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Claverham Limited
SUBMARINE TECHNOLOGY DEMONSTRATOR
COMMON HYDROPLANE ELECTRO-MECHANICAL ACTUATION
SEAL TEST RIG – CRITICAL DESIGN REVIEW
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
AGENDA INTRODUCTIONS
SEAL TEST RIG
TEST PLAN
RELIABILITY
PROJECT MANAGEMENT PLAN - SCHEDULE
ANY OTHER BUSINESS
WASH-UP
OTHER TOPICS
CONTROL MEETING
SAFETY MEETING
TRAFALGAR CLASS DATA
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
CONTRACT - DESIGN PHASE UP TO CDR
• PRIME CONTRACTOR BAE SYSTEMS, CS & S NAVAL
• SPONSOR DEFENCE EQUIPMENT & SUPPORT, MXS
SUBMARINE IPTs
• PRELIMINARY & DETAIL DESIGN
•TYPE OF CONTRACT FIXED FIRM PRICE
• DURATION NOMINAL 13 MONTHS
• PAYMENT MILESTONES PDR, SEAL TEST 1, CDR, SEAL TEST 2
• FOLLOW-ON CONTRACTS - DEVELOPMENT COMMENCING AUGUST 2008
- IN SERVICE TESTING – 2011
• TARGET SUBMARINE - ‘TRAFALGAR’ CLASS SSN
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
PROGRAMME LOGIC
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
PRELIMINARY DESIGN
PRELIMINARY DESIGN
PRELIMINARY DESIGN
DETAILED DESIGN
DETAILED DESIGN
DETAILED DESIGN
BUILD & TEST
BUILD, CODE, TEST & QUAL
TRIALS
SURVEY & UPDATE
UPDATED PHASE 2A PHASE 2B ACTUATOR UNIT
ACTUATION SUB-SYSTEM ELECTRONICS
SEAL TEST TRIAL
Claverham Limited
ACTUATION SUB-SYSTEM (AS)
STATUS
ECU ‘A’ ACU
SINGLE MOTOR
DRIVE
POWER
ON
LAMP TEST
ECU ‘B’
QUIET HOLD
LOCK AU
OPERATOR CONTROL PANEL
REMOTE/LOCALAU
PRESSURE
ASU RESET
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
ACTUATOR UNIT (AU) - ROTATING SCREW, UNBALANCED
TWIN BRUSHLESS DC MOTORS
GEAR BOX
PLANETARY ROLLER SCREW
POSITION
SENSORS
OUTPUT ROD &
CLEVIS
‘TILLER ARM’
TRUNNION MOUNTING
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
FAILURE MODES
• LOSS OF MAIN POWER – DUPLEX MOTOR / MOTOR CONTROLLERS FED FROM DIFFERENT SECTIONS OF THE RING MAIN WITH BATTERY BACK-UP
• LOSS OF AUXILIARY POWER (24V DC) - DUPLEX
• LOSS OF COMMAND – DUPLEX ANALOGUE DATA LINK & EMERGENCY DATA LINK
• LOSS OF CONTROL – DUPLEX ELECTRONIC CONTROL UNITS & A LOCAL CONTROLLER
• LOSS OF SENSOR – QUADRUPLEX SENSORS
• LOSS OF A CABLE – DUPLEX FOR HIGH & LOW POWER, CONTROL & SENSING
• SLOW FLOOD – SENSOR, DRAIN, VENT & BLOW (TBD)
• MAJOR FLOOD – BACK-UP SEALING ARRANGEMENTS, DUPLEX AFT HYDROPLANES
• SEIZURE OF ROLLER SCREW / GEAR BOX – SUBSTANTIAL OVER-RATING (FOR LOW FAILURE RATE, EXTENDED LIFE & TRANSIENT FORCES DUE TO WAVE/SEA SLAP)
• ACTUATOR ‘RUN AWAY’, or ‘HARD-OVER’ – ANALOGUE ‘WRAP AROUND’ CIRCUITS
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
RISK
• WATER TIGHT INTEGRITY OF THE ACTUATOR UNIT DESIGN
- INNER & OUTER SEAL PACK WITH INTER-SEAL SPACE DRAIN
- COMBINED OUTER BEARING & CHOKE RING
• SUSCEPTIBILITY OF THE DESIGN TO MARINE GROWTH: SURFACE FINISH & MATERIAL
