CHAPTER 6

INDIGENOUS WARSHIP DESIGN

PREAMBLE

    In the post independance Indian Navy, ship design made a modest beginning in 1962 with the setting up of a small Design Cell within the Directorate of Naval Construction (DNC). By 1965, this cell had expanded to become the DNC's "Central Design Organisation (CDO)".

Mr Parmanandan recalls:-

By 1968, this Design Organisation had successfully designed and handed over to the Navy numerous auxiliary vessels: 200 ton water boat AMBUDA (1966), 500 HP Tug BALSHIL (1966), Hopper Barges SEVAK and SAHAYAK (1967), Bucket Dredger NIKARAKSHA (1967), and Victualling Barges PANKAJ and AMRIT (1967/68).

Under construction were Landing Craft Utility (LCU's Mk1), an Ocean Going Tug (GAJ), Avcat Tankers (PURAK and POSHAK), HSD Tankers, 150 men Ferry Craft, Harbour Cargo Boats and diverse types of pontoons.

At the design stage were Oilers, Tugs, Ammunition and Water Barges and Diving and Water Boats. In 1966, the Design Organisation had also assisted in the construction of the new Fleet Tanker DEEPAK in Germany.

A list of Naval Yardcraft and by whom they were built during the period 1966 to 1975 is given in the table at the end of this chapter.

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THE START OF MAJOR WARSHIP DESIGN

On 23rd October 1968, the Prime Minister, Mrs.Indira Gandhi, launched INS NILGIRI, the first of the Leander class frigates built at Mazagon Docks in Bombay. Having herself laid the keel in October 1966, Mrs Gandhi seems to have intuitively sensed the very long gestation time of naval construction. On her return to Delhi, the Prime Minister directed that urgent consideration be given to strengthen the Naval Design Office to work out the designs of future naval construction like frigates, submarines and smaller fast craft, suggested that all forms of future marine propulsion be considered, including nuclear propulsion, and stressed the need for both the ship designers and the ship builders to coordinate closely and in good time. This remarkable perspicacity of the Prime Minister was to prove momentous in the ensuing Defence Plan.

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BUILDING UP THE CADRE OF NAVAL CONSTRUCTOR OFFICERS

Captain Lohana recalls:-

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STRENGTHENING OF THE DESIGN ORGANISATION

A major objective of the 1969-74 Defence Plan was self reliance in the field of warship design and warship production. The aim was to meet the Navy's requirements through indigenous efforts and conserve foreign exchange. Accordingly the indigenous construction of frigates, patrol craft, submarines, minor war vessels and auxiliaries had been accepted in this plan.

In 1969, Naval Headquarters proposed to Government that a full fledged Directorate of Naval Design (DND) be sanctioned. At that stage, the Navy did not have either adequate design experience or capability. There was also an acute shortage of technical officers. Naval Headquarters had envisaged induction of foreign designers on loan, with assurance of back up from their parent organisations. However, negotiations with the UK for the deputation of such designers did not bear fruit.

Meanwhile, soon after the start of the Leander construction programme, a choice had to be made whether the second and subsequent Leanders were to be identical to the first Leander (the advantage being standardisation and the disadvantage being obsolescence) or whether design changes should be effected from the second Leander onwards to enhance combat capability. It was decided that indigenous frigates should, as far as possible, have the latest equipment.

In 1970, the Directorate of Naval Design (DND) was approved. It started off with the design for new classes of Seaward Defence Boats (SDBs MK2), Survey Vessels, and a Landing Ship Tank (LST). The most noteworthy feature of the DND was that it was conceived and created as an integral part of the Navy, thereby enabling close interaction at all levels, while functioning under the scrutiny of the Naval Staff.

