEval. The C-5 RERP re-engining program’s Operational Assessment begins. Source.

July 11/06: The C-5 AMP AFOTEC QOT&E test team completes the last test event. Source.

June 28/06: Air Force Operational Test and Evaluation Center (AFOTEC) commander Maj. Gen. Robin E. Scott signs the C-5 RERP operational assessment test plan. Source.

June 19/06: 1st C-5M flight. The first flight of the C-5M, the new designation given to the C-5 aircraft upgraded under RERP, occurs. Source.

C-5M 1st flights.

May 26/06: Sub-contractors. Eagle Tool and Machine Co., Inc. in Springfield, OH received a $7.5 million fixed price with economic price adjustment contract for 104 (each) landing gear cylinder and piston assemblies applicable to the C-5 aircraft. At this time, total funds have been obligated. Solicitations began March 2006 and negotiations were complete May 2006 (FA8203-06-C-0165).

May 16/06: 1st re-engining. The first C-5 RERP modification to re-engine the planes is complete. Source.

April 21/06: AMP’s Eval resumed. Air Force Operational Test and Evaluation Center (AFOTEC) leadership resumes the C-5 AMP’s Qualification Operational Test & Evaluation (QOT&E). Source”.

March 28/06: Flight Safety Services Corp. in Centennial, CO received a $7 million firm-fixed-price contract modification for C-5 Aircrew Training Systems Contract-Fund Option, CLIN installation, integration and testing of the AMP Production Kits. At this time, total funds have been obligated. The scheduled completion date is March 2008. The Headquarters Ogden Air Logistics Center at Hill Air Force Base, UT issued the contract (F42630-99-C-0170/P00144).

March 21/06: Infrastructure. Burns & McDonnell in Kansas City, MO received a $20.8 million firm-fixed-price contract for construction of a C-5 corrosion control hangar. Work will be performed in Martinsburg, WVA and is expected to be complete by Oct. 31, 2007. Bids were solicited via the World Wide Web on Oct. 24, 2005, and 9 bids were received by the U.S. Property and Fiscal Office for West Virginia, Buckhannon, WVA (W912L8-06-C-0002).

Feb 2/06: Training. Flight Safety Services Corp. in Centennial, CO received a $5 million firm fixed price contract modification for C-5 Aircrew Training Systems Contract-Fund Option, CLINs for Dover Modernization Program (AMP) Kits. At this time, total funds have been obligated, and work will be complete by November 2006. The Headquarters Ogden Air Logistics Center at Hill Air Force Base, UT issued the contract (F42630-99-C-0170/P00142)

Jan 19/06: AMP Lot 4. A $33.3 million firm fixed price contract modification for C-5 AMP Production Lot IV Kits, Support, Spares and Maintenance Training Device Spares. This work will be complete in June 2008, and total funds have been obligated. Negotiations were complete in December 2005 (F33657-98-C-0006/P00161).

Nov 10/05: A $98 million firm-fixed-price, time-and-material and cost reimbursable contract. It will provide supply support, engineering and technical support, and software maintenance services to C-5 Galaxys modified under the Avionics Modernization Program (AMP), plus replenishment spares and non-warranty repair.

Solicitations began July 2005, and 1 proposal was received. Negotiations were complete November 2005, and work will be complete by November 2010. The Headquarters Warner Robins Air Logistics Center in Robins Air Force Base, GA issued the contract (FA8525-06-D-0001).

Oct 12/05: AMP Eval Paused. Air Force Operational Test and Evaluation Center (AFOTEC) leadership pauses the C-5 AMP’s QUOT&E evaluation. Source.

FY 2005

1st C-5 AMP delivered; C-5 AMP OpEval; C-5 RERP begins.

C-5, Truckin’
(click to view full)

Sept 13/05: Lockheed Martin reaches a critical milestone as technicians install the first engine pylon on a Reliability Enhancement and Re-engining Program (RERP) test aircraft. Installation of the new pylons, designed and built by Goodrich Aerospace, prepares the aircraft for the new General Electric CF6-80C2 engines which will be installed later in 2005.

The new General Electric CF6-80C2 engines are very widely used on passenger jets, and currently power the President’s Boeing 747, Air Force One. The engine delivers more than 50,000 pounds of thrust per engine, allowing the C-5Ms to carry more than 270,000 pounds and take off and land in distances as short as 5,000 feet. The new C-5 engines deliver 22% more thrust, achieve 30% shorter takeoff distances, enable 58% faster climb, and have a 99.98% departure reliability rate in commercial service, providing a ten-fold improvement in reliability and maintainability over the current TF39 engines. Lockheed Martin release.

Sept 7/05: AMP eval begins. AFOTEC testers began the C-5 AMP’s Qualification Operational Test & Evaluation (QOT&E). Source.

Jan 24/05: AMP Lot 3. A $59.3 million firm-fixed-price contract modification to provide for C-5 AMP Production Lot III Kits, Installation Option, Spares and Support. Total funds have been obligated. This work will be complete by December 2007. Negotiations were completed December 2004 (F33657-98-C-0006, P00126).

October 2004: 1st C-5 AMP delivered. The first upgraded C-5 AMP aircraft with modern avionics, wiring, etc. is delivered to the Air Force. Source.

1st C-5A+

October 2004: C-5 RERP begins. The first C-5 RERP modification to re-engine the planes begins. Source.

May 5/04: Air Force Operational Test and Evaluation Center commander Maj. Gen. Felix Dupre signs the C-5 AMP qualification operational test and evaluation plan. Source.

Dec 29/03: A $42.8 million firm-fixed-price contract modification, exercising an option for 18 C-5 AMP kits. Total funds have been obligated, and work will be complete by March 2005. Solicitation began August 2002, and negotiations were completed March 2003 (F33657-98-C-0006, P00110).

FY 2003 and Earlier

Avionics bought; AMP work begins.

C-5, Antarctica
(click to view full)

June 6/03: A $16.7 million contract modification for a C-5 AMP engineering change proposal – the addition of the Integrated Standby Instrument System. At this time, $6.3 million of the funds has been obligated, and work will be complete by August 2004 (F33657-98-C-0006, P00093).

April 3/03: A $20.3 million firm-fixed-price/cost-plus-award-fee contract modification to provide for support of the C-5 AMP. At this time, all funds have been obligated. Solicitation began in August 2002; negotiations were completed in March 2003, and work will be complete by July 2004 (F33657-98-C-0006, P00080).

June 12/02: AMP begins. The first aircraft to be modified under C-5 AMP is brought into Lockheed Martin’s Marietta, GA facility. Source.

AMP Begins

March 25/02: A $5.3 million cost-plus-award fee contract modification to provide for 1 Lot global air traffic management and airworthiness certification support, in support of the C-5 Avionics Modernization Program. At this time, $2.1 million of the funds has been obligated. This work will be complete December 2003 (F33657-98-C-0006, P00048).

Feb 11/02: A $10 million cost-plus-award-fee and firm-fixed price with economic price adjustment contract modification to provide for FY 2002 engineering manufacturing development effort for the C-5 Avionics Modernization program. At this time, the total amount of funds has been obligated. This work will be completed February 2002 (F33657-98-C-0006, P00053).

Dec 21/99: a $28.8 million modification to a cost-plus-award-fee contract, F33657-98-C-0006-P00011, to provide for FY2000 engineering and manufacturing development in support of the Avionics Modernization Program for the C-5 aircraft. Expected contract completion date is September 2001.

Jan 22/99: a $120.5 million cost-plus-award-fee contract to provide for engineering and manufacturing development through FY 2002 for Avionics Modernization Program kits to be applicable to 126 C-5 aircraft. These kits will include Global Air Traffic Management and All Weather Flight Control systems. There were 17 firms solicited and 2 proposals received. Solicitation issue date was May 15/98. Negotiations were completed Nov 16/98, and the expected contract completion date is October 2005 (F33657-98-C-0006).

Base AMP contract.

Additional Readings Background: C-5M

• Lockheed Martin – C-5 Modernization Program

• GlobalSecurity.org – C-5 Galaxy

• The Aviation Zone, ‘Home of the Heavies’ – C-5 Galaxy. We especially love the C-5 flyby sound file [.WAV].

• GE Aircraft Engines – Model CF680C2: High Reliability, Long Life, Low Fuel Burn

Background: C-5M Program

• Air Force Operational Test and Evaluation Center (Aug 1/07) – Another Galaxy, Another Test: Operational Test and Evaluation of the C-5M. AFOTEC’s historian offers a detailed chronicle of the entire C-5 Galaxy program, from the cost overruns and wing problems that plagued its early years to the present C-5 AMP/RERP program.

• USAF, Wright-Patterson AFB – C-5 Avionics Modernization Program. Solicitation.

• The University of Texas at Austin: Studies in Ethics, Safety, and Liability for Engineers – The C-5 Galaxy: A Question of Need?

• US Joint Aircraft Survivability Program Office – Innovation in the C-5 LFT&E Program. Unfortunately, the old link no longer works and the fragments reproduced on this page are all that’s left. If any readers can give us pointers to the full document, or send us a copy, it was interesting.

• Lockheed Martin Code One Magazine (March 7/12) – Tweak My Ride.

• Lexington Institute (Oct 4/10) – Upgrades To Giant C-5 Galaxy Airlifter Greatly Increase Performance & Reliability. Quantifies some of the C-5M’s advantages over the C-17 in terms of cargo and range.

• USAF (Sept 16/10) – New facility supports C-5 Galaxy software testing. “The building itself cost $658,000, but another $15 million investment was needed for the set up of the lab, including the cockpit wiring and engineering the lab capability, writing the simulation software and validating everything works as intended.”

News & Views

• Aviation Week’s Defense Technology International (Jun 13/07) – A400M could Dominate Strategic Lift. With no C-5 production, and no C-17 production, it would be the only Western choice remaining, competing with Russia’s AN-124s. Also covers the C-17 program, and C-5 AMP/RERP upgrades. There is some question as to whether the upgrades can produce the required readiness rates.

