Skills and expertise: Focus Support: Teams working on world-class supply together to keep build chain Pages 4-5 on track Page 6
News from the Aircraft Carrier Alliance Issue 7 May 2012
Superblock revealed
CONSTRUCTION PROGRESS programme on plan and, thanks Completion of dock cycle A is to the skilled and hard work from everyone involved, we remain The fi rst major stage in the assembly major step in build programme right on track.” of HMS Queen Elizabeth is complete. Superblock 03 is made up Sections of the ship, which deliver the nation’s fl agships has Royal Navy. It’s still some way off of Lower Block 03, the fl ight are being crafted at yards across taken a huge step forward. from being a complete aircraft deck sections and the fl ight deck the country, have been arriving Programme Director Geoff Searle carrier, but already weighs almost as extensions, called sponsons. It at Rosyth Dockyard on the explained: “Superblock 03 is the much as one and a half Type 45 brings together parts constructed Firth of Forth, where assembly mid-section of HMS Queen Destroyers! on the Clyde, the Tyne, at Appledore is taking place. Elizabeth. Getting to this stage, “It’s a critical achievement and in Devon and in Rosyth. Since last summer, several major where the fi rst major section is means we can now prepare to enter To create the structure, the sections of HMS Queen Elizabeth, now fully assembled, marks a big the next stage of integrating the Babcock heavy lift team used the weighing thousands of tonnes, moment for the programme. blocks that make up the forward have been assembled. “To put it in perspective, if it section of the ship. Continued on page 02 Now the fi rst ‘superblock’ is were a complete vessel, superblock “Completing the fi rst super- complete, and the programme to 03 would be one of the largest in the block is necessary to keep the
CONSISTING OF
CVF Carrier Waves book 1 11/05/2012 16:04 02 News from the Aircraft Carrier Alliance NEWS
Contents [MAY 2012] F-35B for Queen Pages 04 and 05 The supply chain is the key link to a successful construction programme Elizabeth Class Pages 06 Update on support ANNOUNCEMENT work taking place F-35B testing across the project at sea The Government has announced Page 07 the selection of the F-35B Joint Shore Integration Strike Fighter as the fast jet that will Facility in Bristol testing operate from the Queen Elizabeth crucial systems Class aircraft carriers. The F-35B is a Short Take Off and Vertical Landing (STOVL) capable aircraft. This means the Queen Elizabeth Class aircraft Contact carriers will be built to support [FOR MORE INFORMATION] them. Programme Director, Geoff Searle, explained: “The STOVL To request further copies capabilities of this aircraft call for or to submit a story for some specific designs. HMS Queen the next edition, please Elizabeth and HMS Prince of Wales contact John Fyall, will be built with a ramp at the bow the aircraft safely back down. action. We will now work ACA Communications and we’ll be developing the flight “We have plans to develop with the Ministry of Defence to Manager at john.fyall@ deck with visual landing aids de- the ships to support this aircraft, ensure both ships meet their baesystems.com signed specifically to help pilots guide and we are now putting them into requirements.”
Carrier Waves is now being made available online as an interactive Moving 4,000 tonnes Superblock revealed PDF. The link to access FROM PAGE 01 the latest version will be distributed via email. is a delicate business... If you would like more giant Goliath crane to move more information on the new than 5,000 tonnes of sections into format, or would like to place with pinpoint accuracy. request Carrier Waves Sean Donaldson, Babcock QEC as a standard PDF, director, said: “The heavy lift team please contact John Fyall, has the operation of Goliath and ACA Communications the meticulous planning required Manager, at john.fyall@ for these complex operations baesystems.com down to a fine art. It’s a precision job, with no margin for error.” © 2012 Aircraft Carrier While the heavy lifts have Alliance. The publishers, been developing the structure of authors and printers cannot the superblock, hundreds of accept liability for any errors skilled workers have been busy or omissions. Articles or inside the block, doing every- opinions expressed in this SECTION MOVE move, the section was carefully publication may not reflect thing from fitting beds to company policy. All rights lined up with the rest of the block, installing hundreds of kilometres reserved. On no account which will collectively form the aft of cables and pipes. may any part of this Two giant sections of Lower Block section of the hull. Geoff Searle said: “The publication be reproduced 04 (LB04) were brought together Almost the full length of a successful construction and in any form without the for the first time in a precision move football pitch, the structure, which assembly of the Queen Elizabeth written permission of the at BAE Systems’ Govan shipyard. is the largest section of hull under Class depends on a combination copyright holder, application for which should be made to Using a fleet of 132 remote construction, is so large that it of skill, timing and teamwork. [email protected] controlled transporters, a huge stretches beyond the doors of the The Aircraft Carrier Alliance is Designed by Connect section, weighing more than 4,000 ship build hall in which it sits. The bringing all the right elements Communications Ltd. tonnes, was carefully manoeu- complete section will weigh more together and is proudly delivering www.connect vred 100 metres across specially than 11,000 tonnes and is expected the nation’s flagships.” communications.co.uk reinforced concrete. In a two-hour to move to Rosyth in November.