• SAFETY OF THE DESIGN: BACK-UP ANALOGUE CONTROL, ANALOGUE SAFETY CIRCUITS, DUPLEX CONTROL & POWER DRIVE, OVER-SPECIFIED MECHANICS
• RADIATED NOISE LEVELS OF THE DESIGN:
- POSITION CONTROL
- SINUSOIDAL MOTOR CONTROL
- RAFT MOUNTED ACTUATION SUB-SYSTEM ELECTRONICS
- QUIET (LOW RATE)
- SOFT START & STOP
- END OF STROKE MANAGEMENT
- HELICAL GEARING
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
ACTUATOR UNIT - ROD GLAND & DRAIN
GLAND ASSEMBLY
SEAL CASSETTE
ORKOT PLAIN BEARINGS (ALSO ACTING AS CHOKE)
BANJO CONNECTION TO FIXED PIPEWORK
ROD
TO PUMPS
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
ACTUATOR UNIT - ROD GLAND & DRAIN
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
PROPOSED SEAL & BEARING ARRANGEMENT
EXISTING SEAL & BEARING ARRANGEMENT (HYDRAULIC)
Claverham Limited
ACTUATOR UNIT - ROD GLAND GLAND ASSEMBLY
SEAL CASSETTE
ORKOT PLAIN BEARINGS OR TURCON GLYD-RINGS(ALSO ACTING AS CHOKE)
ROD REMOVED FOR CLARITY
MAIN DYNAMIC SEALS H-ECOPUR MACHINED POLYURETHANE ELASTOMER
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
ACTUATOR UNIT (AU) - ROTATING SCREW, UNBALANCED
OUTPUT ROD &
TEST BOX
TRUNNION MOUNTING
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
PRESSURE TEST BOX
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
SEAL TEST BLOCK REPLACES CASSETTE RETAINING RING
EYE END REMOVED TO INSTALL SEAL TEST BLOCK
Claverham Limited
PRESSURE TEST BOX
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
SEAL TEST BLOCK REPLACES CASSETTE RETAINING RING
Claverham Limited
ORIGINAL SEAL TEST RIG
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
SECTIONAL VIEW
TEST POSITION
SEAL BLOCK ACCESS
SEAL TEST BLOCK WITH TEST PORTS
PRESSURE TEST BLOCK (PRESSURE TEST ONLY)
REPLACES RETAINING RING
SEAL CASSETTES
INCONEL 725 ROD INCONEL CLAD ROD
Claverham Limited
NEW DESIGN OF TEST RIG
Claverham Limited
NEW DESIGN OF TEST RIG – SECTION THROUGH BODY & TEST BOX
Claverham Limited
NEW DESIGN OF TEST RIG – ISOMETRIC OF SHAFT & BODY
Claverham Limited
NEW DESIGN OF TEST RIG – SECTION THROUGH BODY
Claverham Limited
NEW DESIGN OF TEST RIG – SCRAPERS
Claverham Limited
NEW DESIGN OF TEST RIG – HORIZONTAL, STOWED
Claverham Limited
NEW DESIGN OF TEST RIG – VERTICAL, READY FOR TRIAL
Claverham Limited
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
SEALED TEST RIG – ELECTRONICS INTERFACE
Motor
S1 S4S2 S3
2A Fuse
Servoamplifier
Controller
Actuator
Brake
24V DC 24V DC
GND 24V DC
GND
Encoder
24V DC
24V DC 5V DC
Strain
Gauge
Analogue
I/O
Module
DC
24V DC
Digital I/O
Module
Digital I/O
moduleDigital I/O
module
Analogue I/O
module
Digital I/O
moduleServoamplifier
Analogue I/O
module
Digital I/O
module
60A Fuse
Claverham Limited
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
