In January 2024, the United States Coast Guard (USCG) has just one operational heavy icebreaker in service, the nearly 50-year-old Polar Star (WAGB 10) that deploys solely to the Antarctic South Pole to resupply the U.S. scientific bases there.The USCG’s newer medium-class icebreaker, USCG cutter (USCGC) Healy, operates only in the Arctic Northern Pole waters.
The Repairs and Enhancements to the 48-year-old Polar Star
After each annual “Operation Deep Freeze” mission to the Antarctic, USCGC Polar Star gets serviced, usually at Mare Island Dry Dock in Vallejo, California, as part of its Service Life Extension Program (SLEP) until the new Polar Security Cutters (PSC) are delivered sometime in 2025.
Naval News asked the USCG Headquarters, Office of Public Affairs, Washington DC, in December 2023 on what the latest SLEP repaired and replaced for the Polar Star.
Besides the propellers and shafts that are normally disassembled and dismounted during each dry dock, USCG Headquarters told Naval News, “Polar Star SLEP recently completed year three of a five-year phased work program to extend the service life of the cutter by replacing obsolete systems. The work occurs between Operation Deep Freeze deployments where Polar Star supports National Science Foundation initiatives in Antarctica.
“Recent work included the replacement of the ship’s evaporator salinity monitoring system for making drinking water, replacement of the fire detection system to increase shipboard safety, improvements to shipboard ventilation systems for crew comfort, and replacement of galley cooking appliances. Additionally, the high-frequency power converters were replaced, providing more reliable power to sensitive electronics. A complete redesign of the propulsion and machinery control systems was completed, reducing the time required for system maintenance from weeks to days and ensuring the equipment was supportable and maintainable. Propeller and shaft work are routine maintenance items completed every one to two years. This work was completed during SLEP but is not part of the SLEP program funding.”
Working on a heavy icebreaker built and commissioned in the 1970s presents daunting challenges for the engineers, shipyard workers, and mechanics at dry dock due to vendors, manufacturers, supply chains, and spare parts no longer available after over four decades. Naval News asked how can these challenges be addressed for an icebreaker so old. “Polar Star is in good condition structurally,” replied USCG Headquarters. “Therefore, SLEP work is focused on various systems that are obsolete or difficult to maintain. These systems are upgraded and/or replaced to increase reliability and maintainability while reducing costs. A simple analogy is the structure of a house can be in good condition, but the systems within the house such as the water heater, appliances, HVAC system, etc. need renewal as the home ages.
“Numerous engineering challenges were encountered in the effort to upgrade many antiquated systems aboard a nearly 50-year-old ship. However, with great teamwork that included such diverse entities as NAVSEA [U.S. Navy’s Naval Sea Systems Command] Philadelphia and a Coast Guard Yard “Road Team”, these challenges were overcome. Polar Star recently completed Phase Three of the SLEP program. She departed Mare Island Dry Dock on October 18, 2023, meeting this year’s schedule requirements in support of Operation Deep Freeze. Polar Star also successfully supported Operation Deep Freeze following SLEP Phase One in 2021 and SLEP Phase Two in 2022.”
USCG Headquarters’ Office of Public Affairs
More Polar Star Phase Three SLEP information is also available on the USCG’s website. With Phase Three SLEP completed, USCGC Polar Star is currently headed down to Antarctica for its “Operation Deep Freeze” deployment as of December 2023.
New Information on the USCG Polar Security Cutter Heavy Icebreakers
Naval News inquired about the design and new features of the Polar Security Cutters (PSC) over the past few years and these PSC inquiries were often not answered due to the prematurity of the PSC program. Now, in December 2023, USCG Headquarters replied with some information as to how the PSCs are designed and what new features they will contain.
“The PSC design includes several important new features and capabilities relative to Polar Star, such as:
- An integrated diesel-electric propulsion plant allowing flexible and economic power generation, resulting in equivalent or better icebreaking performance with significantly lower fuel consumption;
- Directional thrusters providing enhanced maneuverability in both open-ocean and icebreaking operations;
- Double hull for enhanced safety and reduced risk of environmental impacts;
- Multi-beam sonar for high-resolution seafloor mapping;
- Hangar space for two helicopters and support for unmanned aerial systems; and
- More than 2,000 square feet of flexible mission space.”
The Polar Security Cutters should be the first USCG ships to mount the Mark 38 Mod 4 30mm autocannons.
Author’s Comments
The USCG Headquarters remained purposefully vague in details as to the new PSC feature information and how the engineers will incorporate these systems. One design feature of the new PSCs is that the engines rest underneath the smokestacks, so unlike the medium-class icebreaker, USCGC Healy, where the dock workers had to cut a hole into the side of the hull to replace an engine damaged by fire, the PSCs’ engines can be lifted straight out through the smokestacks by crane.
This is important because the Polar Star’s sister icebreaker, the Polar Sea, suffered an engine malfunction. To replace the Polar Sea’s engines deep inside the hull would mean cutting through the upper decks and the hull to remove them, a monumental job. Thus, the Polar Sea remains inactive, tied and docked to a Seattle pier and is used to feed necessary spare parts to the Polar Star.