• USAF (Nov 23/07) – AMC commander discusses modernization, recapitalization issues. Among other topics discussed, Gen. Lichte favors re-engining only the C-5Bs, and acquiring more C-17s. Congressional priorities eventually gave him exactly that, in a very roundabout way.

• Defense News (Oct 29/07) – Airplanes on Life Support. Moseley, Wynne Plead: Let USAF Pull the Plug. They’re talking about aircraft that can’t fly but must be kept per Congressional directives, which includes a number of C-130E Hercules and KC-135E Stratotankers. It also talks about the C-5 programs, and thoughts of discarding the C-5As.

• Gannett’s Air Force Times (Oct 29/07) – MRAPs going to Iraq on Russian cargo planes. “The Air Force has been forced to use Russian commercial cargo jets to rush Mine Resistant Ambush Protected vehicles from the U.S. to Iraq because it does not have enough C-5 and C-17 planes to do the job, the service’s top civilian official said recently…” Ever consider sealift?

• Vacaville Reporter (Oct 29/07) – C-5, C-17 topic of planned study.

• DID (Oct 21/07) – USAF Talking to Airbus About A380 Air Force 1, C-5 Replacement? But how serious are they on either score?

• Gannett’s Air force Times (Oct 19/07) – Bill wants a study on airlift capabilities.

• Macon Telegraph (Oct 7/07) – C-5 future hangs on Air Force, Lockheed price differences. “The Galaxy fleet – sixty 1960s-vintage C-5As, forty-nine 1980s-era C-5Bs and two C-5Cs for use by NASA – has been plagued by nagging deficiencies. The C-5Bs were mission ready 66.6 percent of the time last year. The C-5As were much worse at 49.1 percent. The C-5’s counterpart, the much newer C-17 strategic airlifter, registered reliability of almost 85 percent.”

• Flight International (Oct 1/07) – USAF rounds on Congressional C-5 protection

• Defense News (Oct 1/07) – C-5 Upgrade Effort Imperiled by Cost Confusion.

• Stars & Stripes (Oct 1/07) – ‘Winglets’ could save Air Force millions on fuel. The C-5 fleet might be a candidate.

• Flight International (March 20/07) – Latest C-5 flies into budget storm.

• Government Executive (March 8/07) – Lawmakers divided over cargo plane options.

• House Armed Services Committee Air & Land Forces Subcommittee Hearing (March 7/07) – Statement Of Christopher Bolkcom, Specialist In National Defense, Congressional Research Service, On Air Force And Army Airlift And Aerial Re-Fueling Fixed-Wing Aircraft Programs [PDF].

• Air Force Link (Sept 25/06) – Dover AFB receives new maintenance trainer. A training simulator for maintenance? Yes, and it’s working well for the C-5M AMP program.

• Air Force Link (Feb 8/06) – C-5 Galaxy aircraft engine test successful.

• DID (Nov 14/05) – Delayed Pentagon Mobility Study Finally Offers a Preview.

• GE (Sept 16/04) – GE Engine Certified for U.S. Air Force C-5 Galaxy Program.

• Aviation Today (Feb 1/04) – GATM-izing Galaxy: New C-5 Avionics.

• USAF Agile Acquisition magazine (February 2004) – Teamwork, Innovation Eliminate Travis’ C-5 ‘Cannibalization’ Jet.

• Air Force Magazine (January 2004) – Saving the Galaxy.

• Aviation Today (Aug 1/2000) – C-5 Modernization, Step By Step.

• AFA Air Force Magazine (December 1998) – Nickel Grass: The airlift that saved Israel.

Americas

Raytheon is being contracted to develop a new propulsion system for the US Army’s TOW missile. The contract is valued at $21 million and covers three years of research and development necessary to make required performance improvements to the tube-launched, optically tracked TOW missile. “Improving TOW’s propulsion system will increase range and deliver enhanced protection for ground troops while providing them with more capability,” said Kim Ernzen, Raytheon Land Warfare Systems vice president. The wire-guided, operator-controlled BGM-71 TOW missile family external link remains a mainstay thanks to modernization, specialization, improved sighting systems, and pre-existing compatibility with a wide range of ground vehicles. The new propulsion system will be integrated into all TOW missile variants, including the top and direct attack 2B, direct attack 2A and Bunker Buster missiles. The TOW weapon system is scheduled to remain in the US Army’s inventory until the 2050s.

Lockheed Martin is being tapped to introduce a full rate production configuration to the new AN/TPQ-53 (Q-53) radar. The US Army is awarding Lockheed with a contract modification that sees for the insertion of Gallium Nitride into the Q-53. The Q-53 is a mobile, maneuverable, fully supportable and easily maintained counterfire target acquisition radar. Compared to currently deployed systems, the new, battle-tested Q-53 offers enhanced performance, including greater mobility, increased reliability and supportability, a lower life-cycle cost, reduced crew size, and the ability to track targets in a full-spectrum environment, a vital capability on today’s battlefield. According to the press release, the transition to GaN will provide the Q-53 with additional power for capabilities including long-range counterfire target acquisition. GaN has the added benefit of increasing system reliability and reducing lifecycle ownership costs. Work will be performed at Lockheed’s factories in New York, New Jersey and Florida.

Flight Global reports, that the new SB-1 Defiant is still on track to make its maiden flight before the end of 2018. The Defiant is a third-generation X2 aircraft jointly developed by Sikorsky and Boeing. It will be their main pitch in the US Government’s Future Vertical Lift program and is a direct rival to Bell’s V-280. The aircraft’s first flight will be conducted with a one-year delay due to problems during the composite blade manufacturing process. The companies have already installed a testbed for the Defiant’s powertrain systems at a West Palm Beach, Florida facility and plan to test the helicopter’s turbines, transmission and rotors in the coming weeks. This Powertrain System Test Bed (PSTB) lets them run the engines at their full combined 9,000 shaft horsepower and show how used components behave under increased stress. The Sikorsky-Boeing team plans to make ground runs with the Defiant in November. Both the Defiant and V-280 are aimed at satisfying the Army’s requirement under capability set-3, or “medium” variant that would be analogous to a legacy UH-60 Black Hawk.

Middle East & Africa

Chinese UAVs are becoming increasingly attractive to Middle-Eastern customers. Chinese arms dealers are especially attractive to those countries in the region which are restricted from purchasing US-manufactured UAVs because of their poor track record in protecting civilian lives during operations. Song Zhongping, a Chinese military analyst and former lecturer at the People’s Liberation Army Rocket Force University of Engineering recently told Military Times that “the Chinese product now doesn’t lack technology, it only lacks market share,” and “the United States restricting its arms exports is precisely what gives China a great opportunity.” Preferred Chinese products include CASC’s Cai-Hong 4 and 5 models which are quite similar to General Atomics’ Predator and Reaper drones, but much cheaper. According to Ulrike Franke, an expert on drones and policy fellow at the European Council on Foreign Relations, China has sold more than 30 Chai-Hong 4s to countries such as Saudi Arabia and Iraq in deals worth over $700 million.

Europe

Jane’s reports that French shipbuilder Naval Group is one step closer in finishing the last two of the French Navy’s six Aquitaine-class FREMM (frégate européenne multi-mission) anti-submarine warfare (ASW) frigates. The FREMM European multi-mission frigate is a joint programme between France and Italy. It will build 21 FREMM frigates for the French Navy and the Italian Navy. Both the Bretagne and Normandie have now be fitted with the latest Sylver A50 vertical launchers. One Sylver A50 module can carry 8 missiles with a length under 5m, like the self-defense Aster15 and the tactical Aster30 missile. The MBDA Aster15 air defense missile system provides protection against supersonic and subsonic threats. The Aster 30 is an advanced two-stage hypersonic missile system for area defense against aircraft and missile attacks. Both ships are currently at Naval Group’s Lorient shipyard. After the successful completion of a set of sea trials the ships are expected for delivery in 2019. The French DGA confirmed to Jane’s that the decision to install the A50 was made to mitigate the risk created by a gap in the French Navy’s anti-air warfare (AAW) capability between 2020 and 2022/23.

Asia-Pacific

Japan’s submarine program is marking another major milestone. Last week Japan’s Mitsubishi Heavy Industries (MHI) and Kawasaki Shipbuilding Corporation launched their first Soryu-class submarine. The JS Oryu, is a diesel-electric submarine that uses long-endurance lithium-ion batteries. The diesel-electric propulsion system gives the vessel a smaller acoustic signature, giving it an edge during sensitive and combat operations. MHI says the 84-meter submarines are the world’s largest conventionally powered boats. They are also Japan’s first submarines to be fitted with air-independent propulsion (AIP) systems that enable them to remain fully submerged for longer periods of time. Lithium-ion batteries allow submariners to shut off the primary diesel-electric power to switch to batteries for longer-endurance propulsion during sensitive operations. Battery operations can, in theory, significantly reduce the acoustic signature of a given submarine, making them harder to detect. The JS Oryu will be delivered to the Japan Maritime Self-Defense Force in 2020. Japan has commissioned 9 units in the class so far while a total of 13 are planned to be operated by 2023.

Today’s Video

Watch: Marines Connect F-35 Jet to HIMARS System For First Time

Americas

The US Air Force is designating its hypersonic research rocket. Formerly known as GOLauncher1, the vehicle now carries the official military designation of X-60A. The rocket is flown by the Air Force Research Laboratory (AFRL), Aerospace Systems Directorate, High Speed Systems Division and is being developed by Generation Orbit Launch Services. The X-60A is an air-dropped liquid rocket designed for hypersonic flight research, including testing of technologies like scramjet propulsion, high-temperature-resistant materials and autonomous control. The X-60A is a research vehicle designed to capture data complementary to AFRL’s ground testing capability. The captured data helps the laboratory to better understand how material and other technologies behave while flying at more than 5 times the speed of sound. According to the Air Force, the X-60A “enables faster development of both our current hypersonic weapon rapid prototypes and evolving future systems.” The single-stage liquid rocket is powered by Hadley rocket engine and is designed to provide affordable and regular access to high dynamic pressure flight conditions between Mach 5 and Mach 8.

