Lockheed Martin Santa Cruz Facility
Ordnance System Design, Manufacture and Test
Lockheed Martin
Space Systems Company
Santa Cruz Facility
16020 Empire Grade Road
Santa Cruz, CA 95060
K8149
831-425-6262
scf.fbm@lmco.com
www.lockheedmartin.com
© 2008 Lockheed Martin Corporation
Ensuring Reliability for Key
National Programs
In the development and
performance of rocket and missile programs,
there is little
room for error.
The ordnance
components
built and tested
by Lockheed
Martin’s Santa
Cruz, Calif., Facility must work
the first time, every time.
Since 1957, the Santa Cruz
Facility has delivered vital support
to important U.S. government
programs such as Peacekeeper
and the space shuttle, and today
supports programs such as the
U.S. Navy’s Trident II D5 Fleet
Ballistic Missile (FBM) and the
U.S. Missile Defense Agency’s
Terminal High Altitude Area
Defense (THAAD) system.
In its role as FBM prime
contractor, Lockheed Martin
uses the facility as the primary
site for manufacture and environmental, safety and functional testing of FBM ordnance
devices and materials. Carried
by strategic submarines, the D5
missile uses these devices during
flight to ignite rocket motors
and gas generators and separate
missile stages and components.
From a remote corner of
California’s San Francisco Bay
Area, the facility has supported
the D5 and five earlier generations of FBM while maintaining an outstanding safety and
performance record, thanks to
a skilled government-industry
partnership. Since 1989, a string
of more than 120 successful D5
missile test launches by the U.S.
and United Kingdom navies has
demonstrated the contributions
of the Santa Cruz Facility to the
reliability of the FBM program.
Conducted at the
Santa Cruz Facility
in late 2004, a “Short
Hot Launch” test for
the THAAD system
helped demonstrate
the program’s readiness for flight testing.
First deployed in 1990, the D5 missile is the
principal armament of 14 Trident Ohio-class submarines and four United Kingdom Vanguard-class
submarines. The three-stage, solid-propellant,
inertial-guided D5 can travel a nominal range of
4,000 nautical miles and carries independently
targeted reentry vehicles.
On the cover:
Lockheed Martin staff at the Santa Cruz, Calif., Facility conducts
a full system test of the Post Boost Control System. This system,
which consists of two pairs of solid-propellant gas generators and
four integrated valve assemblies, maneuvers the U.S. Navy’s Trident
II D5 Fleet Ballistic Missile following the separation of all three
boost-motor stages.
DigitalGlobe
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The Santa Cruz Facility Team
Safe and Reliable Space
and Missile Systems
Ordnance devices and materials, including propellants, are
used on launch vehicles and ballistic missiles to separate stages or
create thrust. Building and testing these devices safely requires
an exceptionally skilled workforce
with an unwavering focus on
meeting performance requirements as well as environmental,
safety and health regulations.
The Santa Cruz Facility
team’s extensive experience in
ordnance and propulsion testing
ranges from the stresses of shock
and vibration to a variety of
thermal environments.
The team of more
than 80 ordnance specialists
includes electrical and mechanical
engineers, physicists, chemists,
energetics experts and technicians.
These specialists design,
develop, manufacture and test a
range of ordnance devices. In
addition to missile stage separators and rocket motor igniters,
the team tests devices for the
Navy’s D5 missile test launch
program. These include flight
termination systems, which
can destroy missiles in flight
to ensure range safety.
State-of-the-art techniques
and equipment include
environmental generators,
high- and low-speed photo
instrumentation, radiographic inspection, leak
detection, metrology, and
chemical and physical
properties determination.
A Line-of-Sight
Stabilization test demonstrates that the seeker for
the Terminal High Altitude
Area Defense System can
stabilize on a fixed point
while the missile’s divert
and attitude control
thrusters are firing.
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Fleet Ballistic Missile
Program
One of the key programs supported by the Santa Cruz Facility
is the Navy’s FBM program. At
the facility, Lockheed Martin
performs FBM work under the
direction of U.S. Navy personnel
from the Program Management
Office, Strategic Systems
Programs Flight Systems, which is
based about35 miles away in
Sunnyvale, Calif. The facility
reports to the company’s FBM
program office, also located in
Sunnyvale, and has access to scientists and engineers at Lockheed
Martin’s Advanced Technology
Center in Palo Alto, Calif.
