Seal Test Rig

Claverham Limited

SUBMARINE TECHNOLOGY DEMONSTRATOR

COMMON HYDROPLANE ELECTRO-MECHANICAL ACTUATION

SEAL TEST RIG – CRITICAL DESIGN REVIEW

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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

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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

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Claverham Limited

PROGRAMME LOGIC

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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

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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

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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

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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

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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

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Claverham Limited

ACTUATOR UNIT - ROD GLAND & DRAIN

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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

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Claverham Limited

ACTUATOR UNIT (AU) - ROTATING SCREW, UNBALANCED

OUTPUT ROD &

TEST BOX

TRUNNION MOUNTING

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Claverham Limited

PRESSURE TEST BOX

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SEAL TEST BLOCK REPLACES CASSETTE RETAINING RING

EYE END REMOVED TO INSTALL SEAL TEST BLOCK

Claverham Limited

PRESSURE TEST BOX

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SEAL TEST BLOCK REPLACES CASSETTE RETAINING RING

Claverham Limited

ORIGINAL SEAL TEST RIG

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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

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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

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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

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Encoder

(speed control)

CompactField Point

(direction control)Control logic PWM H-Bridge

CompactField Point

(enable control)

Motor

Servoamplifier

Claverham Limited

SEALED TEST RIG – SERVOAMPLIFIER

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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

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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

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Claverham Limited

PROJECT MANAGEMENT SCHEDULE

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Claverham Limited

PROJECT MANAGEMENT SCHEDULE (1)

DESIGN

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MANUFACTURE, BUILD & ON SITE TESTING

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OFF SITE TESTING & SURVEY

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Claverham Limited

SEAL TEST RIG CDR

- END -

Seal Test Rig

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