Yes Minister! REME team forges ahead with 1000mph car project

Major Oli Morgan is the Team Leader for the Army’s involvement in the Bloodhound Super Sonic Car project.  As an Aircraft Engineering Officer in the Royal Electrical & Mechanical Engineers, his technical background on Apache is used to good effect to provide the Bloodhound team with technical advice on Engineering Assurance. In addition to his engineering role he is also responsible for recruiting each 6 month attachment of personnel and managing the team on a day to day basis.

Defence Minister visits

It was great to see the Minister for Defence Equipment Support and Technology last week at the Bloodhound SSC Technical Centre in Bristol. Philip Dunne MP visited the Army Team from the Royal Electrical and Mechanical Engineers (REME) working on Bloodhound SSC to see what we had been doing since we saw him at the signing of the MoD-Bloodhound Concordat in Oct 2012.

Minister was impressed how we had integrated into the civilian team building the 1000 mph car and the ground breaking work the guys had been doing. I took the Minister around the workshop to allow each of the REME team to explain their role and what they had achieved during their attachment, which is fast coming to an end in March 13 (Details of the new team coming soon).

Left to Right: Philip Dunne MP, Cfn Rob Fenn, WO2 (AQMS) Mark Edwin, Maj Oli Morgan. Image by Stefan Marjoram

Craftsman Rob Fenn, our most junior tradesman (his rank is equivalent to Private Soldier), showed Philip Dunne MP the work that been done on the Super Sonic car’s lower chassis. Cfn Fenn has been part of a small group building this section of the car and he has also had the opportunity to work with Lee Giles, a very experienced mechanic formerly at McLaren R&D. The Minister was impressed by how much exposure Cfn Fenn had to wider engineering and his goal to work towards a Degree in Automotive Engineering.

Cfn Rob Fenn working with Lee Giles. Image by Stefan Marjoram

Bloodhound Team working on the rear lower chassis at the Bristol Technical Centre. Image by Stefan Marjoram

As a footnote to Cfn Rob Fenn’s role on the project, I must put his experience into perspective – he is 20 years old and has recently completed his apprenticeship after completing training at the Army’s School of Electrical and Mechanical Engineering. He was selected as an outstanding candidate in the REME interview process and has impressed Bloodhound’s F1 engineers and designers with his work ethic, willingness to muck in and drive to expand his knowledge. This knowledge transfer – in essence rocket powered professional development – is one of the key benefits of the MOD’s Concordat with Bloodhound. It will create a lasting legacy in each REME soldier’s career and have a positive impact on the Army’s ability to support equipment maintenance and repair, especially on Operations.

Origins of the Ministry’s Concordat with Bloodhound

The origins of the MOD Concordat go back to last year at a chance meeting between Peter Luff MP, then Minister for Defence Equipment Support and Technology, and Richard Noble. The meeting at DE&S’s Defence Vehicle Demonstration event led to an agreement being proposed that would draw together the various strands of collaborative work that already existed between the MOD and Bloodhound. This would provide a platform for deepening the relationship and express the Department’s and the Minister’s own belief in this ground breaking education project and the benefits that it will return to the Department and the Armed Forces.

Peter Luff MP and Richard Noble. Image by Ashleigh Kane Photography

But nothing in politics is straightforward and before we knew it we had a new Min(DEST). Fortunately, the new Minister, Philip Dunne MP was just as excited about the project and progress on the agreement continued at pace. On 1 October 2012 we were all present in the Officers’ Mess at Wellington Barracks in London to witness the signing of the Concordat by the Minister and Richard Noble amongst a throng of broadcast and newspaper journalists. BFBS TV Report

From Philip Dunne MP: “This is a great opportunity for the Army’s Electrical and Mechanical engineers to share experience and develop their skills whilst working on this innovative technology here in the UK; their experience will feed directly back into the front line as they progress through their Army careers.”

At last week’s visit to Bristol, the Minister got to see an example of REME tradesmen working at the cutting edge of technical development when I handed him over to WO2 (AQMS) Mark Edwin to explain his role developing the primary control system for the developmental EJ200 TYPHOON engines. The control avionics will allow Bloodhound’s driver, Wing Commander Andy Green, to control the engine and get the car up to speed before the rocket kicks in and blasts the car through the sound barrier.

