Early discussions about increasing production of Tomahawk-armed Virginia-Class submarines are underway as the Navy and lawmakers look for ways to more quickly deliver new high-tech attack submarines to the force, Congressional sources told Scout Warrior.
The discussions, involving lawmakers and senior members of the Navy, are still very preliminary and in the early stages. The possibility being considered includes the prospect of building more Virginia-Class submarines per year – instead of the amount called for by the current ship-building plan.
The current status-quo effort to build two Virginia-Class boat per year, however, will drop to one as construction of the Ohio Replacement Program, or ORP, begins in the early 2020s.
The possibility now being deliberated is whether, at this future point in time, the Navy and industry could produce two Virginia-Class boats and one Ohio Replacement submarine per year, increasing the current plan by one Virginia-Class boat per year.
Increasing production hinges on whether the submarine-building industry has the capacity to move up to three submarines per year, the Congressional source said.
Current budget constraints and industrial base capacity limitations may make building three submarines per year too difficult to accomplish, even if the desire to do so was there from both Congressional and Navy leaders.
While Navy officials, including Navy Acquisition Executive Sean Stackley, did tell lawmakers on the House Armed Services Committee Sea Power and Projection Force Subcommittee, production changes could emerge in the future, depending upon funding and industrial base capabilities.
Stackley explained that the service would like to maintain a two per-year production schedule for Virginia-Class attack submarines, even after production of the ORP begins.
"We are working today, and we hope and expect you to work with us, to determine how can we keep two Virginias a year proceeding within all the fiscal constraints and within the limitations of the industrial base, to address this compelling requirement for the nation," Stackley told lawmakers.
The Virginia-Class Submarines are built by a cooperative arrangement between the Navy and Electric Boat, a subsidiary of General Dynamics and Newport News Shipbuilding, a division of Huntington Ingalls Industries.
Each industry partner constructs portions or "modules" of the submarines which are then melded together to make a complete vessel, industry and Navy officials explained.
In the past, various sub-building industry executives have indicated that this might be possible, however such a prospect has not yet been formally confirmed as it would likely involve an increase in resources, funds and man-power.
One industry source told Scout Warrior that the submarine building community would support whatever the Navy and Congress call for.
"We'll support Navy programs," the source said.
Navy Leaders Want More Attack Submarines
The prospect of an acceleration comes as Navy commanders tell Congress they would like to see the fast arrival of more Virginia-Class attack submarines added to the Pacific Fleet.
Pacific Commander Harry Harris told Congress that he would like to see more submarines in his area of operations.
"The Pacific is the principle space where submarines are the most important warfighting capability we have. As far as Virginia-Class submarines, it is the best thing we have," Harris told lawmakers. "As I mentioned before, we have a shortage in submarines. My submarine requirement is not met in PACOM (Pacific Command)."
Virginia-Class attack submarines are necessary for the U.S. to maintain its technological superiority over rivals or potential adversaries such as Chinas, Harris added.
With their technological edge and next-generation sonar, the platform can successfully perform crucially important intelligence and surveillance mission in high-risk areas inaccessible to surface ships. For this reason, Virginia-Class attack submarines are considered indispensable to the ongoing Pentagon effort to overcome what's talked about in terms of Anti-Access/Area-Denial wherein potential adversaries use high-tech weaponry and sensors to prevent U.S. forces from operating in certain strategically vital areas.
Virginia-Class Attack Submarine Technology
Virginia-Class subs are fast-attack submarines armed with Tomahawk missiles, torpedoes and other weapons able to perform a range of missions; these include anti-submarine warfare, strike warfare, covert mine warfare, ISR (Intelligence, Surveillance, Reconnaissance), anti-surface/ship warfare and naval special warfare, something described as having the ability to carry and insert Special Operations Forces, Navy program managers have said.
Compared to prior Navy attack subs like the Los Angeles-Class, the Virginia-Class submarines are engineered to bring vastly improved littoral warfare, surveillance and open ocean capabilities, service officials said.