The Canadian government is requesting the purchase of three King Air 350ER aircraft in their ISR configuration. The State Department is determined to approve this possible FMS with a value of $300 million. The King Air 350ER is a multi-mission, twin-engine turboprop aircraft, which can be deployed to conduct SAR, ISR, transport, and monitoring operations. The aircraft is a derivative of the King Air 350 and incorporates advanced technology and a unique and flexible mission package. It is highly reliable and can last for more than 12 hours with extended range. Canada’s unique customer post-modifications for Intelligence, Surveillance and Reconnaissance (ISR) operations include three WESCAM MX-15D EO/IR sensors, three AN/AAR-47B(V)2 MWS, three AN/ALE-47 CMDS, three VORTEX Dual RF Ku LOS Transceivers and a number of different transponder sets. The DSCA release states that “the proposed sale improves Canada’s capability to meet current and future threats; strengthen its homeland defense and the combined defense of North America; and support coalition partners overseas.” Principal contractor will be Beechcraft (Textron Aviation).

The Marine Corps is experimenting with an innovative slew of ways to make its HIMARS more capable. During a recently held test, one of the USMC’s F-35Bs was able to connect with a HIMARS shot for the first time. According to Lt,. Gen. Steven R. Rudder, the F-35 used sensors to create a data link, and then pushed data about the location of the target to a HIMARS system. HIMARS is a highly-mobile artillery rocket system with the purpose to engage and defeat artillery, air defense concentrations, trucks, light armor and personel carriers. The Marine Corps is currently working on improving and extending its ability to rapidly move the HIMARS by air and destroy a target once landed. A tactic that could prove to be an advantage in the Pacific theatre where Marines will likely be fighting as a distributed force across ships, islands and barges.

Jane’s reports that the Brazilian Air Force is contracting Portuguese aerospace maintenance and aircraft modernisation specialist OGMA to maintain 12 Lockheed Martin C-130 Hercules transport aircraft. OGMA, a subsidiary of Embraer, will provide the Air Force with depot maintenance, replacement and repair of equipment and parts. The deal is valued at $98.9 million and covers work on eight C-130H, two C-130H2 and two KC-130H aircraft. The Brazilian Air Force is the biggest air force in Latin America; it operates more than 600 aircraft and has more than 50.000 personnel. The Hercules is its main heavy transport aircraft.

Middle East & Africa

The Marine Corps is gaining its first experiences with using the F-35B in combat. One of its JSFs recently conducted its first combat mission over Afghanistan. The F-35 is part of the Marine Fighter Attack Squadron 211 currently embarked on the USS Essex, a Wasp-class amphibious assault ship. The USMC was the first service to integrate the F-35 into its fleet, when it declared the aircraft operational in 2015. Col. Chandler Nelms, commanding officer of the 13th MEU told Military Times that “the opportunity for us [now, is] to be the first Navy, Marine Corps team to employ the F-35B in support of maneuver forces on the ground, demonstrating one aspect of the capabilities this platform brings to the region, our allies, and our partners.” The B variant of the F-35 allows for short takeoff and vertical landing which is a key requirement for the Marine Corps. Earlier this year, Israel confirmed that it used its F-35A ‘Adir’ for strikes in Syria.

Europe

French shipbuilder Naval Group confirms that the French Navy will soon receive a new anti-air warfare (AAW) frigate. The AAW configuration includes the PAAMS (E) area air defense system with the Aster 30 long-range surface-to-air missile (SAM). The Frégates de défense aérienne will feature an ASW sensor fit but will not be able to fire naval cruise missiles. The Alsace is set for launch in the first half of 2019 and will, together with its sister ship Lorraine, replace two F70 AA frigates. The new FREDAs are the last of eight Aquitaine-class FREMM frigates for the French Navy. The first six ships are configured to conduct anti-submarine warfare and land-attack missions. The Aquitaine class is a class of multi-mission stealth frigates. The general characteristics of the class is a displacement of 6,000tons, a length of 142m, a beam of 20m, a maximum speed of 28knots and a range of 6,000n.m. with a cruising speed of 15knots. International customers include the Royal Moroccan Navy and Egyptian Navy.

Asia-Pacific

The Russian defense ministry is planning to launch a trainer competition. The ministry wants to procure up-to 230 turboprops for its flight schools. Government officials have yet not disclosed which platform they prefer, however General Alexander Akhlyustin told Mil.Press Today that the Yak-152 has good chances of winning the upcoming tender. The Yak-152 is new-generation primary trainer aircraft developed by Irkut. The aircraft is intended to provide primary pilot training, professional selection, and occupational guidance for future military fighter pilots. The aircraft performed its maiden flight on September 29, 2016. Irkut received a contract from the Russian Ministry of Defense (MoD) in June 2015 to supply approximately 150 Yak-152 aircraft by 2020.

Japan’s Ministry of Defense will develop its own “cooperative engagement capability” (CEC) system to strengthen its net-centric warfare capabilities. A CEC sensor netting system allows ships, aircraft, and even land radars to pool their radar and sensor information together, creating a very powerful and detailed picture that’s much finer, more wide-ranging, and more consistent than any one of them could generate on its own. With this system troops can share enemy information in real time and carry out joint counterattacks against enemy weapons. The ministry has earmarked about $60 million for the development of high-speed, high-capacity communications devices necessary for a CEC system in tis FY19 budget request. Japan’s Self-Defense Force plans to have a prototype system by 2022 and conduct its first operational tests in 2023. Japan is part of the US CEC system which is integrated on its two latest Maya-class destroyers. The decision to develop a Japanese system stems from concerns about the US system’s hefty price-tag.

Today’s Video

Watch: First Time in History US Air Force F 15C Eagle fighter jets arrive in Ukraine

MC-12 arrives
(click to view full)

Despite all of the high-tech fighter hours flown in theater, Hawker Beechcraft’s twin-propeller King Air 350 continues to gain traction as an affordable, long-endurance option for light cargo delivery in remote areas – and effective manned battlefield surveillance and attack. Iraq’s Air Force was the first to order them, and an initial 6-plane UC-12W order from the US Marines/Navy followed in July 2008.

Former US Secretary of Defense Robert Gates pushed hard to improve ISR (Intelligence, Surveillance & Reconnaissance) capabilities on the front lines, and one of those planned purchases involved about 30 King Air 350/ C-12 aircraft for the Army. These “MC-12s” have proven to be very useful as a component of the Army’s Task Force ODIN, which has combined the respective advantages of UAVs and manned aircraft to improve aerial surveillance and response over Iraq. ODIN is credited with a number of successes on the ground, and the concept is being exported to Afghanistan. Part of that process involves buying new, updated aircraft, and the US military continues to buy KA350 turboprops for use in different configurations.

Project Liberty, and the MC-12

C-12 near Washington
(click to view full)

The new King Air 350s are called “MC-12W Project Liberty special mission turboprop aircraft” by the US Air Force. The old C-12/UC-12 is also known as the Huron, and was derivative of the civilian Beechcraft King Air 200. It can land on airfields under 3,000 feet in length, and is normally used for VIP and light transport duties. These short-field capabilities, coupled with the small size of many urgent needs on the front lines, have pressed many C-12s into service in theater.

Secretary Gates gave the green light to buy 37 MC-12 aircraft by the end of 2009, as part of the Project Liberty program. Project Liberty is part of the Secretary of Defense Robert Gates’ ISR task force, which was set up to provide enhanced ISR capabilities to U.S. Central Command.

The new MC/UC-12 orders are King Air 350s, however, a slightly larger aircraft with 23.5% more engine power, improved speed and rate of climb, and slightly more load-carrying capacity. Another advantage they’ll have over their predecessors is built-in protective systems. In contrast, American UC-12s have often had their in-theater flights limited or at risk due to their their lack of protection against shoulder fired ground-to-air missiles like the SA-7.

350-ISR layout
(click to view full)

Taking off with full fuel and payload, an MC-12 can perform medium-altitude surveillance over a designated area for more than 7 hours, fly back 100 nautical miles to base, and still land with more than 45 minutes of fuel on board. That’s significantly less time than an MQ-1B Predator UAV’s 30 hours, but the plane can carry more gear, and has a much wider general field of view.

The MC-12 aircraft are equipped with signals intelligence (SIGINT) electronic interception capabilities, and carry L-3 Westar’s MX-15i surveillance turrets. The first 8 MC-12s were restricted to an infrared pointer, which allowed the aircraft to signal an object or building to soldiers wearing special goggles. It took until September 2013 to begin working with a full laser targeting designator that could mark targets for helicopter or UAV-fired Hellfire missiles, laser-guided AGM-65 Maverick missiles fired from manned fighters, and the laser-guided 70mm rockets that many vendors are currently developing.

Contracts and Key Events

The US military also lets service contracts for King Airs, but those contracts also include existing legacy B200/C-12 aircraft. They are not covered here. Unless otherwise noted, contracts are issued to Hawker Beechcraft Corp. in Wichita, KS.

FY 2014 – 2018

USAF divests the fleet to US Army; Crash.

MC-12W, Bagram
(click to view full)

October 9/18: Canadian order The Canadian government is requesting the purchase of three King Air 350ER aircraft in their ISR configuration. The State Department is determined to approve this possible FMS with a value of $300 million. The King Air 350ER is a multi-mission, twin-engine turboprop aircraft, which can be deployed to conduct SAR, ISR, transport, and monitoring operations. The aircraft is a derivative of the King Air 350 and incorporates advanced technology and a unique and flexible mission package. It is highly reliable and can last for more than 12 hours with extended range. Canada’s unique customer post-modifications for Intelligence, Surveillance and Reconnaissance (ISR) operations include three WESCAM MX-15D EO/IR sensors, three AN/AAR-47B(V)2 MWS, three AN/ALE-47 CMDS, three VORTEX Dual RF Ku LOS Transceivers and a number of different transponder sets. The DSCA release states that “the proposed sale improves Canada’s capability to meet current and future threats; strengthen its homeland defense and the combined defense of North America; and support coalition partners overseas.” Principal contractor will be Beechcraft (Textron Aviation).