In the next blog I will touch on the work the electronic systems team have been doing with the EJ200 engine and the Minister’s reaction to the news that the WO2 (AQMS) Edwin and the team have built a system to control the engine which has been successfully tested on Rolls Royce’s engine simulator.

First job for REME: Europe’s Largest Hybrid Rocket

Major Oli Morgan is the Team Leader for the Army’s involvement in the Bloodhound SuperSonic Car project.  As an Aircraft Engineering Officer in the Royal Electrical & Mechanical Engineers, his technical background on Apache is used to good effect to provide the Bloodhound team with technical advice on Engineering Assurance. In addition to his engineering role, he is also responsible for recruiting each six-month attachment of personnel and managing the team on a day-to-day basis.

Bloodhound. MOD/Crown copyright – Sgt Adrian Harlen

The interview

While the Bloodhound-Army contract was being developed, I took the decision to start the recruitment process to find the best possible REME candidates to fill four positions working with Bloodhound SSC to build a car capable of 1000 mph . It was essential that this selection be completed as soon as possible as there was a risk that contract negotiations would continue up to the proposed start date on 1 Sep 12.

I spent a long time reflecting on how the interviews should be conducted and who was to be on the interview panel. It was absolutely vital that potential candidates could be assessed by both senior Bloodhound engineers as well as REME officers. Also, to ensure that the process was transparent and fair, a marking scheme/range of competencies had to be agreed between both parties. I was very grateful for the support of Colonel Rod Williams (Army Chief Aircraft Engineer) and Mark Chapman (Bloodhound Chief Engineer) in the design of the interview format, which included trade competencies, team work, integrity and secondary skills.

On a warm day in July 2012 and after a brief tour around Training Schools in Arborfield, the joint Bloodhound-REME panel got down to the business of interviewing tradesmen for four posts on the build team. Thirty outstanding applicants were hosted in historic West Court Officers’ Mess.  Getting the hundred initial applications down to thirty was a real challenge as the standard was incredibly high.

The panel was made up of the Head of Manning (REME Corps Colonel – Ian Gibson), Col Rod Williams and from Bloodhound Mark Chapman plus Chris Dee (Chief Mechanic) and Martyn Davidson (Operations Manager).

The interview questions were designed to assess candidates competencies e.g. “can you give me an example when you demonstrated leading a team?” with particular emphasis on providing the interviewee the best opportunity to explain their key skills and why they felt they should be considered by the team.

Left to right: Chris Dee (Col Ian Gibson out of shot), Martyn Davidson, Mark Chapman, Col Rod Williams, Cfn Rob Fenn.

I was very interested to hear what the Bloodhound team thought of the standard of REME Artificers (Fast track middle management) and our NCOs/tradesmen. They were very impressed by the breadth of interviewees’ experience, particularly in very challenging circumstances and the need to think laterally/creatively when faced with a plethora of technical issues. Also the ability to speak clearly and confidently in what must have been an intimidating experience.

Rocket trials begin

The four tradesmen selected were Avionics Warrant Officer (AQMS) Mark Edwin, Artificer Vehicles SSgt Neil Gallagher, Metalsmith LCpl Graham Sargeant and Vehicle Mechanic Cfn Rob Fenn. I had the honour of calling each of them in turn and listening to the woops and celebrations (and silent dancing) at the other end of a mobile phone!

Cfn Rob Fenn
Credit: Stefan Marjoram

I met up with the team met up for the first time at the start of September 2012 in Colerene to take over accommodation before moving off to the Bloodhound Technical Centre in Bristol for introductory meetings and welcomes. The first of which was a full Bloodhound team engineering meeting with around twenty of us being briefed on the project thus far – Craftsman Rob Fenn looked shocked when Wing Commander Andy Green sat down next to him and introduced himself.After the meeting the REME team were straight into the business of engineering and support to the rocket programme and deployed immediately to Cornwall. The main effort for the Bloodhound team during our very first month was to install the Rocket Trial test facility in Newquay Airport. This meant a busy period of assembly to structurally secure the test rig and its associated parts, including an emergency deluge gantry to soak the entire operation in the event of a leak of High Test Peroxide (HTP).

