Modernisation and Security of Shipyards

Modernisation and Security of Shipyards

Government has plans to modernise and upgrade the shipyards where various types of warships and submarines are produced. A comprehensive assessment of the modernisation needs of the Defence Shipyards have been made based on the requirement of the ongoing and future Projects.

 The modernisation programme is intended not only to upgrade the existing infrastructure but also to expand their capacities in a significant manner and induct state of the art technology, so as to reduce build periods and increase productivity. 

Accordingly the DPSU Shipyards i.e. Mazagon Dock Shipbuilders Ltd (MDL), Garden Reach Shipbuilders & Engineers Ltd (GRSE), Goa Shipyard Ltd (GSL) and Hindustan Shipyard Ltd (HSL) have embarked on a comprehensive modernisation programme. Details are as under:-

MDL:

MDL has undertaken the ‘Mazdock Modernisation Program’ at a cost of Rs.966.88 Cr. The modernisation included creation of Module Workshop, 300 Ton Goliath Crane, New Wet Basin and Cradle Assembly Shop.

 MDL, with the completion of the modernisation program is aiming for a paradigm shift in Warship construction i.e. construction from unit assembly to block assembly enabling ‘Integrated Modular Construction’. This would substantially reduce the construction/building periods.

Post modernisation, the capacity of outfitting has increased from hitherto 3 warships 5 Warships and from 3 submarines to 6 submarines. The submarine building capacity is being further enhanced by constructing additional submarine related infrastructure.

GRSE:

The modernisation Plan which was focused on enabling modular construction has been completed at a financial outlay of Rs.606 Cr. GRSE is now capable of constructing concurrently multiple large modern ships. GRSE modernisation plan included creation of the following facilities:-

• Modern hull shop, upgradation of TRIBON ship design software, augmenting capacity of inclined berth, shipbuilding shop etc.

• Dry Dock of 10,000 Ton capacity, inclined berth of 4500 Ton capacity, Pier Quay and associated works & systems.

• Goliath Crane of 250 Ton capacity.

• Module Hall, Paint Cell & Equipment.

GSL:

GSL has undertaken a planned modernisation programme and is in the process of creating infrastructure for indigenous construction of MCMVs (Mine Counter Measure Vessels) for Indian Navy. Infrastructure modernisation plan is being implemented in four phases of which Phase 1&2 has been completed in March 2011. 

Work for balance phases are in progress. On completion of modernisation plan, GSL will have the capacity to build high technology glass-fibre reinforced plastic (GRP) hull Mine Counter Measure Vessels (MCMVs) indigenously with the help of foreign technology provider. In addition, this will also substantially enhance the rate of production and shipbuilding capacity of the yard.

Post modernisation:-

• GSL will overcome the constraints in terms of launch weight restriction by installation of 6000 Ton shiplift & transfer system with associated civil structures (i.e. improvement from the existing 1500 Ton to 6000 Ton capacity).

• There will be addition of construction berths for Offshore Patrol Vessels (from 1 to 3 for OPV size ships).

• Augmentation of Jetty Berthing Space (from 4 wet berths to 10 wet berths).

• Augmented material handling & crane capacity (addition of new workshop cranes from 5 Ton to 80 Ton capacity).

• New Level Luffing outdoor cranes upto 60 Ton Lifting capacity, two new block transporters of 100 Ton capacity.

• Increased repair capability with two berths for repairs of ships upto 6000 Ton and rationalisation of layout and material flow for efficient modular construction methodology.

HSL:

Currently the Repair and Refurbishment of Machinery & Infrastructure (RRMI) to modernise and upgrade the shipyard is under progress. The RRMI activities are being carried out progressively to meet the requirement for construction of future platforms.

The Government regularly reviews the security of the defence factories and shipyards. Periodic ‘Industrial Security Inspection’ of the DPSUs is carried by IB. Progress report on the observations of IB report are submitted every six months by the defence factories and shipyards to IB / MHA. The Department of Defence Production, has also uploaded a ‘Security Manual’ for the licensed Defence Industry on its website

This information was given by Minister of State for Defence Rao Inderjit Singh in a written reply to Shri Sunil Kumar Mondal in Lok Sabha today.

