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Steel in, ships out: ANI reinforces Australia’s future shipbuilding capabilities

ANI reinforces Australia’s future shipbuilding capabilities

Strong, sustainable, and innovative. The words that describe the Australian Government’s vision for the country’s naval industry. In 2016, the island nation published the 2016 Defense White Paper, which laid the framework for the largest expansion of the Royal Australian Navy since the Second World War.

 

The entire investment in the maritime domain is estimated to total approximately $75 billion AUD (Force Structure Plan, 2016). The large-scale initiative has already contributed directly to the nation’s workforce growth but also brought economic and strategic advantages.

To fulfill the commitment and regenerate the nation’s naval industry, in 2017, the Australian Government established a government business enterprise, Australian Naval Infrastructure (ANI).

“ANI’s primary function is to be the owner, developer, and manager of the infrastructure and related facilities. Our motto ‘steel in, ships out’ encapsulates the strategy of the shipyard and is used nationwide.”, tells Phil Cornish, the Project Director of Australian Naval Infrastructure.

As a part of the program, ANI was requested to develop the Osborne Naval Shipyard to support the Australian Government’s ‘Continuous Naval Shipbuilding Plan’. This envisaged the delivery of naval combatants, up to 10000 t destroyer size vessels, in a 2-year drumbeat.

The key objective of this investment was to create an end-to-end shipyard capability.  The solution provider was selected based on the capabilities to provide leading-edge capabilities.

Among the key enablers

In its Naval Shipbuilding Plan, the Australian Government had listed the development of modern, innovative, and secure shipyard infrastructure as one of the key enablers to achieving the naval shipbuilding objectives. The total investment to develop future shipbuilding capabilities were more than $500 million AUD in total.

“The key objective of this investment was to create an end-to-end shipyard capability. Before the Osborne Shipyard used to be a consolidation shipyard, so it was relying on components coming from other locations in Australia or internationally”, Cornish continues.

To follow the “steel in, ships out” motto and make a shift from a consolidation shipyard to having leading-edge shipbuilding capabilities, the search for an equipment provider started. The solution provider was expected to be capable of providing leading-edge machinery and supporting the Government’s objectives. According to Cornish, a tight tendering process was completed after which Pemamek was selected as the partner due to its high expertise in shipbuilding automation and production technology.

Cornish continues: “Ultimately, Pemamek was selected as the key subcontract partner to our Managing Partner, Lendlease. The company was able to introduce new processes for future naval shipbuilding with a focus on high levels of accuracy, reliability, and automation. These were not previously available at Osborne.”

Pemamek's delivery included high-tech shipbuilding automation such as robotized block and curve panel welding stations.

Our motto ‘steel in, ships out’ encapsulates the strategy of the shipyard and is used nationwide.

Phil Cornish, the Project Director of Australian Naval Infrastructure

Forefront of shipbuilding

One of the extensive upgrading initiatives in the country’s maritime domain involves the Hunter Class Frigate program, among others.

“Current activities in the Osborne Naval Shipyard, since the completion of upgrade works in mid-2020, have focused on the progression of the Hunter Class Frigate Program ‘prototype’ phase works. This program is done in collaboration with BAE Systems Maritime Australia. The first of the nine Hunter Class Frigates is scheduled to commence production from 2023”, says Cornish.

Pemamek’s extensive welding and production automation delivery included a vast amount of high-end shipbuilding technology, such as advanced PEMA flat panel and micro panel lines, PEMA T-beam manufacturing line, PEMA profile processing line, and robotized block welding stations, as well as plate milling technology.

“Additionally, I want to bring up the importance of being able to use the network creatively and collaborate with industry partners. Pemamek does this successfully, as an example with HGG, which we are pleased to see”, Cornish comments.

The highly innovative welding and production automation solutions were designed to enable efficient and high-quality ship hull fabrication. Furthermore, the solutions support the Australian Government’s objectives to have modern manufacturing technology and state-of-the-art shipbuilding infrastructure at Osborne’s shipyard.

“In terms of commissioning, we were pretty much locked in with what we can do. Pemamek was able to cover over multiple pieces of equipment, such as the one-side welding station, but also T-profile and T-cutting lines which provided us a better outcome and helped us to advance our layout”, Cornish says.

Modern shipbuilding process focuses on bringing high levels of accuracy, reliability, and automation to naval shipbuilding.

Big smile

By looking at the map, one can notice that geographically Finland and Australia are not just a stone’s throw away from each other, and the time difference is 7,5 hours. Furthermore, the collaboration was colored by the global pandemic. Nevertheless, questions and challenges were addressed together in varied ways, such as detailed design interface management and open communication across all parties.

“Regular executive-level engagement and discussions occurred between ANI, Lendlease, and Pemamek to support the project teams, both in Finland and Australia. The Shipyard design team at OMT from Denmark also assisted in providing attendance and support at this level”, Cornish adds.

At the Osborne shipyard, PEMA shipbuilding solutions have raised the level of automation and brought the expected production capabilities for element and unit fabrication.

Cornish continues: “PEMA has played the main role in providing shipbuilding technology and capability, and the high level of automation. The most important achievements are accuracy, reliability, and control of distortion in handling and fabricating steel elements.”

Now, welding automation is available to the shipbuilders at Osborne and maximizes production capabilities. According to Cornish, the shipbuilders are seemingly pleased with modern equipment: “Shipbuilders are impressed with the equipment capabilities under training and familiarization activities, leading into the Hunter Class Frigate Program ‘prototype’ phase works. They have a big smile on their face.”

Finally, Cornish gives some tips to other customers who consider investing in PEMA shipbuilding automation.

“Integrating key equipment providers to the infrastructure works, such as the shipyard design at an earlier timeframe is important to gain the greatest benefit from efficiencies and spatial outcomes. Pemamek supports the infrastructure design process for foundations and superstructure elements of the shipyard”, Cornish summarizes.

Ani Naval shipyard

Pemamek's delivery included several high-tech solutions, such as a fully robotized micro panel line.

The most important achievements are accuracy, reliability, and control of distortion in handling and fabricating steel elements.

Phil Cornish, the Project Director of Australian Naval Infrastructure

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