In 1973, a team of designers from the Soviet Union were invited to visit India to suggest an organisation to design frigates and submarines. They quantified a requirement of over 170 qualified designers each for tackling the design of the new frigate and the design of the new submarine. These requirements of manpower were just not implementable within available resources. The Naval Staff therefore accepted the revision of the staff requirements and approved a modified Leander hull with a different weapon package, instead of insisting on an altogether new frigate design. This decision was to result in the GODAVARI class frigates of Project 16, which retained all the indigenous propulsion machinery and other equipment already developed for the six earlier Leanders.

In early 1975, the Design Organisation commenced conceptual design work on Project 16. By end 1975, the Naval Staff and the Government accepted the design. Detailed drawing and design work started in 1976.

The Petya class submarine chasers had been acquired from the Soviet Union in the mid 1960's. They would therefore need replacement in the mid 1980's. Naval Headquarters decided that their replacement would be indigenously designed and constructed as "Corvettes" for the defence of the island territories and off shore oil rigs. In 1975, design work commenced on ships of the Corvette Project, which eventually culminated in the commissioning of the KHUKRI class corvettes of Project 25.

Throughout the decade 1965 to 1975, the non availability of sanctioned manpower constrained the balanced growth of the Design Organisation. The shortage of service officers was particularly acute. In retrospect, the successful achievements in warship design during this period can be attributed to two factors:

Shri Parmanandan was awarded the PADMASHRI in 1970 in recognition of "his eminence as the leading naval architect in the country and his dynamism, dedication and drive in building up the capability of his organisation".

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THE CHALLENGES POSED IN WARSHIP DESIGN

Warship design and construction comprise five main stages:-

- The first stage is the Formulation of Preliminary Staff Requirements by the Naval Staff. These are the requirements that the ship will be required to meet, based on the evaluation of future threats and the ships' role. These are first conceived as staff targets, which form the basis of the dialogue between the Naval Staff and the designers to establish that what is demanded is technically feasible and conversely, that what is technically feasible will meet the staff aspirations. A number of feasibility studies are carried out. Eventually the Preliminary Staff Requirements are generated which spell out the role of the ship, its weapons, sensors and the other major equipment which the ship is required to carry. In addition, important parameters like speed, endurance, type of propulsion, restrictions on dimensions and complement are indicated.

- The second stage is of Concept Design, which is the first interpretation of the preliminary staff requirements. During this stage, a number of design options are explored and developed up to a stage which enables comparative evaluation. The design proceeds on the basis of inputs from similar past ships, empirical relations, past experience and the designer's judgment. The process is essentially iterative. At the end of Concept Design, the most promising of the options are compared and the one likely to best meet the staff requirements is chosen for further development, in consultation with the Naval Staff.

- The third stage is of Preliminary Design. Various aspects and parameters, provisionally determined during the concept design stage, are investigated in detail. Design proceeds along a converging spiral form, investigating various aspects of dimensions, weights, volumes, stability, speed and powering, until an acceptable compromise of all the important and often conflicting parameters is achieved. All design calculations are prepared during this stage. System schematics are generated to facilitate weight, volume, flotation and stability calculations. At the end of Preliminary Design, a presentation is made to the Naval Staff, indicating aspects/areas in which the design may entail a compromise in Staff Requirements. After the Naval Staff approve the preliminary design, the preliminary staff requirements, as modified, are promulgated as the final or frozen Staff Requirements.

- The fourth stage is of Detailed Design. Hydrodynamic model tests are carried out at the beginning of the Detailed Design stage. These validate the predictions made through the analytical processes. Shortcomings emerging out of the results of model tests are rectified by modifying the design features. During this stage, special studies are undertaken in the critical design areas. Detailed structural drawings, system details, layout and composite drawings are prepared. Comprehensive specifications are written out. A dialogue is then initiated with the ship builder and the detailed specifications and drawings are made available to him.

- For a typical warship project, nearly 2000 drawings, some running into several sheets, and over 15 volumes of specifications of nearly 2000 pages, are required to be generated and over 1000 guidance drawings supplied to the ship builder. In turn, the shipyard generates over 1500 drawings for submission to the designers for approval. These then form the basis for the shipyard to prepare its working drawings, which would number several thousands.

