Forsvarsudvalget 2014-15 (1. samling)
FOU Alm.del Bilag 20
Offentligt
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Danish frigate program
Setting a new standard for affordable
defense procurement
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Introduction to Danish frigate program
The aim of the Danish frigate program is to provide the Royal Danish
Navy with a platform capable of operating independently or as part of
a group (i.e. NATO). The frigates have a flexible design to ensure that
multiple tasks can be carried out efficiently, effectively and
economically, performing tasks ranging from sea control to warfare.
The platform is designed for a 30-year lifespan and modularity enables
technology refresh and insertions. Navy ships today have the perfect
opportunity to raise standards by looking at new and efficient ways of
operating.
The modularity
The Danish Defence and Logistics Organization (DALO) ran the
program with inspiration from the world’s largest shipping company,
Maersk.
The result was a new frigate procurement model based on fixed prices
and open book principles, leveraging commercial shipbuilding
principles from Maersk (Odense Steel Shipyard) and DALO’s military
acumen, combining the best from both worlds. The ships can be
delivered on budget and on schedule and are exceeding the required
specifications from DALO.
By demonstrating respect for taxpayers’ money and using common
sense, DALO has created a new standard for affordable defense
procurement.
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Flexible Navy concept
– the background
The standard flex concept was developed in the eighties when the Danish Navy faced the
urgent need of replacing their old ships on a limited budget while being unsure about the
future type of missions that the Navy would be engaged in. In other words, the situation
required innovation.
The flexible navy concept was developed in close cooperation between the Danish Navy
and the Danish maritime industry. The concept allowed a standard vessel to be configured
for various roles and to share modules across the fleet.
The advantage of the modular concept is the ability to reconfigure the platform into new
roles as well as the ease of future upgrades and retrofits. With platform flexibility, DALO is
able to operate at higher levels of availability by optimizing:
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System reliability/portability
Small logistics footprint
Low maintenance
Life cycle cost
Armament
Missiles
Lockheed Martin MK41 VLS Harpoon Block II missiles, Evolved
Sea Sparrow missiles, long-range missiles for area air defense
(vertical launch)
Oto Melara 76mm Super Rapid guns, one of which is prepared
to be substituted with a 127mm gun. Furthermore, the Danish
Iver Huitfeldt has a 35mm CIWS gun and several 12.7mm
machine gun positions
Boeing Harpoon anti-ship missile system, a twin torpedo
launcher in each side
Sonar
Torpedoes
Countermeasures
Radars
Atlas ASO 94 hull-mounted active search and attack medium
range sonar
Fixed ASW launchers
Terma 12-barrelled decoy launchers for 360° coverage against
incoming anti-ship missiles. Decoys, chaff and ESM
Thales AESA multi-function radars for surveillance and
fire control. Medium- to long-range air and surface
surveillance radars
Terma SCANTER 6000 surveillance and helicopter guidance
radar
Saab CEROS 200 fire control radars
ES-3701 Tactical Radar Electronic Support Measures (ESM)
Combat Management
System
and intelligence
Helicopter
Terma C-FLEX command, control, communications, computers
and (C4I) systems, link 11 and 16, commercial and military
SATCOM
Helicopter deck and hangar to support the operations of
medium-sized helicopters (EH101).
Flight deck can handle larger and heavier helicopters of
up to 20 tonnes
Prepared for tactical, unmanned aerial vehicles and unmanned
underwater vehicles, cargo space for 20-feet ISO containers
Guns
The innovative platform allows DALO to postpone specific investments and reduces the
time the ship will be out of service during in-service support retrofits. The modularity
offers the Navy an effective way of adapting to technical uncertainty.
The platform meets standard IMO, SOLAS and MARPOL requirements for a vessel with
165 persons on board and features a life-saving system for dry evacuation of the entire
crew.