SEALED TEST RIG – ELECTRONICS COMPONENTS: SERVOAMPLIFIER: MESA MSD1 SERVOAMPLIFIER NI CFP-2120 CONTROLLER NI CFP-DIO-550 DIGITAL I/O MODULE NI CFP-AIO-610 ANALOGUE I/O MODULE NI LABVIEW SOFTWARE NI CHASSIS, BACKPLANE AND CONNECTOR BLOCKS MOTOR, BRAKE, ENCODER, STRAIN GAUGE AND LIMIT SWITCHES IP RATED ENCLOSURE, CONNECTORS, CABLES, BATTERY, DIODES, RESISTORS, FUSES, FUSE HOLDERS
Claverham Limited
ELECTRO-MECHANICAL ACTUATOR
KEY CHARACTERISTICS – ‘H’ SERIES
DYNAMIC LOAD 10kN
LINEAR SPEED 46mm / s
MAXIMUM STROKE 900mm
MOTOR SIZING 550W
SWITCHES EXTEND / RETRACT & LIMIT SWITCHES
Claverham Limited
ELECTRO-MECHANICAL ACTUATOR – ‘H’ SERIES
Claverham Limited
ELECTRO-MECHANICAL ACTUATOR
KEY CHARACTERISTICS – ‘M’ SERIES
DYNAMIC LOAD 50kN
LINEAR SPEED 46mm / s
MAXIMUM STROKE 250mm
MOTOR SIZING 1.1KW
GEARING 6:1 WORM GEAR
BALLSCREW Ø40mm X 20mm LEAD
SWITCHES LIMIT SWITCHES
VELOCITY SENSOR INCREMENTAL ENCODER
MANUAL DRIVE YES
BRAKE YES
INTERFACE FORK END
Claverham Limited
ELECTRO-MECHANICAL ACTUATOR –’M’ SERIES
Claverham Limited
SEALED TEST RIG – SERVOAMPLIFIER, BLOCK DIAGRAM
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Encoder
(speed control)
CompactField Point
(direction control)Control logic PWM H-Bridge
CompactField Point
(enable control)
Motor
Servoamplifier
Claverham Limited
SEALED TEST RIG – SERVOAMPLIFIER
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
SEAL TEST RIG - TEST PLAN, SEQUENCE OF TESTS SEAL BLOW OUT TESTS
PRESSURE TEST TO 45bar & VACUUM TEST TO - 0.25bar
OPEARATIONAL CYCLES
HOT & COLD TESTS
ICING TESTS
OPERATIONAL CYCLES
PNEUMATIC CHOKING
MARINE GROWTH
Claverham Limited
SEAL TEST RIG - TEST PLAN SEAL BLOW OUT TESTS
1. AIMS:
A. TO CONFIRM CALCULATIONS FOR THE EFFECTS OF A MAJOR SEAL FAILURE
B. TO PROVIDE EVIDENCE IN SUPPORT OF THE SAFETY CASE
2. METHODOLOGY
A. TO COMMENCE THE TEST WITH SEAL PACK REMOVED
B. TO APPLY WATER PRESSURE AT 5bar STEPS & MEASURE FLOW RATE
C. IDEALY, TO DETERMINE DOWN TO MAXIMUM TEST PRESSURE
Claverham Limited
SEAL TEST RIG - TEST PLAN PRESSURE TEST TO 45bar & VACUUM TEST TO - 0.25bar
1. AIMS:
A. TO DEMONSTRATE INTEGRITY OF THE SEALS TO 45bar
B. TO DEMONSTRATE INTEGRITY OF THE SEALS AT MINIMUM SUBMARINE PRESSURE
C. TO MEASURE THE FRICTIONAL FORCE ON THE SEALS AT VARIOUS PRESSURES
2. METHODOLOGY
A. TO COMMENCE WITH ATMOSPHERIC PRESSURE AND TEST TO 45bar IN 5bar STEPS
B. TO PULL A VACUUM TO – 0.25bar AT THE INTER-SEAL DRAIN POSITION
C. TO REPEAT THE PRESSURE TEST AT 30bar
Claverham Limited
SEAL TEST RIG - TEST PLAN OPERATIONAL CYCLES
1. AIMS:
A. TO DEMONSTRATE THE INTEGRITY OF THE SEAL DESIGN
B. TO CONFIRM INTEGRITY DURING THE OPERATIONAL CYCLING
1. METHODOLOGY
A. TO CONDUCT 40,000 OPERATIONAL CYCLES WITH A PERIODIC TIME OF 15s
B. TO CONFIRM INTEGRITY OF SEALS AT THE START OF EACH DAY
C. TEST TO BE RUN IN COMPANY HOURS; RE-CHARGE BATTERY OVERNIGHT
Claverham Limited
SEAL TEST RIG - TEST PLAN HOT & COLD TESTS
1. AIMS:
A. TO DEMONSTRATE THE INTEGRITY OF THE SEAL DESIGN AT HOT & COLD EXTREMES