PTI

The future of India's silent warriors - 1

The futuristic submarines of the Indian navy

Scorpene Submarine; Source - DCNS

      Sailing silently and stealthily where the fishes sleep these are the ultimate weapons of war ever invented by the mankind. Sailing hundreds of feet below the water, these naval platforms are the weapons of apocalypse and which can wipe out continents at the press of a button. ‘The silent warriors’ are respected highly for they sail silently in a piece of tin can measuring several hundred feet in length avoiding any contact and not witnessing sunlight for days together. These warriors are a class apart from the community and are always at war, even when docked, the ship is just not off-duty, the men never off-guard. They’re the silent warriors of the deep seas, the ‘Submariners’ sailing silently in the deepest oceans known to the mankind.


           Indian navy operates a sizable fleet of these technologically advanced pieces of machinery. The underwater force of the Indian navy is composed around the diesel-electric attack submarines. The navy operates 13 diesel-electric attack submarines and 1 nuclear powered attack submarine. The Kilo-class submarines acquired from the Russians are the backbone for underwater operations. The Kilo-class submarines were commissioned to the force as Sindhughosh class, the navy acquired 10 of these advanced submarines from Russia in the late 1980’s and have served for the past three decades.

Shishumar class submarine; Source - Net

       Indian navy also operates the Shishumar-class submarines a refined version of the Type 209 submarines developed by HDW, Germany. Indian navy currently operates 4 of these submarines which are propelled by diesel-electric motors. INS Chakra, an Akula-class nuclear powered attack submarine is being operated by the Indian navy. Chakra is on a 10 year lease from Russia. INS Chakra serves as a training platform for the Indian navy personnel who will be operating the indigenously built boomer, INS Arihant.

       For a country with more than 2500 kilometers of coastal waters an underwater force consisting of 14 submarines is extremely small. India is a rising global power and India’s interest in its resource rich backyard ‘Indian Ocean’ is increasing with every passing day. India is contemplating of increasing its EEZ from the existing 250 kilometers to at least 330 kilometers to utilize the readily available resources in IOR. With India’s arch rival ‘China’ lurking in the IOR, it is crucial India deploys a sizable fleet of the underwater force in the region. With India being an initiator for the ‘No first use’ policy it is crucial India maintains a ‘nuclear triad’ or ‘second strike capability’ platform for retaliatory strikes when provoked.

      Submarines will serve as the key conspirators in imposing a naval blockade on an enemy. China imports 80% of its oil and commodities through shipping lanes, these international shipping lanes pass through the strategic Malacca Straits in the Indian Ocean. The Andaman and Nicobar are strategically placed right at the mouth of ‘Malacca Straits’ and thus a naval blockade imposed at this position can cut off all the major supplies to China crippling its ‘war sustainability’ capabilities to a great extend. The blockade can be imposed only by maintaining a sizable fleet of both surface combatants and submarines, even though India operates highly advanced surface combatants the submarine force has been a matter of worry for the navy.

Kilo-Class Submarine; Source - Broadsword

       Indian government has floated tenders to procure the latest submersible platforms to complement the surface. Constituted under the P-75 project, Indian navy currently has six diesel-electric submarines under construction at Mazagon docks, Mumbai. The recently constituted P-75 I project also promises the navy with six more advanced diesel-electric submarines. Not much is known about the Advanced Technology Vessels (ATV) project, but over the years sources have confirmed about India acquiring 3 SSBN’s. India has also set apart funds for 6 nuclear powered attack submarines (SSN) or hunter killer submarines. In the decades to come India is expected operate at least 30-35 submarines.

The P-75 Project/ Kalvari Class – DCNS Scorpene 

INS Kalvari, the lead vessel; Source - MDL

          Constituted in 2005 the P-75 project was to provide India with the latest diesel-electric submarine.  A tender for acquiring six state-of-the-art conventionally powered submarines at a cost of US $3 billion was floated by India. DCNS of France, Amur Shipyard of Russia and HDW from Germany competed in the project. After a thorough evaluation program, DCNS was awarded the contract to supply India with six diesel-electric powered submarines. DCNS offered India with the ‘Scorpene’ submarines. Initially two of the six submarines were to be built in a French shipyard, and the rest four in an Indian shipyard under an agreed ToT agreement. But the project agreement was reversed and it was decided to manufacture all the six submarines in the Indian shipyard.

        DCNS teamed up with Mazagon Docks Limited (MDL) based at Mumbai, the project kicked off with MDL boost to its the infrastructural capabilities. This paved way for the painstaking work of designing the Kalvari class submarine, by a joint team of highly qualified team of marine engineers from DCNS, MDL and NDB. Based on the Scorpene submarines the Kalvari class proved to be the most advanced submarine to be designed and to be manufactured by any Indian shipyard.