The hull structure meets DNV ice class C standards and the entire ship is designed and
tested to withstand shock from underwater explosions. The hull is divided into five gas-
tight citadels with external wash systems for chemical warfare. It features a degaussing
system for mine avoidance and sensitive electronic equipment is EMC protected. Stealth
low radar signature design; low infrared exhaust signature. Propulsion set-up with two
Controllable Pitch propellers, each connected to two diesel engines delivering 8.2 MW
each.
Miscellaneous
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Flexibility provided
Iver Huitfeldt Class
Frigate
Danish Iver Huitfeldt Frigate
– cost
Total cost for the frigate was USD 325 million in 2010. This is only USD 80 per kilogram
frigate or just 1/3 of what has been reported as low-end prices in Europe. The Royal Danish
Navy, DALO and OMT (OSS) have accurately tracked the Danish Iver Huitfeldt program
expenses and have an indisputable assessment of costs.
Figure 1: frigate cost
3%
12%
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The platform as
delivered for yard
System integration
Anti-aircraft warfare (AAW)
31%
51%
Weapons/electronics
Other
Absalon Class
Command and support ship
4%
The platform has been designed, developed and delivered with standardized equipment,
combat systems, weapons and sensors from global suppliers.
Public and private partnership
Collaboration between DALO/the Royal Danish Navy and the OMT (OSS) on ship design
which significantly minimized program risk and production costs.
Commercial off-the-shelf components
Off-the-shelf component robustness is tested 24-7-365 on commercial ships and considered
for the frigate program. The target was long-term cost savings but not if robustness and
reliability were compromised. The ships are shock tested according to NATO standards.
Knud Rasmussen Class
Offshore patrol vessel
Efficient manufacturing set-up at the yard
Efficiency assembly measures formed the basis for the production set-up of the Danish
frigate program and created a new benchmark for productivity in naval shipbuilding. The
Danish frigates were assembled in 56 days followed by 146 days for outfitting,
commissioning and trials. 700.000 hours was used to construct the vessel.
Project model
The shipyard was allowed to make a decent profit on the ship platform itself. The shipyard
had nothing to do with procurement of weapons, AAW and system integration. DALO had the
role of main contractor and system integrator and saved Danish taxpayers approximately
USD 65 million per ship with this project model.
SAR 1
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Designed for life cycle cost
Figure 2: total average cost to tax payers: USD 67 million per year
11%
7%
CapEX
OpEx (e.g. crew)
VoyEx (e.g. fuel)
14%
44%
Maintenance
Upgrades (AAW, ASuW,
artillery, communication)
24%
The Danish frigate program targeted total life cycle cost and applied principles from
commercial shipping. In commercial shipping focus is on reduction of crew cost, fuel cost
and emissions. Understanding these commercial cost efficiency principles gave DALO
another perspective on the frigate program.
Striving for low fuel cost at cruising speed (18knots) while meeting the requirements
for fast acceleration and high top speed became a core part of the propulsions system
concept developed for the frigates.
The result was a propulsion system giving best-in-class fuel economy. At 18 knots cruising
speed, the frigate requires 31 tonnes of fuel per day giving an endurance of 9,300 nautical
miles. This endurance is 80-100% better than other new frigate designs on the market today.
Despite the excellent fuel economy at cruising speed, the frigate can reach 29.3 knots in less
than 120 seconds. A propulsion system based on a gas turbine could deliver a slightly higher
maximum speed but it was not selected as it significantly increases CapEx and fuel costs and
reduces endurance by approximately 50%.
In short, Navy ships must be role models and set new standards by continuing to look at new
efficient ways of operating.
Life cycle cost
– operating expenses (OpEx)
The platform is largely based on commercial off-the-shelf equipment. Real operating costs
have proven to be even lower than expected.
An important cost driver is crew, inspired by Maersk. For example, an ultralarge
containership can be operated by 14 crew members. The Danish frigates can be operated by
20 crew members.
To operate the frigate during missions, a total crew of 100 is required with additional space
for 60 mission-dependent crew members.
The space in the super structure can potentially accommodate up to 200 crew members.
However, DALO and the Danish politicians decided to stick to the lean crew concept and
used the space for a supplementary missile launcher.