For instance, the ships can be driven primarily through software code and electronics, thus freeing up time and energy for an operator who does not need to manually control each small maneuver.
"What enables this is the ship control system that we use. You can drive the ship electronically. This allows you the flexibility to be in littorals or periscope depth for extended periods of time and remain undetected," former Virginia-Class attack submarine program manager Capt. David Goggins said several years ago.
The Virginia-Class submarine are engineered with this "Fly-by-Wire" capability which allows the ship to quietly linger in shallow waters without having to surface or have each small move controlled by a human operator, Goggins added.
"There's a person at the helm giving the orders of depth and speed. There's always a person in the loop. The software is telling the planes and the rudder how to move in order to maintain a course and depth. You still have a person giving the electronic signal," he said.
Also, unlike their predecessor-subs, Virginia-Class subs are engineered with what's called a "Lock Out Trunk" – a compartment in the sub which allows special operations forces to submerge beneath the water and deploy without requiring the ship to surface, service officials explained.
"SEALs and Special Operations Forces have the ability to go into a Lock Out Trunk and flood, equalize and deploy while submerged, undetected. That capability is not on previous submarine classes," Goggins added.
The Block III Virginia-Class submarines also have what's called a Large Aperture Bow conformal array sonar system – designed to send out an acoustic ping, analyze the return signal, and provide the location and possible contours of enemy ships, submarines and other threats.
Unlike their "SSBN" Ohio-Class counterparts armed with nuclear weapons, the Virginia-Class "SSN" ships are purely for conventional attack, Navy officials said.
Thus far, more than ten Virginia-Class subs have been delivered to the Navy, and seven are currently under construction. Like other programs, the Virginia-Class submarines are broken up into procurement "Blocks."
Blocks I and II totaling ten ships, have already been delivered.
The program has also delivered its first Block III Virginia-Class Submarine, the USS North Dakota.
The Block III subs, now under construction, are being built with new so-called Virginia Payload Tubes designed to lower costs and increase capability.
Instead of building what most existing Virginia-Class submarines have -- 12 individual 21-inch in diameter vertical launch tubes able to fire Tomahawk missiles – the Block III submarines are being built with two larger 87-inch in diameter tubes able to house six Tomahawk missiles each.
"For each one of these tubes you have hydraulics and you have electronics. What we did for Block III is we went to two very large Virginia Payload Tubes – now you have two tubes versus twelve. It is much easier to build these two tubes," Goggins said.
Although the new tubes were conceived and designed as part of what the Navy calls its "Design for Affordability" strategy to lower costs, the move also brings strategic advantages to the platform, service officials say.
"In the future, beyond Tomahawk -- if you want to put some other weapon in here-- you can," Goggins said.
Also, for Block V construction, the Navy is planning to insert a new 97-foot long section designed to house additional missile capability. In fact, the Navy has already finished its Capabilities Development Document, or CDD, for what's called the "Virginia Payload Modules."
The Block V Virginia Payload Modules, or VPM, will add a new "module" or section of the submarine, increasing its Tomahawk missile firing capability from 12 to 40.
The idea is to have additional Tomahawk or other missile capability increased by 2026, when the "SSGN" Ohio-Class Guided Missile Submarines start retiring in larger numbers, he explained.
Navy engineers have been working on requirements and early designs for a new, 70-foot module for the Virginia-class submarines engineered to house an additional 28 Tomahawk missiles.
While designed primarily to hold Tomahawks, the VPM missile tubes are engineered such that they could accommodate a new payload, new missile or even a large unmanned underwater vehicle, Navy officials said.
The reason for the Virginia Payload Modules is clear; beginning in the 2020s, the Navy will start retiring four large Ohio-class guided-missile submarines able to fire up to 154 Tomahawk missiles each. This will result in the Navy losing a massive amount of undersea fire power capability, Goggins explained.