The rocket trial was held in front of the international press with more than 100,000 people watching online. I can vividly recall the sound of the control centre buzzing with a mix of nervous excitement and expectation before the Cosworth Engine started its run up routine. The noise of the engine alone was incredible – team members suggested turning the speaker sound down to be told the sound was coming from the other HAS and coming through the walls! Then start: Cosworth engine at 16,000 rpm – rocket ignition – the build up of sound and vibration and the ROAR of the hybrid rocket….then the cheers from the crowd!

High class Engineers

The first few months has seen a frantic level of work whilst integrating into a world leading team of engineers. I am pleased to report that the REME team have been well received and we have held our own.

Bloodhound team inspecting the rocket after firing. Credit Stefan Marjoram

Receiving positive feedback from our new colleagues has been immensely humbling and has dispelled any concerns that we may have been out of our depth.  Our technical skills have been put to good use with the opportunity to demonstrate the positive work ethic and initiative displayed by all service personnel.  We have also been grateful for the chance to publicly showcase wider REME capability to the civilian sector who appear eager to recruit high class engineers and managers.

Supersonic project takes off

Major Oli Morgan is the Team Leader for the Army’s involvement in the Bloodhound SuperSonic Car project.  As an Aircraft Engineering Officer in the Royal Electrical & Mechanical Engineers, his technical background on Apache is used to good effect to provide the Bloodhound team with technical advice on Engineering Assurance. In addition to his engineering role, he is also responsible for recruiting each six-month attachment of personnel and managing the team on a day-to-day basis.

Bloodhound SuperSonic Car

Bloodhound SuperSonic Car (SSC) is the name of a UK project aiming to break the land speed record with a car powered by a jet engine and a hybrid rocket motor. The car has a design speed of 1,050 mph (1,609 km/h).

Bloodhound SSC is being developed and built with the intention of breaking the land speed record by the largest ever margin to inspire future generations of schoolchildren into careers in Science, Technology, Engineering and Maths (STEM). Record attempts are aimed for late 2013 (850 mph) and 2014 (1,050 mph) on the Hakskeen Pan in South Africa, with run data being published on the internet for the student population to follow and download.

The Bloodhound SSC project is headed by Richard Noble OBE, former driver of Thrust 2, who broke the land speed record and achieved 633 mph in 1983.  In 1997, RAF Wing Commander Andy Green set the current record at 763 mph in Thrust SSC, and he has joined Richard Noble once more for the Bloodhound Project.

At the end of 2011, Richard Noble approached the Royal Electrical & Mechanical Engineers (REME) to lease technical manpower, workshop equipment and deployable engineering facilities. The proposal was put to Major General Paul Jaques and the REME Corps Colonel and received unanimous support. However, the initiative required careful financial modelling and – more importantly – approval.

Bloodhound Project Director Richard Noble OBE

I was asked to staff the proposal through the Army financial chain along with a case setting out the benefits of involvement before it was sent to the Chief of the General Staff and then to the then Permanent Under Secretary (PUS) Ursula Brennan.

In considering the benefits of the REME’s involvement, I spoke with a wide range of interested parties in recruitment, training, procurement and scientific domains. I knew that the project would provide REME team members with ‘rocket powered’ professional development and benefit the field force by bringing cutting-edge knowledge and expertise back into the Army. The benefits, however, went much further…

The potential for Army Electrical and Mechanical engineers to engage with a young student population was unique. Using technology owned by every family to tell the story of science and engineering, we had the opportunity to inspire young people into STEM careers with the excitement and danger of the land speed record!

This meant that we could support the growth of future British scientists and engineers. Some may join the REME or REME Territorial Army, and others might consider the Civil Service as a potential career path, be it Defence Equipment & Support (DE&S) or the Defence Scientific & Technology Laboratory (DSTL).

Even if those individuals inspired into STEM careers did not consider the Defence sector, they will be able to make a contribution to the wider economy and support growing sectors such as the civil nuclear industry.