CVF Carrier Waves_p1-3.indd 2 14/05/2012 14:20 NEWS News from the Aircraft Carrier Alliance 03
News in brief
Programme Director Geoff Searle Power up watches as Commander-in-Chief In a major milestone for the Fleet Admiral George Zambellas construction of HMS Queen cuts the fi rst steel Elizabeth, workers in Portsmouth completed all the wiring and powered up the ship’s fi rst installed switchboard on LB02. Paul Bowsher, Project Leader in New milestone in HMS Portsmouth, said: “This is a massive result for our teams.” Prince of Wales build Best in UK Two Aircraft Carrier Alliance HMS PRINCE OF WALES Next stage begins by Babcock at its Appledore facility, apprentices have been named as made the 780-nautical mile journey among the best in the UK. on construction around the south and east coast Mechanical Fitter Claire Grant, A new chapter in the construction to Rosyth. 22, who works for Babcock at of the second of class, HMS Prince of forward section Sean Donaldson, Babcock QEC Rosyth, took fi rst place in a national of Wales, opened in Portsmouth Project Director, said: “Less than competition to fi nd the best trainees recently as Commander-in-Chief Admiral Zambellas said: “These two years after completing the bow of 2011. Fleet Admiral George Zambellas two ships – each of which will be sections for the fi rst carrier, we are And David Crawford, 20, who cut the fi rst steel for Lower Block 02. in service for more than 50 years – again celebrating an important works for BAE Systems Naval Ships The forward section of the lie at the heart of our national step in the carrier programme with at Govan, won the Craft Fabrica- hull will weigh about 6,000 tonnes security posture. With the the arrival of this section for HMS tion Achievement at the company’s upon completion and will house equipment that will operate from Prince of Wales.” apprentice of the the ship’s machinery spaces, them, they will be pivotal to the In Govan, work on HMS Prince year awards. stores and switchboards, as well UK’s ability to project power at of Wales has been forging ahead for Claire and David as some of the accommodation, range for decades to come.” the last year. Now the ship’s mid are two of including 85 cabins. Meanwhile, the bulbous bow for section – LB03 – is already weighing more than 700 Commander-in-Chief Fleet HMS Prince of Wales, constructed in at more than 2,500 tonnes. apprentices cur- rently playing a part in the con- Heavy Lift team said: “Sponsons are struction of the Claire Grant very large and complex shapes, so to aircraft carriers. Jack be help us work with them, we devel- oped the Synchronous Lift System. This is a really clever piece of kit which nimble gathers information from lots of sen- sors to accurately calculate just how Jacks are used to each sponson needs to be supported. ASSEMBLY place the sponsons “It uses 48 individual jacks, Follow us operated by a touch-screen controller. Almost 1,000 people regularly Once a sponson has been moved into receive news, the latest pictures Sponsons, the extensions to sections of the fl ight deck, it’s position by Goliath, the Synchronous and build updates about the the Queen Elizabeth Class fl ight deck, crucial they are aligned with Lift System keeps it supported and programme through Twitter. are notoriously tricky to work with. absolute precision while they can make minute adjustments to its To join them, search for They weigh about 800 tonnes, are integrated into the build. position, ensuring it’s in exactly the @QEClassCarriers and you’ll get all they’re irregularly shaped, and But now, engineers at Rosyth right place. the latest information from across their centre of gravity is off-centre, have developed a new system which “In fact, it’s so accurate it’s been the alliance as soon as it’s released. meaning lifting and levelling them allows them to perfectly align and able to keep an entire 40-metre You can also fi nd the most can be extremely challenging. support each sponson. section of fl ight deck level to within recent tweets at www.aircraft And, because they are key Willie Richards from the Babcock just three millimetres.” carrieralliance.co.uk