From 2002 to 2008 the U.S. Navy modified four of its oldest nuclear-armed Ohio-class submarines by turning them into ships armed with only conventional missiles -- the USS Ohio, USS Michigan, USS Florida and USS Georgia. They are called SSGNs, with the "G" designation for "guided missile."
"When the SSGNs retire in the 2020s – if no action is taken the Navy will lose about 60-percent of its undersea strike launchers. When we design and build VPM and start construction in 2019, that 60-percent shortfall will become a 40-percent shortfall in the 2028 timeframe. Over time as you build VPM you will eliminate the loss of firepower. The rationale for accelerating VPM is to potentially mitigate that 40-percent to a lower number," Goggins explained.
Shipbuilders currently working on Block III boats at Newport News Shipyard, Va., say Block V will involve a substantial addition to the subs.
"Block V will take another cylindrical section and insert it in the middle of the submarine so it will actually lengthen the submarine a little and provide some additional payload capability," said Ken Mahler, Vice President of Navy Programs, Huntington Ingalls Industries, said several years ago.
The first Block V submarine is slated to begin construction in fiscal year 2019, Navy officials said.
Early prototyping work on the Virginia Payload Modules is already underway and several senior Navy leaders, over the years, have indicated a desire to accelerate production and delivery of this technology – which will massively increase fire-power on the submarines.
Virginia-Class Acquisition Success
The official baseline for production of Virginia-Class submarines calls for construction of 30 boats, Navy spokeswoman Collen O'Rourke told Scout Warrior. However, over the years, many Navy officials have said this number could very well increase, given the pace of construction called for by the Navy's official 30-Year Shipbuilding Plan.
The submarines are being built under a Dec. 22, 2008, the Navy awarded a contract for eight Virginia Class submarines. The third contract for the Virginia Class, or Block III, covering hulls numbered 784 through 791 -- is a $14 billion Multi-Year Procurement, Navy officials said.
Multi-year deals are designed to decrease cost and production time by, in part, allowing industry to shore up supplies in advance and stabilize production activities over a number of years.
The first several Block IV Virginia-Class submarines are under construction as well -- the USS Vermont and the USS Oregon. In April of last year, the Navy awarded General Dynamics' Electric Boat and Huntington Ingalls Industries Newport News Shipbuilding a $17.6 billion deal to build 10 Block IV subs with the final boat procured in 2023.
Also, design changes to the ship, including a change in the materials used for the submarines' propulsor, will enable Block IV boats to serve for as long as 96-months between depots visits or scheduled maintenance availabilities, service and industry officials have said.
As a result, the operations and maintenance costs of Block IV Virginia-Class submarines will be much lower and the ships will be able to complete an additional deployment throughout their service live. This will bring the number of operational deployments for Virginia-class submarines from 14 up to 15, Navy submarine programmers have explained.
Overall, the Virginia-Class Submarine effort has made substantive progress in reducing construction time, lowering costs, and delivering boats ahead of schedule, Goggins said.
At least six Virginia Class Submarines have been delivered ahead of schedule, Navy officials said.
The program's current two-boats per year production schedule, for $4 billion dollars, can be traced back to a 2005 challenge issued by then Chief of Naval Operations Adm. Mike Mullen. As mentioned, deliberations are already underway to consider stepping up this production schedule.
Mullen challenged the program to reduce production costs by 20-percent, saying that would allow the Navy to build two VCS-per year. This amounted to lowering the per-boat price of the submarines by as much as $400 million dollars each.
This was accomplished through a number of efforts, including an effort called "capital" investments wherein the Navy partnered with industry to invest in ship-building methods and technologies aimed at lowering production costs.
Other cost-reducing factors were multi-year contract awards, efforts to streamline production and work to reduce operations and sustainment, or O&S costs, Navy officials explained.
The U.S. Navy is working to adjust the documentation paperwork regarding the size of its fleet of Virginia Class Submarines, changing the ultimate fleet size from 30 to about 51 ships, service officials have said.