February 23/18: FMS-Kuwait The possible foreign military sale (FMS) of four King Air 350ER Intelligence, Surveillance, and Reconnaissance (ISR) aircraft has been cleared by the Trump administration to the government of Kuwait. An announcement posted by the US State Department’s Defense Security Cooperation Agency (DSCA) estimate the sale at $259 million, with the package to include enhanced PT6A-67A engines, AN/AAQ-35 WESCAM MX-15HDi Electro-Optical & Infrared Imaging Sensor Turrets, Selex Seaspray 7500E Active Electronically Scanned Array Radars (AESA), AN/AAR-47 Missile Warning Systems (MWS), AN/ALE-47 Countermeasure Dispenser Systems, as well as other systems, training and support. Furthermore, one of the four aircraft will be further modified to accommodate VIP/senior leadership personnel for transport and Med Evac capability or command and control,and other related elements of logistical support. Sierra Nevada Corp will act as lead contractor on the sale.

February 25/16: Iraq is to receive a $350 million five-year sustainment package for its KA-350 fleet after the sale was approved by the US Congress. The six King Air aircraft were purchased from manufacturer Beechcraft in 2007 with five possessing intelligence, surveillance, and reconnaissance (ISR) capabilities. The latest package will include provision of operational and intermediate depot level maintenance, spare parts, component repair, publication updates, maintenance training, and logistics. The majority of the aircraft have been used in supporting Iraqi military operations against Al-Qaeda affiliates and Islamic State militants in the country.

Nov 12/14: Transferred. After an initial period that transferred some USAF MC-12W ISR aircraft to US Army control, the USAF announces that they’re divesting the entire fleet to a combination of the US Army, and Air Force Special Operations Command.

“…so it can invest in capabilities suited for highly contested operations. Even so, the MC-12 will be regarded as an extraordinarily successful program. During the 400,000 combat hours flown, the MC-12W Liberty aided in the kill or capture of more than 8,000 terrorists, discovered more than 650 weapons caches, helped divert convoys around improvised explosive devices, provided over watch for large numbers of coalition forces, and saved coalition lives.”

By 2015, only the Army will own the aircraft, and USAF crews will augment Army personnel. The Air Force will also provide the back-end processing, exploitation and dissemination of MC-12W information until FY 2016, at which point Army personnel will take on the whole mission. Sources: USAF, “ISR aircraft hones in on strategic agility”.

Transfer to US Army/ SOCOM

Jan 10/14: Crash. An MC-12 crash near Baghram Airfield in eastern Afghanistan kills 2 US soldiers and a civilian. Officials denied that enemy action was responsible. Sources: Defense News, “2 soldiers, civilian killed in Afghanistan MC-12 crash”.

Crash

FY 2012 – 2013

Company goes bankrupt, almost bought by China; 5 ordered; MC-12Ws add laser designators.

USMC UC-12W
(click to view full)

Sept 12/13: Target! MC-12W Liberty planes have traditionally needed to pass targets on to Joint Terminal Attack Controller troops, who would then direct fire from aircraft, artillery, etc. They can still do that, but a USAF release says that the MC-12Ws at Beale AFB, CA have added laser designators to their sensor systems, and are training with nearby A-10 and F-15E units.

It’s an obvious benefit to front line troops, who asked for “buddy lasing” capabilities in a recent Tactics Improvement Proposal. That seems to have pushed the USAF to move on something that had been an envisioned upgrade for years. Sources: USAF, “MC-12W airframe now boasts ‘Buddy Lase’ capability”.

Oct 18/12: No boat to China. Hawker Beechcraft, Inc. announces that it couldn’t reach an agreement with Superior Aviation Beijing Co., Ltd., and will go through normal Chapter 11 bankruptcy procedures instead. They do keep the $50 million deposit, and the plan remains the same: exit jets, keep the rest. They expect to emerge from bankruptcy in Q1 2013 as Beechcraft Corp. Reuters says that:

“At a conference in New York on Thursday, Hawker CEO Steve Miller said China-bashing by U.S. presidential candidates may have contributed to failure of the sale talks, which involved many complex issues. “Global politics may have interfered,” said Miller, who was in Beijing last week trying to sell the firm.”

Hawker Beechcraft’s legal representative is Kirkland & Ellis LLP; its financial advisor is Perella Weinberg Partners LP; and its restructuring advisor is Alvarez & Marsal. The Ad Hoc Committee of Senior Secured Lenders’ legal representative is Wachtell Lipton Rosen & Katz. Credit Suisse serves as agent for the lenders under Hawker Beechcraft’s secured pre-petition and DIP credit facilities. Credit Suisse’ legal representative is Sidley Austin LLP and its financial advisor is Houlihan Lokey. The Unsecured Creditors Committee’s legal representative is Akin Gump Strauss Hauer & Feld LLP and its financial advisor is FTI Consulting, Inc. Hawker Beechcraft | Reuters.

No Chinese sale, regular Bankruptcy instead

July 27/12: +4 used. L-3 Communications’ Mission Integration Division in Greenville, TX receives a $12.5 million firm-fixed-price contract for 4 used King Air Model 350 basic aircraft platforms for the US Army, including Rockwell Collins Pro Line 21 integrated avionics systems.

Work will be performed in Greenville, TX and is expected to be complete in August 2012. This contract was not competitively procured pursuant to the FAR 6.302-1 by the Naval Air Warfare Center in Lakehurst, NJ (N68335-12-C-0338).

4 used King Air 350ERs

July 20/12: +1. A $7.5 million firm-fixed-price contract for 1 Hawker Beechcraft King Air 350ER aircraft with program support. Work will be performed in Wichita, KS with an estimated completion date of Sept 30/14. The bid was solicited through the Internet, with 1 bid received by Army Contracting Command at Redstone Arsenal, AL (W58RGZ-12-C-0117).

1 King Air 350ER

July 17/12: Chinese negotiations. HBC announces that the U.S. Bankruptcy Court for the Southern District of New York has approved HBC’s motion to enter into exclusive negotiations with Superior Aviation Beijing Co., Ltd., giving them up to 45 days of exclusive negotiations.

As part of the exclusivity agreement, Superior will make an initial deposit of $25 million, with a second $25 million deposit payable within 30 days. Any definitive agreement reached with Superior would be subject to approval by the Committee on Foreign Investment in the United States (CFIUS) and other regulatory agencies. In addition, any definitive agreement with Superior will be subject to termination if another potential purchaser succeeds in the mandatory competitive auction overseen by the U.S. Bankruptcy Court.

July 9/12: Chinese ownership? Hawker Beechcraft, Inc. signs an exclusivity agreement that may lead to a buyout by China’s Superior Aviation Beijing Co. for $1.79 billion. The Chinese firm had approached Hawker Beechcraft “several years ago” with the same intentions, but there are 3 reasons for HBC’s new receptiveness:

1. Superior intends to maintain Hawker Beechcraft’s existing American operations, saving thousands of jobs.

2. Their proposal was the best the company saw in its ongoing review of strategic options, and includes both additional investment and continuing to operate as a standalone entity.

3. HBC believes that this combination would give Hawker Beechcraft greater access to the Chinese business and general aviation marketplace, which is forecast to grow more than 10% a year for the next 10-15 years.

This deal explicitly excludes Hawker Beechcraft Defense Company (HBDC), which would remain a separate entity. That would keep the T-6 and AT-6 out of China’s Hands, but the USA is mostly done with its JPATS trainer buys, so HBDC’s stand-alone survival would be questionable. Superior seems to think so, too, and if HBDC is sold, up to $400 million will be refundable to Superior. Meanwhile, the base King Air 350 would be owned by a Chinese company.

If negotiations with Superior fail, HBC will go back to the Joint Plan of Reorganization it filed with the U.S. Bankruptcy Court on June 30/12, and wind down the company’s jet-related businesses.

Chinese bid

July 9/12: Special Mission Sales. Hawker Beechcraft Corporation (HBC) reports that over the past 5 years, markets outside of the United States accounted for 68% of its special mission aircraft sales. Their definition is fairly broad, and includes air ambulances, trainer aircraft, and even weather modification planes, which are apparently popular in the Middle East. The split is about 33% USA, 34% for Europe, the Middle East and Africa combined, 26% Asia/Pacific and 7% Latin America. VP Special Missions, Jay Gibson, adds that:

“In particular, we expect to see an increase in demand for ISR globally and maritime surveillance aircraft in Africa and Latin America as countries there look to increasingly secure their borders – both on land and at sea.”

May 3/12: Bankruptcy. Hawker Beechcraft, Inc. and “a significant number of its senior secured lenders and senior bondholders” agree to the terms of a financial restructuring plan that will eliminate approximately $2.5 billion in debt and approximately $125 million of annual cash interest expense. The next day, the company’s entry into bankruptcy begins:

“Hawker Beechcraft, Inc. today announced that the U.S. Bankruptcy Court for the Southern District of New York has granted approval of the company’s “First Day Motions” as part of the company’s voluntary filing for reorganization under Chapter 11 of the U.S. Bankruptcy Code… [including] approval to continue to pay employees, and to pay all vendors and suppliers in the ordinary course for goods and services delivered after the commencement of the Chapter 11 case. The company will utilize a commitment for $400 million in Debtor-in-Possession (DIP) financing, negotiated as part of the prearranged restructuring, to meet these obligations.”

Bankruptcy begins

The company’s legal representative is Kirkland & Ellis LLP, its financial advisor is Perella Weinberg Partners LP, and its restructuring advisor is Alvarez & Marsal.