- The fifth stage is of Construction. On the basis of inputs from the designer, the shipyard orders long lead items and materials and proceeds with activities preparatory to commencing production in the workshops. These includes faring of lines, preparation of workshop drawings and assembly of jigs and fixtures. To minimise the overall period of design and construction, the activities are telescoped and shipbuilding functions are commenced in the latter half of the detailed design phase. Throughout the construction stage, a continuous flow of drawings and information has to be maintained between the designers and the shipyard.

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PROJECT 16 GODAVARI CLASS FRIGATES

The lessons learnt in the 1971 Indo Pakistan War, the detailed discussions with Russia for the next series of Russian acquisitions and the progress made in the development of indigenous systems made it possible for the Naval Staff to consider major improvements in the combat capability of frigates. The Directorate of Combat Policy and Tactics suggested that the entire missile and gun package of the Soviet Nanuchka class missile corvette be installed in the frigates which would follow the VINDHYAGIRI, together with two Seaking anti submarine helicopters, the latest Indian APSOH Sonar, a mix of Soviet and Indian radars and Italian CAIO and EW systems. The Directorate of Marine Engineering suggested that steam propulsion be replaced by gas turbine propulsion.

The Naval Headquarters Technical Team which visited Canada in 1974 saw the Canadian 4100 ton Destroyer DDH - 280 which had two Seakings embarked. Naval Headquarters decided to try and embark two Seakings in the smaller Leander hull.

The Design Directorate was headed by Shri S Parmanandan. The new frigate design was entrusted to a project team headed by Commander (later Captain) NS Mohan Ram, a Naval architect, trained in the United Kingdom and who had worked in the Royal Navy's Leander Design Section. Organisational capability had to be built up concurrently with the design, as there were not enough trained draughtsmen or junior designers. Expertise too had to be developed in-house.

In recognition of this achievement, Commander Mohan Ram was awarded the Vishist Seva Medal.

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PROJECT 25 KHUKRI CLASS CORVETTES

In the mid 1960's, Government had accepted in principle the Navy's requirements for 500 ton patrol craft. In subsequent years, various options were considered - building them in Bombay in the Gun Carriage Basin near INS Kunjali, building them in the new Naval Dockyard at Visakhapatnam etc. By the early 1970's, two schools of thought had emerged. One view was that with the cost of ships steadily increasing, the Navy had no option but to go in for small, fast, missile armed corvettes. The other view was that in view of foreseeable threats, all the staff requirements could not be met in a 500 ton patrol craft. The outcome was that the 500 ton patrol craft got renamed as the Corvette Project, to be built in two versions - anti aircraft and anti submarine. International tenders were called for and various weapon packages were considered. Eventually, in 1973 the project was dropped because of the serious shortage of foreign exchange. NHQ then decided that the corvettes would be designed and built indigenously.

Mr Parmanandan, the Director General of Naval Design at that time, recalls:-

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WARSHIP MODIFICATIONS UNDERTAKEN 1965 TO 1975

Major modifications designed and implemented between 1965 and 1975 were:

Fitment of Surface to Surface Missiles in TALWAR and TRISHUL

In 1973, the Naval Staff commenced a study on the half life modernisation of the two Type 12 British frigates, TALWAR and TRISHUL, which had by then completed over 11 years in service. In view of the proven efficacy of the Soviet surface to surface missiles in the 1971 war, the Naval staff directed that the feasibility be examined of lifting a complete surface to surface missile system from a non operational Soviet missile boat and fit it on board TALWAR. Concurrently, it was decided to fir a modern electronic warfare system which would help in identifying enemy warships from their radar transmissions at ranges compatible with the range of the missiles.

Mr Parmanandan then the DGND, recalls:-

Conversion of BRAHMAPUTRA, BEAS and BETWA for Cadets Training.