B. TO CONFIRM INTEGRITY DURING OPERATIONAL CYCLING WHILST HOT & COLD
1. METHODOLOGY
A. TO SOAK TO SPECIFIED TEMPERATURE
B. TO CONDUCT OPERATION, FLOODED AT +45ºC
C. TO SOAK TO SPECIFIED TEMPERATURE
D. TO CONDUCT OPERATION, FLOODED AT -2ºC
Claverham Limited
SEAL TEST RIG - TEST PLAN ICING TESTS
1. AIMS:
A. TO DEMONSTRATE THE INTEGRITY OF THE SEAL DESIGN IN AIR AT LOW TEMPERATURES
B. TO CONFIRM INTEGRITY DURING OPERATIONAL CYCLING ON DIVING
2. METHODOLOGY
A. TO SOAK DRY TO THE SPECIFIED TEMPERATURE OF -29ºC
B. TO SPRAY WATER ONTO THE OUTPUT SHAFT
C. TO OPERATE SLOWLY AT THIS TEMPERATURE
D. TO RAISE THE TEMPERATURE TO - 2ºC & OPERATE IN WATER
E. TO CONDUCT A PRESSURE TEST ON COMPLETION
Claverham Limited
SEAL TEST RIG - TEST PLAN PNEUMATIC CHOKING
1. AIMS:
A. TO INVESTIGATE THE PRINCIPLE OF PNEUMATIC CHOKING
2. METHODOLOGY
A. TO SCORE AN OUTER SEAL
B. TO APPLY A STANDARD 1bar LOW PRESSURE AIR TO THE SEAL DRAIN
C. PRESSURISE THE OUTER SEAL IN 5bar STEPS AND MEASURE FLOW
D. DETERMINE THE AIR / SEA PRESSURE DOMAIN
Claverham Limited
SEAL TEST RIG - TEST PLAN MARINE GROWTH TESTS
1. AIMS:
A. TO DEMONSTRATE THE INTEGRITY OF THE SEAL DESIGN, STATICALLY IN A TIDAL STREAM
B. TO CONFIRM INTEGRITY OF THE SEAL WHEN OPERATED SLOWLY AFTER ONE MONTH
2. METHODOLOGY
A. TO SUBMERGE THE TEST SECTION IN A TIDAL STREAM WITH CLOSED CENTRES
B. TO REMOVE THE TEST SECTION AND OPERATE MANUALLY
C. TO CONDUCT A PRESSURE TEST
D. TO INSPECT THE SHAFT FOR DAMAGE & BODY FOR CORROSION
D. TO REPEAT THE CYCLE 3 -4 TIMES (TBC)
Claverham Limited
RELIABILITY MODEL (1)
SEAL
λ = 10.1.10-6
SEAL
λ = 10.1.10-6
ROLLER
SCREW
λ = 1.07.1.10-6
GEAR BOX
λ = 10.1.10-6
SENSOR
λ = 1.25.1.10-6
SENSOR
λ = 1.25.1.10-6
SENSOR
λ = 1.25.1.10-6
SENSOR
λ = 1.25.1.10-6
MOTOR
λ = 15.1.10-6
MOTOR
λ = 15.1.10-6
MCU
λ = 10.1.10-6
MCU
λ = 10.1.10-6
ECU
λ = 7.5.1.10-6
ECU
λ = 7.5.1.10-6
ACU
λ = 7.5.1.10-6
NORMAL SUB-SYSTEM CONFIGURATION
λ =79.82.1.10-6 MTBF = 12,500 HOURS
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
AVAILABILITY MODEL
SEAL
λ = 10.1.10-6
SEAL
λ = 10.1.10-6
ROLLER
SCREW
λ = 1.07.1.10-6
GEAR BOX
λ = 10.1.10-6
AVAILABILITY CONFIGURATION
λ =21.07.1.10-6 MTBF = 47,450 HOURS
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
PROJECT MANAGEMENT SCHEDULE
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
PROJECT MANAGEMENT SCHEDULE (1)
DESIGN
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
PROJECT MANAGEMENT SCHEDULE (2)
MANUFACTURE, BUILD & ON SITE TESTING
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
PROJECT MANAGEMENT SCHEDULE (3)
OFF SITE TESTING & SURVEY
1
Claverham Limited This Presentation contains data which is proprietary to Claverham Ltd.
It is disclosed subject to the IPR conditions of the contract between BAE Systems and Claverham Ltd
Claverham Limited
SEAL TEST RIG CDR
- END -