March 27/12: Financial. Hawker Beechcraft, Inc. CEO Steve Miller has a blunt assessment of his company core problem: “the company is operating with a debt load that is restricting its ability to succeed.” As an immediate step, the firm announces:

“…an agreement with certain lenders that will provide the company with approximately $120 million of additional liquidity through an incremental term loan facility under its existing credit facility. The company intends to use the proceeds of this loan to fund its ongoing operations as Hawker Beechcraft continues working with its lenders toward a comprehensive recapitalization. As part of the agreement, lenders currently holding approximately 70 percent of Hawker Beechcraft bank debt have agreed to defer the company’s obligation to make certain interest payments on the company’s senior secured revolving and term loans when due, and have granted the company relief from certain existing loan covenants. This forbearance agreement is scheduled to expire on June 29, 2012.”

See: Hawker Beechcraft | Wichita Eagle.

March 27/12: Support. Hawker Beechcraft Corp. in Wichita, KS receives an $8.5 million dollar firm fixed price contract for 6 months of contractor logistics services. Effort includes total maintenance, logistics for intelligence, surveillance and reconnaissance aircraft and associated ground support equipment. The location of the performance is Wichita, KS. Work is expected to be complete by Sept 30/12. ASC/WINK, Wright Patterson Air Force Base is the contracting activity (FA8620-11-C-3000 P00012).

FY 2011

Orders begin under a new contract (4); LIDAR?; Electric power boost option; L-3’s similar Spydr.

L-3’s Spydr
(click to view full)

July 13-18/11: L-3’s Spydr. L-3’s Mission Integration Division (MID) displays a Spydr King Air 350-ISR surveillance plane, similar to the popular MC-12W Liberty, but a technological step ahead. L-3 is the technology integrator for the MC-12W, but the firm tells Defense News that they’re working on versions built with key technologies from non-American suppliers, in order to avoid ITAR issues. SELEX Galileo’s PicoSAR radar, optics from Zeiss, and other choices yet to be announced are specifically designed to minimize export clearance requirements.

The Spydr Spiral 1 unveiled by L-3 at the UK’s RIAT featured a fuselage-mounted electro-optical/infrared turret, a fuselage pod with a 100-pound payload, a tactical data link, satellite communications, a full signals intelligence system, 4G cellular, and other options. Spiral 2 will add 2 feet to the plane’s nose, to house a 2nd sensor turret. Saudi Arabia and the United Arab Emirates are seen as potential customers in the near term, and L-3 expects to compete in other locations as well (incl. the USA) against offerings from Raytheon, Boeing, and Lockheed Martin. Like Lockheed’s Dragon family of systems, L-3 sees its equipment suite as transferable to a number of different aircraft types. L-3 MID | Defense News | defpro re: PicoSAR selection.

June 21/11: Power up. Hawker Beechcraft Corporation announces an upgraded electric power system for its late model Beechcraft King Air 350 turboprops, designed to add more power for special mission needs. It includes two 400 amp starter generators with paralleled output of 760 amps, an additional mission electrical bus with cockpit control, and automatic load shedding. Overall, it provides another 190 amps of 28 VDC power for late model King Air 350s (serial FL-500 and on) as an aftermarket kit, and is available as an option for on new production special mission King Air 350 aircraft.

The company expects FAA certification in Spring 2012, but has begun accepting orders.

June 16/11: +2 A $15.3 million firm-fixed-price contract for 2 King Air 350ER aircraft. Work will be performed in Wichita, KS, with an expected completion date of Dec. 29/11. Six bids were solicited with two bids received. The U.S. Army Contracting Command, Redstone Arsenal, AL manages the contract (W58RGZ-11-C-0133).

2 King Air 350ERs

March 9/11: 2 + LIDAR. A pair of FBO.gov pre-solicitations cover 2 KA-350ER aircraft, and their LIDAR sensors. Because of its characteristics, LIDAR is especially useful at seeing through foliage.

The first pre-solicitation is for 2 KA-350 ER aircraft, bought as a sole-source, firm-fixed-price contract (amount not mentioned) from HawkerBeechcraft under FAR Part 12, for delivery L-3 in Greenville, TX within 150 days from the date of Award. (FBO# N0016411RJQ95)

L-3 Communications Corp. in Greenville, TX received the sole-source, cost plus fixed fee contract (amount not announced) to integrate the Tactical Operations Light Detection and Ranging (TACOP LIDAR) quick reaction capability aircraft, “…to avoid the significant duplication of cost. Integration required to be completed 12 months from award of contract.” (FBO# N0016411RJQ96)

Dec 2/10: +2. Hawker Beechcraft Corp. in Wichita, KS receives a $15.2 million contract for 2 Hawker Beechcraft King Air 350ERs. At this time, all funds have been obligated. The 645th AESG/SYK at Wright-Patterson Air Force Base, OH (FA8620-11-C-4008).

When asked about this order, Hawker Beechcraft said these were US Army planes, to be delivered in a configuration “similar” to the MC-12W Liberty surveillance variant. Note that most of the gear that could make it a surveillance aircraft would be delivered under separate contracts.

2 King Air 350ERs

FY 2010

More orders under the base contract; MC-12W fielded in Afghanistan; MC-12Ws become communications relays; Sensor contracts; USMC UC-12W rolls out; Study showing UAVs and manned aircraft are complementary.

MC-12: 1st combat mission
(click to view full)

Aug 17/10: Comms. ViaSat Inc. announces that it has deployed airborne communications-on-the-move (COTM) terminals onboard “several dozen” MC-12W aircraft, using the ArcLight Ku-band mobile broadband system, configured in this application for data rates up to 1 Mbps off the aircraft. ViaSat.

July 23/10: Sensors. L-3 Communications announces that its WESCAM subsidiary announces a $200 million indefinite delivery/indefinite quantity (ID/IQ) contract from the USAF. It will buy MX-15Di high-definition surveillance and targeting turrets for MC-12W Project Liberty ISR planes, and MX-20D HD surveillance and targeting turrets for “an undisclosed customer.”

The contract is the 3rd in a series of US military contracts over the last 18 months, worth of to $400 million and covering 6 different surveillance turret types. WESCAM’s L-3 parent is also the prime contractor and systems integrator for Project Liberty. L-3 Communications.

June 1/10: A USA Today article offers some useful background regarding the MC-12W Liberty program. Hyperlinks added by DID:

“MC-12 crews have flown more than 2,000 missions in Iraq, Air Force records show. The first aircraft arrived in Afghanistan last December. The Air Force plans to spend $100 million to train airmen on using the aircraft’s spy technology over the next two years, Air Force budget records show… The Air Force initially bought seven used planes from private businessmen and retrofitted them. It now buys new planes… In April, the Air Force narrowed candidates vying to be the official MC-12 base to facilities in Oklahoma, Mississippi, Virginia, Georgia and Missouri. The final decision will be made next year, the Air Force said in a statement.

Col. Dan Johnson, who commands the 480th Intelligence, Surveillance and Reconnaissance Wing… interviewed, researched and wrote a paper for the Air Force exploring whether drones or manned planes were better at spying on insurgents. “It turned out that we need both,” he said in an e-mail.”

May 18/10: USMC UC-12. Hawker Beechcraft Corporation officially rolls the first UC-12W Operational Support Airlift King Air 350 for the United States Marine Corps. The plane is 1 of 6 ordered in July 2008, with additional options that would let the Marines replace their remaining 6 previous-generation UC-12/ King Air 200 light cargo aircraft. Hawker Beechcraft release [PDF].

UC-12W rollout

March 19/10: Sortie #2,000. The USAF announces that its MC-12W program has completed its 2,000th combat sortie. Capt. Ryan Woodman of the 362nd Expeditionary Reconnaissance Squadron, at Joint Base Balad in Iraq:

“A year ago the commander and I were learning how to start the new aircraft, and now the program just flew its 2,000th mission… Given what this program accomplishes for the troops on the ground, it is a great feeling.”

Many USAF programs spend over 10 years in development, and operational ramp-up is often a more measured process, so Capt. Woodman’s summary is more than just PR.

2,000 MC-12W sorties

Dec 27/09: Afghan arrival. Bagram Airfield welcomes its first USAF MC-12W aircraft to Afghanistan. US Military DVIDS | USAF.

Oct 19/09: +6 MC-12W. Hawker Beechcraft Corporation announces [PDF] that the USAF has exercised a $45 million option for 6 additional MC-12W special mission aircraft in support of Project Liberty, per the original November 2008 contract. The company adds that the first 23 planes have all been delivered, on or ahead of schedule. See also Flight International.

FY 2008 – 2009

Base contract for 23-29 MC-12Ws, and orders; $17 million price broken down; Britain’s “Shadow R1s”.

SecDef Gates speaks to
MC-12W production line
(click to view full)

Sept 15/09: Price breakdown. A comment at the US Air Force Association’s Air & Space Symposium helps clarify the price breakdown of an MC-12W. Lionel G. Smith, L-3’s director, Strategic Development Special Programs, is quoted as saying that:

“It costs about $7 million [per plane] from Hawker Beechcraft, and about $10 million in modifications. From [initial] contract to [deployment in] combat was about eight months.”

July 28/09: +3. Hawker Beechcraft Corporation in Wichita, KS receives a $21.6 million firm-fixed-price contract for the purchase of 1 King Air B350 aircraft, and 2 King Air B350Cs in the air ambulance/medical evacuation, with cargo door options. There are also 6 one-month options for storage of the aircraft.

Work is to be performed in Wichita, KS, with an estimated completion date of Feb 28/11. One was bid solicited with one bid received by U.S. Army Aviation and Missile Command, CCAM-RD-F at Redstone Arsenal, AL (W58RGZ-09-C-0087).

June 16/09: Export potential. Defense News reports that Iraqi and American buys may be the forerunner of a much larger trend:

“…in the coming decade [L-3 and HawkerBeechcraft] saw a potential domestic market for up to 75 of the [King Air 350 ISR] aircraft at a value of $1.3 billion. [L-3 VP Allison] Hartley said Africa, the Middle East and other regions were all potential markets. The international market could be worth double that in platform sales with a value of about $2.5 billion… She specifically named the United Kingdom as a potential sales opportunity. The British have already ordered a handful of King Airs for the ISR mission. One has been delivered.”