With the starting up of the Naval Academy in 1971 to increase officer intake, it became necessary to increase the capacity afloat for training cadets and midshipmen at sea. The cruiser DELHI was converted to undertake the sea training of midshipmen. Thereafter the three Type41 frigates which had joined the fleet in 1958, 1959 and 1960 were converted in the 1970's for undertaking the sea training of cadets.

Phase One Modernisation of VIKRANT.

After the 1971 war, VIKRANT needed a long refit to replace her cracked boilers. Since this was expected to be a long refit of about three years, it was decided to concurrently undertake as much modernisation of weapons, sensors and AIO as possible.

"The second thing we spent a lot of money and a lot of time on was that a lot of DC/AC alternators were put on board Vikrant to create a larger AC power capacity for dedicated services. There was a proposal to fit Bofors guns and a new type of laser sensor for anti missile defence. I do not know whether it ended up as a success or not. The initial proposal was to fit the Soviet 30 mm gun mountings in lieu of the hand operated Bofors. If we had gone firm on that, probably we would have achieved it at a much lesser cost and much quicker. While the Soviet weapon systems had their own deficiencies, they had the advantage that it suited our culture and way of working and maintainability. Each 30 mm mounting had its own dedicated radar and its own display which made it autonomous for operation. So if one mounting did not work, at least the other one would be available. That philosophy was not accepted half way through. And when they changed over to the new weapon system, our Directorate was not any further involved.

During this phase of modernisation, VIKRANT was fitted out with:

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INDIGENOUS WARSHIP DESIGN IN RETROSPECT

As in the case of the Leander Frigate Project, the Navy's achievements in Indigenous Warship Design were astounding. The transfer of talented young officers between the Frigate Project and the Design Organisation generated enormous synergy. Soviet warship designers and the Soviet weapon system supply organisations were generous and unstinting in their help. The exchange of detailed information in the 1970's regarding the new Soviet acquisitions enabled weapon planners in the Naval Staff to suggest cost effective staff requirements which would achieve the much mished for standardisation of systems and economies in weapon inventories. The confidence built up in Mazagon Docks during the Frigate Project helped to build the ships which earned much praise from the Navies of the world.

INDIGENOUS NAVAL YARD CRAFT BUILT BETWEEN 1966 AND 1975

Sl.No. Name Type Commissioning Ship Date Builders
1. AMBUDA Water Barge 31-3-66 GRSE Calcutta
2. BALSHIL Tug 30-8-66 -do-
3. AMRIT Victualling Barge 23-5-67 Peoples Engineering works Calcutta
4. PANKAJ -do- 23-5-68 -do-
5. SAHAYAK Hopper Barge 31-12-67 GRSE Calcutta
6. SEVAK -do- 31-12-67 -do-
7. NIRAJ All weather 20-7-67 AFCO Bombay boat
8 NIKARAKSHA Bucket Dredger March 67 MDL Bombay
9. PURAK Avcat Tanker 05-6-70 -do-
10. POSHAK -do- 03-7-70 -do-
11.      - Boat Pontoon 20-5-70 Andrew Yule Calcutta
12.      - -do- 20-5-70 -do-
13.      - -do- 20-5-70 -do-
14.     - Berthing Pontoon 16-5-70 CIWTC Calcutta
15.     - -do- 16-5-70 -do-
16. LSA-1 100 ton Barge 24-7-70 Alcock Ashdown Calcutta
17. LSA-2 -do- 07-8-70 -do-
18. LSA-3 -do- 21-8-70 -do-
19. ANGAD Tug 03-3-74 MDL Bombay
20. AJRAL -do- 30-10-94 -do-
21. ANJAN -do- 16-11-73 -do-
22. ANUP -do- 29-6-74 -do-
23. ATHAK -do- 30-10-74 -do-
24. KHADAN Grab Dredger 30-4-75 -do-
25. KICHODHARA BucketDredger 01-5-75 -do-

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