     

        The Scorpene submarines were selected over the U214 submarines mainly for its capability to fire the Exocet anti-shipping missiles and with DCNS readiness to equip the submarines with Indian-made AIP systems. The first submarine of the class was laid down in May 2009. Due to holdups in the design and fabrication phase, the project is five years behind the schedule. The first breakthrough in the project came when the first submarine of the class, INS Kalvari was launched on 6^th April 2015 by MoD Manohar Parrikar. The submarine will now enter harbour trials and after completion of controlled dives will enter the final sea trials by the year end. The submarine is expected to be inducted to the force by September 2016.

      The Scorpene submarines are a class apart, diesel powered hunter killer submarines developed by DCNS of France. Displacing 1900 tonnes of water when submerged these submarines can sail almost at zero noise underwater thus avoiding any detection by enemy submarines. This enables the submarine to tail enemy high value targets like the ‘aircraft carriers’ or ‘SSBN’s’ and gain acoustical and thermal images which will prove vital in war times. Powered by two diesel engines the submarine can attain a maximum speed of 37 km/h when submerged and can cut through the waters at 22 km/h when surfaced. The diesel engines are complemented by two Jeumont-Schneider EPM Magtronic batteries which collectively churn out 2800 kW of power, allowing the submarine to operate ultra quite when tailing targets.

Scorpene undergoing Harbor trials; Source - Net

        The hull of the Scorpene submarines is fabricated with HLES-80 high grade steel, which can withstand extremely high pressure and allows the submarine to dive to depths up to 1200 feet. The hull of the submarine can be classified into three sections namely, the bow section containing the torpedo tubes, electric batteries, storage compartments and ballast tanks. The midship of the submarine houses the control rooms, crew quarters and living area. The stern section consists of the main propulsion units, electric batteries, AIP units, control machinery and another set of ballast tanks.

        The Scorpene submarine is equipped with some of the most advanced electronic and sensor suites. These features clubbed with the latest machinery on board makes the submarine extremely nimble and efficient. The SUBTICS or Submarine tactical integrated combat system is a fully integrated tactical suite designed for the coherent functioning of various sub-systems fitted on the submarine. SUBTICS, is packed with state-of-the-art acoustic sensor suites which are crucial in increasing the battle theatre awareness.

      The submarine is also equipped with the latest optronic sensors and navigational sensors enabling the sub to sail through the waters effortlessly. The submarine is also equipped with environmental awareness and tactical navigation planning kits which help in meticulous planning of sea lanes for the submarine to traverse. Secured VLF/SHF communication channels and tactical data link, enables the submarine to relay secured information over the network to other naval platforms.

      Scorpene submarines are equipped with Thales DR 3000 electronic warfare system. The submarine is also equipped with Sagem Series 20 Attack Periscope System (APS) and Series 30 Search Mast System (SMS). The primary radar system for the Scorpene’s is the extremely accurate and efficient Sagem Series-10 compact submarine radar system. The SONAR system of the sub is composed by the, Thales S-cube integrated sonar suite and passive ranging distributed array sonar. 

       Primarily being a hunter killer submarine, it is equipped with six 533mm mts torpedoes which can strike naval targets with pin-point accuracy. The submarine can carry up to 18 black shark heavy weight torpedoes. The sub’s unique ability is to launch cruise missiles capable of striking land targets for which the sub employs the SM39 Exocet anti-shipping missiles. The submarine is redesigned to be fitted with the BrahMos cruise missiles and the indigenously developed Nirbhay cruise missile. The submarine can carry up to 30 mines for mine laying missions.

Article By Karthik Kakoor 

Scorpene is in the Sea

Scorpene is in the Sea 

A Scorpene Class SSK

Indian Model of Scorpene Submarine

      To augment its depleting conventional submarine fleet the Indian navy came up with the ambitious “ Project 75 “ which would arm the navy with six state of the art conventional attack submarines and was valued at around $4.6 billion. The government approval for construction of the six submarines was sanctioned in September 2005. The contract was signed in October 2005. DCNS was awarded the contract under which the Scorpene design was approved. French DCN and the Spanish company Navantia were to help Indian state-owned Mazagon Docks based in Mumbai manufacture these state-of the art submarines under a technology transfer agreement. The first Scorpene submarine was to be delivered to Indian Navy by 2012.