As of 2012, Britain operates 5 “Shadow R1” planes.

June 10/09: The first MC-12 Liberty combat mission is flown from Joint Base Balad, Iraq, by the 362nd Expeditionary Reconnaissance Squadron. The specialty reconnaissance aircraft flies a 4-hour mission, after arriving at Balad on June 8/09. Air Force Report: MC-12

| Pentagon DVIDS re: arrival | Pentagon DVIDS re: combat mission.

MC-12W in combat

April 8/09: The USAF announces their acceptance of the first MC-12 from Hawker Beechcraft. Deployment will take place in May 2009.

Dec 24/08: +2. Hawker Beechcraft Corporation in Wichita, KS received a $12.7 million firm-fixed-price contract for the purchase of 2 Super King Air Model 350 aircraft. Work will be performed in Ozark, AL, with an estimated completion date of July 31/09. One bid was solicited and one bid received by the U.S. Army Aviation and Missile Command in Redstone Arsenal, AL (W58RGZ-09-C-0087).

Nov 21/08: L3 Communications Integrated Systems in Greenville, TX received a firm fixed price commercial contract for $7.5 million. This action will provide for 1 Beechcraft King Air 350ER aircraft. L3 does not make the aircraft, but it does perform integration for the ISR version, which will use their MX-15 line or surveillance and targeting turrets.

At this time, the entire amount has been obligated in advance by 645 AESG/SYK at Wright-Patterson AFB, OH (FA8620-09-C-3021)

Civilian 350
(click to view full)

Nov 18/08: Hawker Beechcraft Corp. in Wichita, KS receives a firm-fixed commercial contract for 23 Beechcraft King Air 350ERs, with an option for 6 additional aircraft. The contract’s value is $171.5 million, and the entire amount has already been obligated.

The 645 AESG/SYK at Wright Patterson Air Force Base, OH manages this contract (FA8620-09-C-3020). Hawker Beechcraft’s subsequent release [PDF] confirms that these are “special mission” ISR variants.

23-29 MC-12W

July 10/08: USMC. Hawker Beechcraft Corp. in Wichita, KS receives an estimated $48.8 million firm-fixed-price contract from the US Navy for 6 “C-12 replacement aircraft.” The USMC’s UC-12 fleet, based on the King Air 200, is more than 25 years old.

The USMC’s new planes, based on the King Air 350ER, are eventually given the designation “UC-12W.”

Work will be performed in Wichita, KS and is expected to be completed in February 2011. This contract was competitively procured via electronic request for proposal by the Naval Air Systems Command, Patuxent River, MD manages the contract (N00019-08-C-0057).

6 USMC UC-12W

Additional Readings

• Beechcraft – King Air 350i.

• Beechcraft – Special Missions: Surveillance.

• L-3 Communications – MX-15. The MC-12W’s electro-optical surveillance and targeting turret.

Similar & Related

• DID – Task Force ODIN: In the Kingdom of the Blind….

• DID – MARSS: Quasi-Civilian Spy Plane Service Ordered by Pentagon, Canada. The Canadian order involves King Air 300s, modified for the ISR role.

• Aerial Surveillance Systems, Inc. – SkyEye 350. A private venture based on the King Air 350, similar in concept and equipment to the MC-12W.

News & Views

• US NAVAIR (March 28/13) – Light lift; heavy load: Small aircraft pull their weight.

• DoD Buzz, via WayBack (Oct 2/12) – Army seeks commonality in fixed wing fleet.

• USA Today, via Google Cache (June 1/10) – Newest manned spy plane scores points in war effort.

• Pentagon DVIDS, via WayBack (Sept 1/09) – Gates to MC-12 Workers: Your Work Is Saving Troops’ Lives.

• Defense News, Paris Airshow 2009 (June 16/09) – Beechcraft May Add Weapon-Carrying Capability to King Air [dead link]. They haven’t, yet, but by 2013 they had added laser designation.

• DID (July 16/08) – $48.8M Buys 6 King Air 350s for US Marines.

Americas

The US Air Force is ordering a large batch of Joint Air-to-Surface Standoff Missiles (JASSMs) from Lockheed Martin. The firm-fixed-price, fixed-price-incentive-fee contract is valued at $390.8 million and covers the delivery of 360 JASSMs, three FMS separation text vehicles and one FMS set consisting of a flight test vehicle, tooling and test equipment. The 2,000 lbs. AGM-158 JASSM is a stealthy, inexpensive cruise missile costing about $1 million per unit. The JASSM is currently integrated on a variety of platforms ranging from B-1B Lancer bombers to F-16 Block 50 fighter jets. Work will be performed at Lockheed’s facility in Orlando, Florida and is expected to be completed by October 31, 2021.

General Dynamics is being contracted to upgrade more Strykers for the US Army. The awarded contract modification is priced at $366.9 million and covers the conversion of several Stryker flat-bottom vehicles to the Double V-hull configuration. The V-hull configuration was the Army’s answer to vehicle’s poor performance during IED attacks. The new design channels blast force away from the vehicle and its occupants thus drastically enhancing soldier protection. The Army plans to acquire 742 Stryker DVH vehicles, as retrofits and as new production vehicles. That’s the full extent of the current plan, which was a major step beyond the program’s initial plan of 450 Stryker DVHs. Work will be performed at GD’s factory in Sterling Heights, Michigan, and is scheduled for completion by April 30, 2021.

Boeing is currently in talks with Brazil’s Embraer to set up a KC-390 assembly line in the United States. This round of talks follows a July agreement between the two companies that resulted in Boeing gaining a 80% stake in the Brazilian company’s commercial business. Boeing and Embraer established agreements in 2012 and 2014 that allow the US firm to have a hand in global marketing and logistics support of the KC-390, but a defense related joint venture would allow for a more intensive collaboration. The KC-390 is designed to be a jet-powered rival to compete with Lockheed Martin’s C-130J. The multi-mission aircraft is capable of in-air refueling operations, cargo transport and SOF deployment.

Middle East & Africa

The government of the United Arab Emirates is ordering more attack helicopters for its armed forces. Boeing will provide the Middle-Eastern country with a total of 17 Apache AH-64E aircraft. The $242.1 million contract modification covers the remanufacture of eight, and the production of nine newly build Apaches by Boeing. The AH-64E Guardian Block III is the platform’s next big-leap forward. The upgraded attack helicopter incorporates 26 key new-technology insertions which keep his 1980s airframe at the leading edge of technology. Work will be performed at Boeing’s factory in Mesa, Arizona. Production of the aircraft is estimated to be completed by February 28, 2023.

Iraq is requesting the purchase of five additional Bell 407GX helicopters to support ongoing counter-insurgency operations. The FMS contract has a value of $82.5 million and is currently pending approval by Congress. The possible deal covers the delivery of all helicopters armed with M240 7.62mm Machine Guns. In addition the order also includes options for five M3P .50 caliber machine guns, five M260 rocket launchers in APKWS configuration and five GAU-19 .50 caliber machine guns. The helicopters would be equipped with MX-15Di EO/IR sensors and RF-7850A secure communications radios. Self-Defense measures include the AN/ALE-47 airborne countermeasure dispensing system and AAR-60 MILDS detectors. Installed systems include the Pathfinder MMS, the ARES WMS and MCAS. The DSCA notes that “the addition of five Bell 407GX helicopters will help compensate for the combat loss of seven IA407 helicopters in recent years and increase the Iraqi Security Forces’ combat effectiveness against ISIS and other terrorist elements in Iraq.”

Europe

Jane’s reports that Swedish defense contractor Saab and Raytheon are currently co-developing a new round for the Carl-Gustaf reloadable weapon system. The new round would be the first guided one for the 84 mm recoilless weapon and is designated as Guided Carl-Gustaf Munition (GCGM). The Carl-Gustaf, which the Army calls the M3 Multi-Role Anti-Armor Anti-Personnel Weapon System (MAAWS), entered service in 1991 and has been a staple infantry support weapon in the wars in Iraq and Afghanistan. The MAAWS has similarities to the AT4 shoulder-fired, anti-tank system. But the MAAWS is unique in that the system itself is not disposable, which means it can be used more than once. Jane’s notes that “the GCGM development is effectively an evolutionary progression of the earlier Saab Ultra Light Munition concept, which, under the teaming agreement with Raytheon, has been matured and defined in terms of capability and performance requirements.”

Northrop Grumman confirms that the Italian Air Force successfully completed operational testing of the company’s Advanced Anti-Radiation Guided Missile (AARGM). The missiles are integrated on Italy’s Tornado fighter jets. A series of flight tests ended with two direct hits on critical air defense targets, this milestone allows for the transition of the AARGMs into operational squadrons. Italy and the US signed a MoU in 2005 to cooperatively develop the AGM-88E AARGM missile. The AARGM is a medium range, supersonic, air-launched tactical missile whose primary job is to attack and kill enemy radars. Italy currently plans to buy a total of 250 AARGMs.

Asia-Pacific

Japan’s ATD-X (X-2) program is taking a new turn. The Japanese Ministry of Defense is determined to develop a new fighter jet, that will eventually replace its fleet of F-2s. Proposals from three American and British companies failed to meet Japan’s costs and capability requirements, hence the decision to indigenously develop a new fighter jet. The companies made offers to upgrade their existing models, Lockheed for the F-22, Boeing for the F-15 and BAE for the Typhoon. Development of the new aircraft could cost trillions of yen and could be a major financial burden on Japan’s defense budget. To mitigate the overall cost the ministry has an eye on a joint development with foreign companies. The government is looking towards British or German-French partners as they are also looking into developing next-generation jets. Japan’s Air Self-Defense Force currently operates 92 F-2s which will begin to reach the end of their service life in the 2030s.