Outreach with schools to inspire the next generation of engineers

After an uncomfortable wait, I received the news in May 2012 that the proposal had been agreed by Chief of the General Staff in consultation with PUS and a contract could be written by Army HQ’s Wider Markets team who specialise in requests by industry to lease Army resources. After another round of staffing, contract writing by the commercial staff (an excellent learning experience!) and lengthy negotiation, Army Headquarters signed a contract with Bloodhound SSC to supply technical services and equipment over a two-year period.

All I had to do now was find four REME technical experts for the first six-month work attachment…

The Army’s Royal Electrical and Mechanical Engineers (REME) are amongst the world’s leading engineering and management organisations, supporting cutting-edge equipment and technology in the most challenging environments across the world

Blowing things up

Sapper Bradnam

Sapper Bradnam’s latest blog from the Royal School of Military Engineering looks back at an explosive week!

Demolitions week. Everyone was in high spirits as the demolitions phase has a high reputation for being one of the better aspects of the course. To begin with, however, we had to learn all of the theory and safety relevant to the use of demolitions. Theory varied between learning the names of various components and their uses to learning the exact burning rates of safety fuse. We also had to learn the various different types of explosive charges such as simple slabs of PE4 to shaped charges designed to cut through bridges. It is, however, not very useful knowing what the parts do without being able to set them up, so we spent a considerable amount of time learning how to put together demolitions using dummy equipment including simple initiation sets and a bridge demolition. The bridge demolition practical was my favourite part of the theory side as it was good to step back and see in practice what you had been learning.

Once the theory was complete it was time to use live explosives, with our first venture being into the bull ring, which  is a sand circle in a wooded area used for detonating small initiation sets. Eight  people at a time sets up small charges at regular spacing around the sandy opening. Each had a different burning rate, timed go off one after another. Everyone initiates the set and then, as calmly as possible, walks out in a line back the way they came past the burning fuses. This might not sound much but when you are walking past a fuse which is burning shorter and shorter into a lump of PE4, all you want to do is run. My heart was pounding as I walked past!

With the bull ring completed we came to the most anticipated day of all – Demolitions Day. On this day we all travelled down to Salisbury Plain Training Area for a day of blowing things up. Each section set up different explosive devices. My section made an improvised claymore (which to the shock of some wasn’t little box with a red laser from “Call of Duty”!) We also showed how to effectively cut through objects such as telegraph poles and trees using small amounts of explosive. Other sections showed how to cut through bridge panels and make a shaped charge out of wine bottles and also how to strip reinforced concrete structures. Once everything was set up we moved back to a bunker and watched as we detonated each set in turn. Once the explosions had awed us all we returned to the wreckage to have a look at the devastation we had achieved. I was shocked to see how accurate the use of explosives can be with things such as the bridge panel being cut almost perfectly in two. With all the fun, there was a serious side to the whole day – to give us confidence in handling explosives and also to teach us how dangerous and powerful they are. One thing that really stuck in my mind was when a detonator alone was detonated. It would be enough to cause severe damage! When using detonators we were always told to crimp down the correct end or it would explode and after seeing that I definitely do not want to be crimping the wrong end!

With the Demolitions phase over it was time for the Field Fortifications phase. This module taught us how to build and defend fortifications. This included razor/barbed wire fences, 2 and 4-man battle trenches, low wire entanglements and even down to the basics of filling sandbags and building a wall. It was a short and sharp phase and I really enjoyed it. We built a Super Sangar which is a bit like the cuplock tower from the water purification module, except it has a permanent stairway and a roof. It is used out on operations at the moment and provides good protection whilst providing good fields of view and arcs of fire. I love building structures like this as there is something strangely satisfying looking at a huge scaffold tower that has been erected from scratch in just a couple of hours.

I thought the first 2 weeks went fast but the course is now flying by. Weeks 5 and 6 involve watermanship (driving around in boats) and mine warfare modules, which I cannot wait to do. If the course continues to be like this then I don’t think I am going to want to leave.

A lot harder and more demanding

Sapper Bradnam – formerly Junior Soldier Bradnam – describes the transition from Phase 1 to Phase 2 training, as he begins to learn the trade of a Royal Engineer at the Royal School of Military Engineering (RSME) at Chatham in Kent.