CVF Carrier Waves book 3 11/05/2012 16:04 04 News from the Aircraft Carrier Alliance NEWS
The strongest l A robust supply chain is the driving force behind the production of a new cl
SUPPLY CHAIN almost 13 million parts in about 700,000 pieces requires a truly world-class supply chain to of equipment, it takes more than the ACA mem- bring it to life,” said ACA Supply Chain Director bers alone to create them. Dougie McInnes. Building any new class of ships is an incredibly “A programme of this size and importance “We need to make sure the right parts, of complicated task. the right quality, are in the right place at the But when the vessels in question are the right time. largest and most powerful warships ever “Given the complexity and scale of this pro- constructed for the Royal Navy, with gramme this is a real challenge. accommodation for hundreds and an on-board But, without excep- airport operating fast jets and helicopters, the tion, every job doesn’t get much more demanding. supplier As such, the task of delivering the has grasped Queen Elizabeth Class is too big for the need for any one company to undertake alone, industry-leading per- which is why the Aircraft Carrier formance,” added Dougie. Alliance (ACA) – the partnership of There are literally hundreds BAE Systems, Thales UK, of companies providing parts for Babcock and MOD – the ships, everything from microwave was born. ovens to mission systems, and they all need However, with each to be delivered, tested and integrated ship made up of at the right time.
CVF Carrier Waves book 4 11/05/2012 16:04 NEWS News from the Aircraft Carrier Alliance 05
Thousands of people are working to create the new Case Study Queen Elizabeth Class Kevin Jones, Kempsafe Project Manager
Facts... s 4HERE ARE MORE THAN 300 companies involved in the programme, ranging from multi-national organisations to Win secures small, specialist companies s 4HE VAST MAJORITY OF THE supply chain is based in the UK firm’s future s #ONTRACTS WORTH MORE THAN £1.6 billion have been placed Southampton-based Kempsafe’s contract s -ORE THAN PEOPLE ARE with the Aircraft Carrier Alliance was not involved in the supply chain. just the biggest in the company’s 50-year history. It also protected the business from the global recession and helped to safeguard the jobs of all its 20 staff. Kempsafe Project Manager Kevin Jones said: “Our contract to provide galley and laundry equipment to the QE Class was the most valuable piece of work this company has ever secured. “The fact is it came along just in time to reduce the effects of the recession. link... We’re not a large company, so without this work, there’s no telling what would have happened to some areas of the business. w class of aircraft carriers “It has certainly assisted in guaranteeing the employment of the 20 members of staff here at Kempsafe. And making this complicated supply “But what’s more, delivering such a chain a success are thousands of skilled large contract has put us in a stronger workers across the UK, each aware of their position than ever to compete for more role in supporting what will become the work in the future. centrepiece of the UK’s defence strategy for “It gave us the opportunity to upgrade decades to come. our facilities and our skills. All our Dougie said: “The Queen Elizabeth Class customers, present and future, know we is a truly national endeavour. The huge depth can deliver to the volume and standard of skills the programme is supporting and the expected by the Aircraft Carrier Alliance work it is generating is remarkable. and we’re really proud to be playing a part “Suppliers all over the UK are providing in this historic programme.” an incredible range of equipment and services, but the one thing they all have in common is a huge sense of pride that they have been able to contribute to these ships and play a “We are really proud role in this historic programme. to be playing a part in “Going forward, it is really important that the supply chain, as a whole, works with us this historic programme” as we install, commission and test every aspect Kevin Jones, Kempsafe of the ships to make sure we can meet our customer’s requirements.”