Today’s Video

Watch: S-97 hits 200 knots

Americas

The Navy is procuring support equipment for its MQ-8B Fire Scout UAV. Telephonics Corp will deliver a number of AN/ZPY-4 Radar supplies at a cost of $23.5 million. This includes the delivery of 14 complete AN/ZPY-4 Radar sets and associated equipment ranging from signal processors to Radar Command and Control Systems. The MQ-8B is an unmanned full-sized light naval utility helicopter. The AN/ZPY-4 Radar is an X-band radar that uses state-of-the-art ground clutter cancellation techniques to automatically detect and track moving targets. The enhanced radar is capable of supporting missions ranging from blue water to shoreline, and land operations. The radar is configured to uniquely enable the VTOL UAV to conduct broad area intelligence, surveillance, and reconnaissance (ISR) missions. Work will be performed at Telephonics’ Huntington, New York facility and expected to be completed in September 2019.

Northrop Grumman is being tapped to to support organizational level maintenance for the MQ-4C Triton UAS. The awarded firm-fixed-price delivery order is valued at $64.8 million and provides for the production of spares needed to keep the Triton’s Multi-Function Active Sensor (MFAS) operational. According to the company’s website the AN/ZPY-3 MFAS is a 360-degree field-of-regard AESA radar designed for maritime surveillance. The initial spares requirement includes six antenna group assemblies, six wideband receivers/exciters, ten radar signal processors (RSP), two antenna drive electronics and two RSP external power supplies for the MFAS. The MQ-4C Triton provides real-time intelligence, surveillance and reconnaissance (ISR) including vessel detection, tracking and classification over vast ocean and coastal regions. Work will be performed at multiple locations inside and outside the continental US, including – but not limited to – Linthicum, Maryland; Exeter, New Hampshire and San Diego, California. The delivery order is scheduled to run through June 2022.

The Navy is contracting Bell for the delivery of essential parts for its fleet of V-22 Osprey tilt rotor aircraft. The company is being awarded with two firm-fixed-price delivery orders each valued at $48.4 million. They cover the procurement of V-22 PRGB right- and left hand aircraft assembly parts. The V-22’s propulsion system’s external link consists of dual counter rotating proprotors attached to gearboxes driven by two turboshaft engines. PRBG, or proprotor gearboxes are an integral part of the Osprey’s gearbox system, which also includes one mid-wing gearbox (MWGB), two tilt-axis gearboxes and the emergency reservoir system (ELS).

The Air Force is stocking up on aircraft parts. Harris Corp will provide the service with parts for its B-52 bombers and SOF configured C-130 transport planes. The fixed-price, requirements contract is valued at $255.4 million. The B-52H Stratofortress is the mainstay of the US strategic fleet. It provides both penetrating and standoff capabilities that allow the USAF to hit targets almost anywhere in the world. The aircraft is an essential part to the country’s nuclear and conventional posture. The C-130J is a combat proven aircraft system that served as the tactical airlift backbone since 1956. SOF configured airframes include the AC-130J, EC-130J, HC-130J, and MC-130J. Work will be performed at Harris’ New Jersey facility and will run through May 24, 2026.

Middle East & Africa

South African Paramount Group and Italian defense contractor Leonardo are planning to jointly develop a weaponised version of the M-345 trainer jet for the African market. The two companies recently signed a letter of intent during the Africa Aerospace & Defence exhibition. The M-345 is a training jet aircraft with costs comparable to those of a turboprop aircraft, however it features superior performances compared to other airframes. The aircraft is powered by one Williams International FJ44-4M turbofan engine accelerating it to speeds of up to 460 mp/h. The trainer is equipped with five hardpoints supporting up to 2.205 lbs of external stores in the form of drop bombs, rocket pods, and gun pods. Leonardo and Paramount, will evaluate cooperation for the development of an operational configuration of M-345 jet trainer marketed in the African market and will include the possible involvement of Paramount in the SF-260 program and its Logistic Support services.

Europe

The State Department is determined to approve a possible Foreign Military Sale to the United Kingdom. The UK is looking to purchase 50 Mk15 Phalanx CIWS upgrade kits at a cost of $75 million. The radar-guided, rapid-firing MK 15 Phalanx Close-In Weapons System serves as a last-ditch defense against incoming missiles and other targets. The Block IB Baseline 2 Upgrade Kits incorporate digital off-the-shelf signal processing electronics, a new signal source and mixer, and a “surface mode” software upgrade that improves performance against targets on or near the water’s surface. The deal would also include support equipment, test equipment, initial spare parts, technical documentation, training, and engineering technical assistance, and other related elements of logistics and program support. Prime contractor will be Raytheon.

The French government is reaffirming that it will speed up the upcoming delivery of 12 aerial tankers to the French Air Force. The A330-200 MRTT is a derivative of the Airbus A330, and was designed from the outset to be able to function as an aerial tanker and a transport aircraft at the same time. The French Air Force wants the Phénix by 2023, two years earlier as initially envisaged. The new tankers will replace France’s fleet of ageing C-135FR and KC-135R aircraft, some of which are close to 60 years old. The acquisition is part of a number of equipment modernization measures included in the 2019-2025 military budget law.

Asia-Pacific

The Russian Navy adds a second Project 667 submarine to its fleet. Russian media reports that the country launched a new Lads-class diesel-electric submarine in a special ceremony at the Admiralty Shipyards in St. Petersburg on Thursday September 20th. The Kronstadt is a fourth-generation sub that succeeds Kilo-class vessels and offers a much quieter, powerful propulsion and new combat systems. The vessel can achieve speeds of up to 21 knots and is operated by a crew of 35. It carries club-S submarine launched cruise missiles and can fire a total 18 torpedoes, tube-launched anti-submarine and anti-ship missiles. The Lada-class submarines are intended for anti-submarine and anti-ship defense of naval bases, costal installations and sea lanes, as well as patrol and surveillance tasks.

Today’s Video

Watch: Russia deploys 3rd S-400 air defense missile system in Crimea

C-135FR refuels A330
(click to view full)

France currently relies on 14 C-135s for its aerial refueling needs, but these militarized relatives of the Boeing 707 are expensive to maintain, lack key technologies required for unrestricted flight, and are approaching 50 years old. Over those intervening decades, European governments have built up their own aviation industry, and the Airbus A330 MRTT has been ordered by a number of countries. In 2014, France is finally joining them, and beginning a EUR 3 billion program for 12 A330 “Phenix” aerial tanker-transports.

The French purchase will cap a series of interim moves to keep the existing fleet operational. French governments have searched for space in their multi-year military budgets to fund recapitalization, even as technical delays held up key projects…

What’s Now, and What’s Next

C-135FR
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France’s aerial refueling fleet consists of 11 C-135FRs modernized from KC-135A equivalent status, and 3 KC-135Rs. Both fleets fly with GE/Snecma CFM56-2 turbofan engines, in place of more primitive Pratt & Whitney J57 turbojets. In addition to standard aerial refueling roles, they remain vitally important to the reach France’s nuclear deterrent, which retains a significant dependence on Mirage 2000N and Rafale F3 fighters armed with ASMP-A missiles.

In 2009, France’s DGA announced that they would be modernizing the avionics in the Armee de l’Air’s 11 C-135FR aerial tankers to the C-135FR RENO2 standard, in order to keep them compliant with ICAO regulations for operation in civilian airspace. The goal was to deliver the first modernized aircraft in 2011, finish deliveries by 2013, and begin replacing the fleet in 2015 with A400Ms and A330 MRTTs. Budget problems (A330, see below) and late projects (A400M, late by 3.5 years) have scrambled that timeline, and so France added its 3 KC-135Rs to the upgrade program.

France also has a small passenger transport fleet, made up of 3 shorter-range A310s and 2 long-range A340s. They can fly long distances more efficiently than France’s C-160 Transall and C-130H Hercules fleets, using civilian airports and other infrastructure to carry larger numbers of troops and some cargo.

Unfortunately, the sum total of all current French fleets would only meet 25% of the airlift requirements set out in France’s 2008 defense white paper, and falls well short of aerial refueling requirements. France’s aerial refueling and large/ long-distance transport fleets will be replaced in a 2-part maneuver.

Airbus: A330 MRTT

At the high end, France is buying 12 A330 MRTT tanker-transports to replace 14 C-135 variants, and 5 Airbus passenger jets. They are significantly larger than the C-135s and A310s they replace, albeit slightly smaller than the 2 A340s. They will be delivered in a conventional core configuration, powered by Rolls-Royce Trent 700 engines and equipped with both Cobham’s underwing hose-and-drogue refueling units and the Airbus Refuelling Boom System (ARBS). France will be the 1st customer for an “MRTT Enhanced” option that upgrades the mission system, flight controls, IFF, and refueling boom, while providing better cruising performance.

The planes are expected to carry full defensive systems, and can be configured in a variety of layouts for carrying up to 271 passengers. MEDEVAC arrangements will include the French MORPHEE intensive care module, which can carry up to 10 patients and 88 passengers. Cargo payload can be up to 40t of containerized freight.

C-160 Transall
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At the lower end, France has modernized the avionics on its 14 C-130H medium tactical transports, and bought a fleet of 27 new CN-235 light tactical transports from Airbus to offset the decrepit state of their 52-plane C-160 fleet. The ultimate solution involves around 50 A400M Atlas medium-heavy tactical transports, which finally began delivery in “austere configuration” by 2013. The A400M is covered in-depth via its own DII FOCUS article.

If the appropriate Cobham plc wing pods are added, fully equipped A400Ms will be capable of refueling both jets and helicopters, though their 4-turboprop design will make them less efficient than the A330s in the jet refueling role. They’ll also become France’s core cargo airlifters, with short take-off capability and in-air refueling ability that will let them carry 35t+ loads intra-theater distances. They won’t be as efficient as the new A330s for long-range cargo work, but their ability to carry tactical loads like vehicles, helicopters, etc. will more than make up for it.