It’s time to begin the next phase of my training as a Royal Engineer. Combat Engineering is the focus of the first part of my Phase 2 training and from day one it was far from what I expected. We arrived on the Sunday to begin training on the Monday, with some more excited than others. Nervous anticipation would be a good way to describe the feeling of starting a new course. However the nervousness rapidly wore off as realisation hit home when the pace of the course was unveiled. From the start we were straight into locker inspections and into the first module of the course – Basic Construction Techniques. To be honest I thought the standards of previous locker inspections were high but this was a whole new level – every single detail of the locker and block was meticulously inspected from the floor upwards and every minute fault found! The standard expected of us now had certainly been raised…

Basic Construction Techniques (BCT) covers various things, from setting up formwork and concreting to learning how to tie basic knots. Every day, new information was fed to us and we were expected to learn very fast. The “best books” [notebooks] that we had were an excellent way of helping us absorb this information. After all the elements of basic construction had been taught, we had our first modular test. There was a theory paper and 3 different practical tests that had to be completed in order to pass. The 3 practical tests included setting out a 2-metre squared formwork, tying basic knots and creating a square lashing, and setting up and using a Makita drill.

Safety on the drill was a main focus, however all the tests were just as difficult. Not everyone passed the test first time – some had re-sit.

Once the basic construction module had been completed the next module we started was Water Supply. This module covered everything that enables us to source, pump, purify and store water. We built a cuplock tower (water tower), set up a small groups water purification unit, NBC purification units and APE (Purification Equipment). Water supply is one of the main roles that Royal Engineers undertake in Afghanistan and it is therefore a very important subject. The module was slightly shorter than BCT however there were a lot of facts and figures that needed to be learnt in order to pass the test. Again the test comprised a theory paper and 3 practical assessments which included using a gilkes pump, using the APE unit and naming component parts from various pieces of equipment.

The pass rate was a lot higher than that of BCT, which I think was down to people understanding the standard required to pass the test and how much work and revision was needed.

On top of all the Combat Engineering we had learnt we also continued to complete physical training, which, in keeping with the rest of the course, is a lot harder and more demanding. In the first week alone we had a personal fitness assessment, military swim test, 4-mile run and a 5-mile loaded march (tab). After 2 weeks of leave this amount of PT was hard work, but everyone pushed on and worked hard and actually did OK on the sessions and tests.

The start of this course has been a real eye-opener into the standards expected in the Royal Engineers and in the rest of the Army. It is a lot harder than Phase 1 and what I expected. That said, I am enjoying rising to the mark and can’t wait to carry on with the rest of the course. Next week is Demolitions week, which has a reputation of being one of the best weeks in the course. I cannot wait!

Building bridges with the ANA

Sergeant Stewart Plummer is an engineer with 21 Engineer Regiment. He is attached to 1 SCOTS for Operation HERRICK 12, running a Combat Engineer Course for Afghan National Army soldiers. Here he writes about teaching Afghans to build bridges.

The third week of the combat engineer course with the ANA engineers is now over, but it actually feels like a lifetime with them already. We have been teaching them non-equipment bridging. Before we could start we had to quickly ensure that they could safely lift the steel beams, so with a quick lesson on manual handling done to our satisfaction we proceeded with the remainder of the teaching.

Building bridges with whatever is to hand

Our first job was to place and fill the Hesco which would form part of the bridge abutments, which to our surprise was done very quickly and to a very high standard. With the Hesco in place the rest of the abutments could be built under the supervision of the instructors. Whilst this was being done the ANA said we weren’t doing it right. When I asked “Why?”  they said it didn’t look exactly like the demonstration bridge next to us. I explained that it wasn’t always going to look the same because it depends on the equipment you can get. I think this satisfied them for the time being.

With the abutments done it was time for them to build the superstructure of the bridge using the ‘I’ beams. We needed to teach them the cantilever method for launching the beams across the gap, which was met with cries of “This is not safe!” from the ANA.