CVF Carrier Waves book 5 11/05/2012 16:05 06 News from the Aircraft Carrier Alliance NEWS
ACA is working with the Royal Navy News to keep the carriers ship shape in brief
A real heavyweight
To move huge sections of aircraft carrier across the country safely, the teams responsible need to know how much they weigh. But how do you accurately measure the weight of blocks several storeys high and the best part of 50 metres wide? ACA Project Leader, Paul Bowsher, said: “Understanding the weight and centre of gravity is really important when it comes to arranging for sections to be lifted, floated or moved by barge. It means we know exactly what we need to do to prepare for a safe operation. We weigh each section at least three times to make sure teams in place across the whole the readings are accurate.” ACA, working hand in hand with areas like engineering, Keeping safe procurement, shipbuild and Network commercial. “And of course the Royal Navy personnel, who join the programme at the end of this year, will be key to developing of support the right level of support. They will assist with maintenance right The work of teams across ACA up to delivery and will help com- mission the ships’ systems.” will keep ships operational With the painted areas of the ship exceeding the size of Hyde Park, even routine tasks such as PLANNING AHEAD throughout their 50-year lifespan. cleaning and preservation will In fact, the design and build need extensive shore support. contract has a built-in requirement And all the support needs to fit The Chair of the Health and Safety When a ship weighs 65,000 tonnes, to make sure the ships are put to- around the operational tasking of Executive, Judith Hackitt, visited doubles as a floating airport and gether so key parts can be properly the ships. The aircraft carriers will Rosyth to see first hand the ACA’s can operate as a headquarters for serviced. Spares, technical data, operate as part of a task group, commitment to Safety, Health military action and humanitarian support equipment and training all including frigates, destroyers and and Environment. relief, keeping it in peak condition need to be provided too. support ships, and so co-ordinat- Judith Hackitt said: “It is encour- is no small task. ACA Support Director, Derek ing support across the whole task aging to see the commitment to But that’s the challenge Holliday, explains: “The Aircraft group will add to the challenge. create a safe work environment for facing the Aircraft Carrier Alliance, Carrier Alliance is delivering not Derek said: “We’ll need to find the project team at Rosyth. Strong as it is not only constructing just a new class of ships, but also innovative ways of smoothing the leadership on health and safety is the new class of ships, but is an entire process to make sure peaks and troughs of maintenance essential on projects of this scale helping the MOD develop they can continue to meet their so we can keep the ships in top and encouraging workers to take processes to keep them prop- requirements for decades to come. condition and maximise their ownership of health and safety erly supported and maintained “There are dedicated support operational availability.” promotes a spirit of teamwork.”
CVF Carrier Waves_p6-8.indd 6 14/05/2012 14:23 NEWS News from the Aircraft Carrier Alliance 07
Shore Integration Facility at L-3’s offices in News Bristol allow team to test crucial systems in brief
F-35 takes-off The first UK test pilot to fly the F-35 Joint Strike Fighter has described what it’s like to fly the fifth-generation jet after In control of he took to the skies earlier this the situation
Setting up the new Shore Integration Facility
Squadron Leader Jim Schofield
year. Squadron Leader Jim Schofield said: “The F-35 has the best handling of any jet I’ve flown, which means it’s going to be easier to land on a ship than current aircraft. And pilots can devote all of their attention to the mission.” Squadron Leader Schofield’s flight is the latest in a series of milestones for the programme, which include the opening of the UK production facility at Samlesbury, where sections of the new aircraft will be produced. Beat the Block II and in harmony. The SIF lets us have Royal Navy operators who Once again, a group of POWER AND CONTROL test all these systems before we will one day be at sea on one of enthusiastic cyclists from across install the hardware and software the QE Class sitting at the same the ACA have accepted the A new Shore Integration Facility on-board. And we can reconfigure workstations they will eventually challenge to ‘Beat the Block’. (SIF) that mirrors just how the it to represent a variety of differ- find on-board, facing precisely Around 50 cyclists are set- Queen Elizabeth Class control ent scenarios depending on which the sort of challenges they could ting off from Portsmouth at the centre will look and operate has system we need to check out.” encounter at sea.” same time as the 6,000 tonne been created in L-3’s Bristol offices. The Bristol facility is set up to be 2012 is a busy year for the LB02 section, which is being The control centre is home to a representative layout of the control SIF, as the first software release barged all the way up the east the Integrated Platform Manage- centre, so the kit can be operated will be delivered in late summer. coast to Rosyth. ment System (IPMS), which and tested in a realistic setting. However, this is just the begin- Event organiser, Kirsty controls and monitors more Iain said: “It could be possible to ning, as there are multiple releases Noble, said: “The cyclists are than 40 of each ship’s vital systems, scheduled. determined to arrive at Rosyth from the gas turbine alternators to Iain said: “Each release will before the block does, and to the ship’s cameras. “The SIF lets us test add functionality to the ships, raise thousands of pounds for Iain Milne, who is responsible but they also demand more charity at the same time.” for delivering IPMS, said: “With systems before we exhaustive testing and de-risking See the next Carrier Waves so many crucial systems required install the hardware to ensure the Queen Elizabeth Class to find out how they got on, or to operate simultaneously on delivers exactly what is required of get live Twitter updates via each ship, it’s vital we can make and software” it when the ships are delivered to @QEClassCarriers. sure they all work flawlessly Iain Milne, IPMS project the Royal Navy.”