France’s future fleet is expected to be:

• 12 Airbus A330-MRTT Phenix aerial tanker-transports
  
• 50 Airbus A400M Atlas tactical transports with aerial refueling capabilities
  
• 27 Airbus CN235 light tactical transports

Contracts & Key Events 2018

A330 order coming at last; KC-135R upgrade contract; A330 training has already begun.

A330 refuels A400M
(click to view full)

September 25/18: Scheduled for 2023 The French government is reaffirming that it will speed up the upcoming delivery of 12 aerial tankers to the French Air Force. The A330-200 MRTT is a derivative of the Airbus A330, and was designed from the outset to be able to function as an aerial tanker and a transport aircraft at the same time. The French Air Force wants the Phénix by 2023, two years earlier as initially envisaged. The new tankers will replace France’s fleet of ageing C-135FR and KC-135R aircraft, some of which are close to 60 years old. The acquisition is part of a number of equipment modernization measures included in the 2019-2025 military budget law.

2014

Nov 21/14: A330. France’s DGA hammers out an agreement with Airbus to supply A330 MRTT tanker-transports, but they haven’t formally signed a contract yet. The EUR 3 billion program is expected to cover 12 A330 planes in France’s specific “Phenix” configuration, It also includes associated support and training systems, spares, ground support equipment, and an initial 5 years of in-service support from first delivery.

Purchases are expected to take place with an initial order for 1 plane before the end of 2014, a major order for 8 planes in 2015, and then 3 more that will be ordered at some future date. The 1st flight of the A330-MRTT Enhanced variant is expected in fall 2015, with flight testing beginning in earnest by July 2016. Initial delivery to the Armee de l’Air is expected to take place in 2018, followed by the 2nd A330 in 2019, and then the rest at a rate of 1-2 per year. In other words, France’s C-135s and existing Airbus transports will be completely replaced somewhere between 2024 – 2029.

France’s A330 MRTTs will use the standard basic configuration: Rolls-Royce Trent 700 engines, 2 underwing Cobham hose-and-drogue pods, and the high-flow, fly-by-wire Airbus Refuelling Boom System (ARBS). French “Phenix” aircraft will also benefit from A330 Enhanced improvements that include upgraded an mission system, flight controls set, IFF, and refueling boom, while providing better cruising performance. Communications and defensive systems, and internal outfitting, are also expected to receive some customization. Once the contract is signed, France will become the A330’s 6th military customer after Australia (5), Britain (13), Saudi Arabia (6), Singapore (4), and the UAE (3); with India (6) and Qatar (2) waiting in the wings. Sources: French DGA, “Le ministre de la Défense annonce la commande de 12 avions MRTT” | Airbus DS, “France announces order for Airbus A330 MRTT air-to-air refuelling aircraft” | Defense News, “France orders 12 “Phoenix” aerial refuellers from Airbus for €3 Billion” | Le Journal de L’Aviation, “Jean-Yves Le Drian officialise les A330 MRTT Phenix”.

12 A330-MRTT Phenix

Oct 28/14: A330. The French Ministry of Defense formally approves the launch of the program to buy 12 A330-MRTTs, during a session of its investment committee. Airbus had reportedly submitted a proposal back in February 2014. Sources: Le Journal de L’Aviation, “Jean-Yves Le Drian officialise les A330 MRTT Phenix”.

Aug 21/14: KC-135R. The 1st modernized KC-135RG is delivered to Istres AB in France, by an American crew who ferried the aircraft from San Antonio.

The upgrades include avionics that meet the RENO Global Air Traffic Management standard, creating navigation standards identical to those of modernized American KC-135s. They also preserved the on-board intercom that’s unique to the French planes, fitted a high-frequency wire antenna, and re-configured the aircraft to carry standard cargo pallets. Sources: French Armee de l’Air, “Le premier KC-135 renove se pose e Istres”.

June 10/13: KC-135R. Rockwell Collins Inc. in Cedar Rapids, IA receives a $44.5 million firm-fixed-price contract to install the KC-135 Global Air Traffic Management Block 40 Upgrade into 3 French KC-135R aerial tankers.

France flies 3 KC-135Rs alongside its 11 C-135FRs, and the Block 40 upgrade is a well proven solution. The USA finished its own KC-135R fleet retrofits in 2010.

Work will be performed at Cedar Rapids, IA and is expected to be complete by Nov 10/15. The USAF Life Cycle Management Center/WKKPA at Tinker AFB, Okla., is the contracting activity (FA8105-13-C-0001).

KC-135 RG upgrade

April 7/14: Training. An AirTanker release highlights the efforts of Armee de l’Air pilot Capitaine Francois Gilbert, who is on secondment to RAF No.10 Squadron at Brize Norton:

“The French Air Force is expected to place its first order for the MRTT later this year. With the first of 12 tankers built by Airbus Defence and Space to be delivered by 2018, they will replace France’s 14-strong [refueling and transport] fleet of C135 FR jets, three A310 and two A340.

“I’m here to build an understanding of the MRTT, its capability and training required to fly it so that when I go back, the knowledge and understanding that I have gained here, can be applied to the French AAR programme”, he says.”

It also provides a solid foundation if France should need to buy FSTA flight hours before 2018, though that’s looking less likely. Sources: AirTanker, “Entente [Most] Cordiale”.

2010 – 2013

C-135R upgrades; A330 delays; Lancaster House accord with UK offers a fill-in A330 option, but France doesn’t bite.

C-135FR & JAS-39C/Ds
(click to view full)

Feb 22/12: A330. Defense Aerospace reports on a 2012 news conference involving French DGA head Lauren Collet-Billon. He leaves the door open to participation in Britain’s FSTA, but makes it clear France will have its own tankers:

“Although it may buy tanker capacity from the Royal Air Force “if the flight hour price is affordable,” France intends to buy its own fleet of A330 tankers which are required to support the French air force’s sovereign nuclear strike mission. These will be ordered in 2013.”

Due to budget difficulties and other commitments, they are not. Sources: Defense Aerospace, “France Could Loan Rafales to Royal Navy”.

Nov 18/11: A330. AIN reports that Libyan lessons learned have made new Airbus A330 MRTT aerial tankers a bigger priority for France, alongside their aging C-135FRs.

An interim contract for 5-7 A330 MRTT planes is now expected in 2013, which means that Britain’s AirTanker LLC partnership is less likely to see any French leasing contracts (q.v. Nov 2/10). Sources: AIN, “French Air Force Chief: Tankers Soon, but Anglo-French UAV Much Later”.

Nov 2/10: UK & France. The “UK-France Summit 2010 Declaration on Defence and Security Co-operation” has this to say:

“15. Air to air refuelling and passenger air transport. We are currently investigating the potential to use spare capacity that may be available in the UK’s Future Strategic Tanker Aircraft (FSTA) programme to meet the needs of France for air to air refuelling and military air transport, provided it is financially acceptable to both nations.”

France currently flies 14 C-135FRs for aerial refueling, and will probably need to keep these Boeing 707 relatives in service for refueling in combat zones and nuclear strike missions. Their planned replacement buy of A330 MRTT refueling and transport planes has been pushed back due to budget concerns, however, creating a need for a stopgap than can lower the C-135FR fleet’s flight hours, and fill some of the gaps. The FSTA tankers will be downgraded versions of France’s own future buy, making it an attractive option that could even result in a reduced future purchase of A330s for the Armée de L’Air.

On the British side, more hours bought by military users beyond Britain makes key modifications like defensive systems easier to justify, and easier to handle operationally because the need for civilian conversions and removal/ modification is reduced.

Oct 12/10: C-135FRs. The French Air Force recaps the C-135FR modernization, and says that the first modified C135 is expected to be delivered in early 2011. Delivery of the equipment will continue until 2013. Sources: French Armee de l’Air, “Renovation des avions ravitailleurs de l’armee de l’air”.

Jan 14/09: C-135FRs. France will replace the avionics in its 11-plane C-135FR fleet, in order to comply with ICAO requirements and fly in civil air space. Modified planes will become C-135FR RENO2.

The EUR 37 million (almost $50 million) installation contract will be handled by Air France, who is also handling a similar set of upgrades to E-3F AWACS fleet. The planes have similar base airframes, with the tankers using the militarized C-135 as their base, and the E-3Fs using the civil 707-320B. DGA release [in French] | Flight International.

C-135FR RENO2 upgrade

July 7/10: A330 delayed. French defense minister Hervé Morin tells the parliamentary defense committee that France will postpone program contracts worth EUR 5.4 billion, in an effort to slash EUR 3.5 billion from the military budget over the next 3 years. France’s plan to replace its aged C-135FR aerial tankers with 14 A330-200 MRTT aircraft by 2015 is one of the delayed programs, even though it’s critical to many of the goals in the government’s 2009 defense white paper.

The parliamentary committee reportedly asked Morin if sharing the British FSTA service might help as a stopgap. If so, it would be a partial one at best. Not only is FSTA unable to operate in even low-threat areas, a commercial service cannot be used to refuel nuclear-armed strike aircraft. That was not an issue for Britain, whose nuclear weapons are limited to submarine-launched Trident missiles. Defense News. “France To Delay Air Programs: Mirage Jets, Tankers, C2 Hit by Cuts”.

Additional Readings

• Airbus Defence & Space – A330 MRTT: the 21st Century Benchmark.

• French DGA – L’avion multirole de ravitaillement en vol et de transport – MRTT.

• DII FOCUS – Airbus’ A400M Aerial Transport: Delays, Development, and Deployment.

• DID – With A400M Delayed, France Beefs up CN-235 Fleet.

Other A330-MRTT Customers

• DII FOCUS – Britain’s A330 Voyager FSTA: An Aerial Tanker Program – With a Difference.

• DID – Saudi Arabia’s A330 MRTT Tankers.

• DID – Singapore’s Aerial Tanker Buy.

• DID – UAEAF’s Long Reach: 3 Airbus A330 Tankers for the UAE.

• DID – India Selects Airbus A330 MRTT in Aerial Tanker Competition.

• DID – Qatar’s Air Force Multipliers: Aerial Tankers and AEW&C.