The ANA soldiers had to be convinced this was safe

I pulled the ANA Sergeant Major to one side and explained that we would never teach his soldiers anything that was unsafe, and this was the method I was taught as a sapper 16 years ago. After a quick word from the Sergeant Major the soldiers decided to give it a go and to their amazement it worked.

With this done it was time to split them into teams and have a timed race which was greeted by some cheers. However trying to explain to them that the empty gap in front of them was actually full of water and they could go in it was a whole different kettle of fish talk. Imagination is not their forte. Both teams completed the build in reasonable times.

The last day of the bridging phase would see our American counterparts come over with some of their modular assault bridges which are very similar to our own.

A bit of American bridging

The ANA seemed to enjoy building the bridge but one soldier did comment that he preferred to build the non-equipment bridge rather than the little foot bridge, which again reassured us that the walls where coming down further and they were enjoying the training.

All that remains for them now is the fourth and final week which is a confirmation week where all their skills will be tested.

Afghan soldiers get to grips with knots and razorwire

Sergeant Stewart Plummer is an Engineer with 21 Engineer Regiment (21 Engr Regt). He is attached to 1st Battalion The Royal Regiment of Scotland (1 SCOTS) for Operation HERRICK 12, running a Combat Engineer Course for Afghan National Army soldiers. He writes about his week.

We were worried the soldiers might cut themselves on the razor wire

The week started on a fairly sombre note as we said farewell to two of our comrades, Lance Corporal Baz Buxton and Sapper Daz Roy. Gone but not forgotten. R.I.P.

As we started week two of the Combat Engineer course which I am teaching, to my surprise the Afghan National Army soldiers turned up 90 minutes early!  When I asked why they had turned up so early I found out they have a big parade on a Saturday morning and they didn’t want to attend it. So just like ‘squaddies’ worldwide, they don’t like parading.  But on the other hand, it was reassuring that they would rather sit on the training ground waiting for the training to start, which tells me they really want to be there.

An ANA soldier learning new skills

With the medics on standby out came the razor wire to begin the fencing lesson. Miraculously nobody cut themselves or their clothing, however the knots and lashings lesson was slightly more challenging for them and resulted in a few ANA tying themselves in knots which was slightly amusing.

By far the most interesting day was the basic carpentry day which we thought would be more challenging than it was. The day’s training was extremely productive. Credit to them, their accommodation now has a nice new range of furniture.

The course has just finished its second week and it’s starting to show with some of the students beginning to wane a little.  Our hardest challenge is keeping them engaged when they are not participating in the task at the time. A manful effort. It’s a good job I am blonde, otherwise I would be grey by the end of the course with all the stress of keeping it on track!

Starting a Combat Engineer School for the Afghan National Army

Sergeant Stewart Plummer of 21 Engineer Regiment (21 Engr Regt) writes about the challenges of passing on all his engineer skills to Afghan National Army soldiers.

Sergeant Stewart Plummer

For Operation HERRICK 12 I have been attached to 1^st Battalion, The Royal Regiment of Scotland (1SCOTS), who have formed 3/215 Brigade Advisor Group, which was formerly known as the Operational Mentoring and Liaison Team Battle Group (OMLT BG). The Advisor Group works closely with the Afghan National Army (ANA), advising and training them in all military functions.

When I heard that I was going to be doing this I was at first a little apprehensive, because of reports that previous engineer units had been used as infantry soldiers rather than in their primary role, as engineers. However, once we arrived in theatre we soon found out that this tour was going to be a little different.

When we had completed our handover/takeover, I discovered that I would be employed as the Training Sergeant, to which I replied “What does that entail?”  Well, I soon got my answer.  The plan was to run a basic Combat Engineer Course for the ANA Engineers. This would enable them to be able to partner the Joint Force Engineers on tasks within Helmand Province. So with this in mind I set about planning the course with the ANA.

After a few disagreements we settled on the course content and started  organising stores and equipment.

British Army Engineers pictured with their Afghan National Army students, holding certificates

Whilst all this planning was going on we had a 4-man team deployed in a patrol base advising the team of ANA Engineers there, which they had deployed with, how to enhance the existing set-up.

While the team was away it was decided that the soldiers they had with them would be given their certificates to denote that they were qualified engineers.

There were big smiles all round.