Altogether, more than 2,600
Lockheed Martin employees in
California, Washington, Georgia,
Florida, Utah, Virginia, and the
United Kingdom serve every
aspect of the FBM program, from
design, development and production to testing and operation.
At all sites, the Navy–Lockheed
Martin team conducts business
according to a set of shared values,
principles and tools proven over
five decades. The FBM approach
includes (1) common priorities and
goals, (2) open and trusted communications—surfacing problems
early and solving them together, (3)
a focus on time-tested solutions, (4)
disciplined technical and business
management controls, and (5) commitment to maintaining a skilled
FBM workforce.
Electro-Optical
Sensing
In addition to ordnance work,
the Santa Cruz Facility serves as a
field test site for active and passive
electro-optical sensing. In this role,
the team supports work on directed
energy/laser research, missile-defense
target sensing and discrimination,
NASA spectroscopy missions, and
space-based communications, intelligence, surveillance, reconnaissance,
and situational awareness.
Strategic Systems Programs Flight Systems
The Program Management Office, Strategic
Systems Programs (PMOSSP) Flight Systems, is the
Navy command that directs and provides technical
oversight to Lockheed Martin and subcontractors to
ensure successful manufacture and test of the Trident
II D5 missile system. PMOSSP Flight Systems also is
responsible for the missile guidance system and for
management of other subsystem prime contractors.
Responsibilities of this command include engineering, design and configuration management, guidance, support equipment, documentation, logistics
and program planning. For more than 50 years,
PMOSSP and Lockheed Martin have conducted a
highly successful partnership to develop increasingly
capable and reliable submarine-launched ballistic missiles. Current objectives of this partnership include the
D5 Life Extension program, which will ensure Trident
D5 missiles will be available for the lifetime of the
Trident submarine fleet, until 2042, and converting
selected Trident submarines to platforms for launching
conventional Tomahawk cruise missiles.
PMOSSP Flight Systems reports to the Strategic
Systems Program (SSP), headquartered in Washington,
D.C. In 2001 Flight Systems received the first Raborn
award, signifying overall command excellence.
It received Navy Unit
Commendations in
1979 and 1990,
respectively, for
successful
development
of the Trident
I C4 missile
and the Trident
II D5 missile.
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Achieving Ignition, Separation and Destruct
Ordnance Events for the Trident II D5 Missile
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Ignition of Thrust Vector Control (TVC) subsystem, 1st stage
Rocket motor ignition, 1st stage
Ignition of TVC subsystem, 2nd stage
1st stage separation
Rocket motor ignition, 2nd stage
Separation and jettison of nose fairing
Ignition of TVC subsystem, 3rd stage
2nd stage separation and 3rd stage rocket motor ignition
Ignition of Post Boost Control System (PBCS)
3rd stage separation and eject motor ignition
Payload (reentry body) release
Destruct events (for test missiles only):
1st stage
2nd stage
3rd stage
PBCS stage
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TBI
LOS Harness
LOS Harness
HVD
TBI
FLSC
LOS Harness
FLSC
SLSC
SLSC
HVD
LOS Harness
LOS Harness
Essential to performance of the three-stage
Trident II D5 missile is a subsystem of small ordnance devices that (1) ignite rocket motors and gas
generators, (2) separate stages and (3) disable missiles in the event of a flight test malfunction. The
conventional explosive charges used for missile
destruct, the Post Boost Control System (PBCS)
destruct assemblies and Flexible Linear Shaped
Charges (FLSC), are armed only in missiles used
for test flights.
A typical ordnance sequence begins with
activation of High-Voltage Detonators (HDV).
The energy from these devices travels through
Aerospike Inertial
Initiator
Separation Charge
Explosive Separation Nuts
Thrusters
FLSC
TBI
HVD
HVD
LOS Harness
FLSC
TBI
HVD
LOS Harness
Ordnance Device Color Key
Ignition / Separation / Destruct
Linear Ordnance System (LOS) harnesses to
specific locations throughout the missile. Throughbulkhead initiators transmit this energy to ignite
rocket motors and gas generators. The gas generators activate the thrust vector control systems that
tilt rocket motor nozzles as needed during flight.