       The Scorpene submarines are a class of diesel-electric attack submarines which was jointly developed by the French DCNS and Navantia. Scorpene submarines are a 1900 tonnage submarines measuring 219 feet in length from aft to bow. The submarines can achieve a maximum speed of 20 knots. The maximum diving depth of the submarine is believed to be 300m which is one of the highest diving depths available for a conventional submarine. The Submarine will be manned by a crew   of 31 sailors and can survive in the sea without returning to its port for about for about 50 days. 

  The Scorpene has two diesel generation sets providing 1,250kW of power. The submarine is also supported by an electronic engine which produces around 2,900kW of power. To lessen the submarine's vulnerability, Scorpene can be equipped with an air independent propulsion system. Scorpene’s are to be equipped with a state of the art Air Independent propulsion system. The heat is generated by ethanol and oxygen. Combustion of ethanol and stored oxygen occur at a pressure of 60 atmospheres. This pressure-firing allows exhaust carbon dioxide to be expelled overboard at any depth without an exhaust compressor. 

    The last two of the six Scorpene submarines will be featuring an AIP system developed by DRDO. The Scorpene attack submarine can carry 18 torpedoes and missiles or 30 mines. It is equipped with six bow-located 21in torpedo tubes providing salvo launch capability. The submarine's weapons include anti-ship and anti-submarine torpedoes and anti-surface missiles. Problems with procuring the modern 533mm Black Shark torpedo's from Italy's Finmeccanica have been floating for a long time thanks to the alleged role of Finmeccanica in the Helicopter scam but the issue is to be soon sorted out. 

    The Newest Scorpenes comes with network centric attack capabilities that are connected to other Submarine Platforms. The Scorpenes are fitted with SATCOM and COMINT that can directly ping to the Navy's dedicated Satellite link through’ Rukmini ‘. This allows the Submarine to track and intercept most targets and also allows high probability of Interceptions. The Communication intelligence module allows tracking, record and monitoring of enemy activities and to share it to among other platforms on a real time basis. Scorpene submarines are believed to be one of the world's most advanced diesel electric attack submarine.

        The first Scorpene submarine built under the project was slated to be launched and inducted to the force by 2012 but has suffered a four year delay. Disclosing the long persisting problems and delays with the project the then MoD A K Antony had said “The delay in construction of Scorpene submarines is attributable to initial teething problems in absorption of new technology, delay in augmentation of industrial infrastructure at MDL and delay in procurement of items by MDL due to their high cost as compared to the earlier indicated cost.” And added “A technical data package had been provided by the collaborator (DCNS) as part of the technology transfer for the six submarines under construction at MDL. 

    This would enable attainment of significant indigenous competence in submarine construction, especially in the field of hull fabrication, outfitting, and system integration by the end of the programme". The much delayed P 75 project has received some boost with the first submarine built under the project believed to be headed out to trials. The first submarine under the project has been cherished INS Kalavari and is believed to be hitting water for the first time very soon. 

    Officials at Magazon dock and Indian Navy have confirmed the much awaited news regarding the INS Kalvari, the first Scorpene class submarine and have claimed that the submarine is slated for HATS (Harbour Acceptance Trails) very soon. The submarine is to be inducted to the force by September 2016 according to the revised schedule set in place for the project. MDL is believed to have completed the Hull fabrication of four Scorpene submarines but is taking time in fitting the subsystems. The remaining five submarines are to be handed over to the Indian navy with a time gap of nine month each. But the credibility of the project can only be ascertained after the first submarine under the project successfully completes its Sea and Harbour Acceptance Trails, integration test under which the fire systems of the vessel is tested.

  

         The Scorpene’s will be replacing the existing fleet of Type 209 and Kilo class submarines which are nearing their service life. Indian Navy has a Requirement of 6 SSN and 3 SSBN for strategic attack capability and High level deterrence against Chinese Navy. The black projects headed by the PMO have designed, developed and nearing induction with the Arihant class Nuclear-powered submarines. Chilean and Malaysian navy operates each two of them, and the Brazilian navy is to receive the Scorpene submarines.  The project once completed will boost the depleting numbers in the Indian navy and empower the navy with state of the art under water force that can challenge the advent of the hostile forces lurking right under their noses.

Malaysian Scorpene and Sea King ASW Helicopter

Rear side view of Indian Scorpene Model

The Heavyweight Black Shark 533mm Torpedo

Article By Karthik Kakoor