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Maintenance cost
The modularity concept and the standard software architecture enable efficient upgrades
during the 30-year life of the frigate. The open architecture design provides flexibility,
allowing military systems to integrate with one another, for example Thales AESA
multifunction radars assimilating with Terma Surveillance Radar.
DALO decided to use DNV navy classification for the vessel. This means that the frigate
will be subject to docking every five years. It also means that the crew has to comply with
DNV maintenance procedures as part of their daily job. This has a positive effect on the
maintenance costs and reduces the in service support cost. The budget for maintenance is
expected to be less than 7% of the total life cycle cost.
The modularity ensures easy upgrades, a longer lifespan for the platform and more value
for money.
Main data
– Iver Huitfeldt Class Frigate
Length o.a.
Beam, max.
Draft, design
Draught, max.
Displacement, design
Displacement, max.
Weapons and deadweight
Speed, design draught
Endurance, design draught
Fuel oil consumption, endurance
Basic crew
Max. crew
138.7 m
19.8 m
5.8 m
6.45 m
5,452 tonnes
6,649 tonnes
App. 1,200 tonnes
29.3 knots
9,300 nm (18 knots, seastate 0)
31 tonnes/day
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Passing on maintenance tasks to the
crew has not been a problem.
Project Manager for Danish Frigate
program, Commander Senior Grade
Hesselberg explains why:
“A busy soldier is a happy soldier”.
Iver Huitfeldt Class Frigate with plug-and-play features
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The modular platform designed by OSS-OMT worked across the industry to ensure best value for money over a 30-year life.
The Danish Defence Acquisition and Logistics Organization is the system integrator: weapons, sensors and combat management system.
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About Odense Maritime Technology (OMT)
OMT traces its heritage back to 1917 when Odense Steel Shipyard (OSS) was founded by
A.P. Møller in Odense, Denmark. The OMT Company was founded in 2010 as a spin-off from
the OSS. Key focus areas for OMT are design of cost-effective and fuel efficient commercial
ships and navy ships.
Likewise, retrofit of existing vessels to make them more fuel efficient and compliant with
new regulations is a key focus area. Our solutions are based on new technology that delivers
energy efficiency and improved environmental performance. The result is proven quality,
reliability and operational high performance of our design. OMT scope involves full design
packages but can be extended to include procurement and production optimization as well.
OSS (OMT) designed and manufactured the Royal Danish Navy’s Absalon Class Supply and
Command Ships and the Iver Huitfeldt Class Frigates. Three frigates of the Danish Iver
Huitfeldt Class Frigates were designed and built for the Royal Danish Navy by OSS (OMT) in
Denmark between 2006 and 2012. After the first three years in operation, the Navy reports
are very positive on functionality, reliability and with maintenance costs lower than
expected.
OMT has an agreement with the Royal Danish Navy to market military platform designs to
other countries. OMT and the RDN continue to work together to ensure that combat-capable,
multi-purpose vessel designs are kept up to date.
About DALO
The Danish Defence Acquisition and Logistics Organization
The Danish Defence Acquisition and Logistics Organization (DALO) is the specialized
materiel center and logistics authority of the Danish Defence. The organization acquires,
maintains, develops and phase out material capacities and ensures provisions in due time
for the Danish Defence operations.
DALO administers a budget of approximately DKK 7 billion of the total defense budget. This
amount is used to provide efficient support, primarily to international operations and
operational units.
DALO has approximately 2,400 employees. Headquarters is situated in Ballerup near
Copenhagen.
Furthermore, DALO comprises the Danish Maintenance Agency East and the Danish
Maintenance Agency West with their respective headquarters in Korsoer and Aalborg, under
which a large number of maintenance workshops are placed throughout the country.
The main depot of the Danish Defence Supply Agency is situated in Skrydstrup with a
number of store facilities, reload centers and depots throughout Denmark.
Odense Maritime Technology A/S
Sverigesgade 4
5000 Odense C
Denmark
www.odensemaritime.com