CVF Carrier Waves book 7 11/05/2012 16:05 08 News from the Aircraft Carrier Alliance NEWS
Channel at Naval Base to be made deeper and wider News in brief Digging deep in Portsmouth
SUPPORT “We’re proud Portsmouth Naval Base will be that Portsmouth home to the Queen Elizabeth Class once the ships have been delivered will be the home to the Royal Navy. of the Queen But although the base has Elizabeth Class” Safety campaign hosted thousands of vessels over the years, it has never played per- Commodore Tony Radakin ‘Proud to be Safe’ is the name of manent host to anything the size the ACA’s new safety campaign of HMS Queen Elizabeth or HMS for 2012. Prince of Wales. So a fundamental ACA Head of Safety, Health part of the future support chal- and Environment, Andy Forbes, lenge is the £140 million project to said: “We’re combining attention- prepare the base for their arrival. grabbing posters and leaflets with Commander of Portsmouth toolbox talks and presentations to Naval Base, Commodore Tony raise awareness of some key safety Radakin, said: “We’re really proud issues with workers across all ACA that Portsmouth will be the official sites.” home of the Queen Elizabeth Class. The campaign will concentrate But their sheer size means we have on different ways of keeping safe to do a lot of work to prepare for throughout the year. their arrival.” The aircraft carriers are so large that the channel that leads to the harbour is currently too shallow to accommodate them. Analysis of the environmental impact of the works required and of the carriers’ presence has been running since and wider to allow the ships to get to cater for additional support ser- 2004. During the winter, a special- to the harbour and expect to be vices, and even a significant increase ist drilling rig (pictured) took more moving about 3.5 million tonnes of in demand for electrical power.” New ACA microsite than 200 borehole samples of the the sea bed over the next few years. Subject to planning consents sea-bed, some as deep as 30m, to “We’ll also be making several and approvals, dredging and shore- The award-winning ACA website prepare for the dredging operation. changes to the jetty where both side construction work will start in regularly receives more than 5,000 Commodore Radakin said: “We ships will berth. We have to make it early 2014 and complete by the time visitors every month. will be making the channel deeper much stronger and we’ll also have the first carrier completes sea-trials. Now, with the launch of the Rosyth time-lapse microsite, visitors can watch the assembly of the carri- s ,OWER "LOCK LEAVES Rosyth dock. ers first hand – no hard-hats required! Diary dates... Portsmouth, scheduled to arrive in Time lapse videos can be found Rosyth at the end of the month. August on the ACA website’s media section. 2012 is getting busy, here are s ," AND SUPERBLOCK SKIDDED www.aircraftcarrieralliance.co.uk just some of the key events that June together. are taking place over the next s #ENTRE "LOCK ARRIVES IN s )NTEGRATION OF ALL MID AND AFT Game on few months. Timings can Rosyth from Merseyside. sections under way. The ACA has developed a unique change, but you can find all the s 2OSYTH DOCK mOODED AND s &IRST STEEL CUT ON ," FOR set of 3D games based on building latest images and news at superblock 03 floated out. ship two. and operating the QE Class. www.aircraftcarrieralliance. s ,OWER "LOCK mOATED Housed in a specially designed co.uk into Rosyth dock, followed by November pod, and controlled using a Wii superblock 03. s ," n THE LARGEST SECTION balance-board, the games challenge May yet – arrives at Rosyth. users to build an aircraft carrier and s ,OWER "LOCK ARRIVES IN 2OSYTH July s &ULL HULL INTEGRATION to land an F-35C on the flightdeck. from Portsmouth. s "ULBOUS BOW CRANED INTO under way. The games will visit special events around the country.
CVF Carrier Waves_p6-8.indd 8 14/05/2012 14:26