The LOS also transmits the energy to ignite
Separation Linear Shaped Charges (SLSC) for
the separation of stages.
HVD
TBI
SLSC
PBCS Destruct
Facility Capabilities for Defense Systems
At the Santa Cruz Facility, Lockheed Martin offers a range of design, manufacturing,
test and support services for defense systems and components.
Design
• Ordnance Systems
• Separation Systems
• Flight Termination Systems
• Energy Transfer Systems
Manufacture
• Linear Ordnance System (LOS)
Harnesses
• Through-Bulkhead Initiators (TBI)
• Post Boost Control System (PBCS)
Destruct Assemblies
• Igniters
• Detonating Cords
• Transfer Lines
• Crossover Blocks
• Union Blocks
Testing
• Erosional – exposure to erosive effects of propellant combustion
• Vulnerability – exposure to structural loads and hydrodynamics
• Environmental – exposure to extreme temperature and humidity
conditions
• Cryogenic – exposure to cold temperatures
• Shock and Vibration – exposure to the rigors of launch and
other stresses
• Over-the-Air Test Range – long- and short-range transmit
and receive
Support services
• Planning – preparing test plans, schedules, specifications and
related test documentation
• Design – designing test setups
• Procurement – procuring test materials as needed
• Machining – fabricating special test equipment as needed
• Instrumentation – equipping test stands so that useful data
can be collected
• High-Speed Photography – capturing rapid events for later analysis
• Chemical Analysis – determining chemical changes that occur
during testing
• Measurement/Metrology – ensuring accurate and precise
measurement of test results
• Failure Diagnosis – analyzing test anomalies
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A Commitment to Community
Lockheed Martin is committed to being a good
neighbor. In the coastal mountain setting of the
Santa Cruz Facility, we are attentive to the need for
rigorous
safety precautions and
for stringent
measures to
preserve the
surrounding
mountain
environment.
In the history of the
facility, no
major chemical spills or improper release of materials have ever
occurred, and our compliance with environmental,
safety and health regulations is validated annually
by county, state, federal and corporate auditors.
We have a manufacturing license from the U.S.
Department of Alcohol, Tobacco and Firearms, and
we are compliant with the U.S. Navy’s ordnance
safety requirements.
Hazardous
materials stored
at the facility
are transported
according to strict
U.S. Department
of Transportation
guidelines. When these materials are no longer
needed, we use state-approved hazardous waste
transporters to transfer them to Environmental
Protection Agency–approved storage, treatment and
disposal sites.
As an additional safety measure, we maintain a
trained emergency response team on site that coordinates with the local Bonny Doon Fire Team, and
we have a longstanding relationship with the
California Department of Forestry.
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In addition to looking out for our mountain
environment, we support outreach and cultural
activities in nearby communities. Our employees,
many of whom live near the facility, volunteer in
local schools and contribute their time and resources
to non-profit organizations. Lockheed Martin also
contributes to local community resources including
festivals, museums and environmental groups.
An Unwavering Focus on Safety
At the Santa Cruz Facility, safety is at
the forefront of every process, every decision.
Occupying 4,000 acres, the facility has been
carefully designed for manufacturing and test
safety, including special equipment and protocols
and adequate distances for the safe handling
of ordnance.
Propellant materials are stored in small quantities and handled according to strict step-by-step
procedures. Typical maximum working quantities
of propellant are 10 grams or less; most test
subjects contain just milligrams of propellant.
Lockheed Martin takes great pride in our
safety record at the Santa Cruz Facility: 30,000plus test sequences conducted during more than
2 million hours of propellant and
ordnance testing without loss
of life or catastrophic test
incident in 50 years
of operation.
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Proven Partnership
For nearly five decades, the United States’ strategic deterrent capability
has depended on the quality of work conducted at the Santa Cruz
Facility and other Lockheed Martin facilities throughout the United
States. Our continuing goal: partner with the U.S. and U.K. navies
to ensure the safety, readiness and reliability of the Fleet Ballistic
Missile program.