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USS Sam Rayburn

USS Sam Rayburn (SSBN-635) was a nuclear-powered fleet ballistic missile submarine of the United States Navy, the eighteenth vessel of the Lafayette class, named for Sam Rayburn (1882–1961), the longtime Speaker of the United States House of Representatives who served from 1940 to 1947, 1949 to 1953, and 1955 until his death.^[1]^[2] Laid down on 3 December 1962 by Newport News Shipbuilding and Dry Dock Company in Virginia, she was launched on 20 December 1963 and commissioned on 2 December 1964 under the command of Commander Arnold F. Fein.^[1]^[1] Following shakedown operations and weapons trials in the Atlantic, Sam Rayburn commenced her first strategic deterrent patrol in January 1965, armed initially with UGM-27 Polaris submarine-launched ballistic missiles and later upgraded to carry UGM-73 Poseidon missiles, contributing to the U.S. nuclear triad's sea-based leg during the Cold War.^[1]^[3] Over her operational career, she completed dozens of extended submerged patrols, including her eighth through fourteenth Polaris patrols between 1967 and 1969, and achieved the distinction of being the first SSBN to surface through Arctic ice during a special test coordinated by Commander, Submarine Forces Atlantic.^[1]^[4] Deactivated in 1985 and formally decommissioned on 31 July 1989, she was reclassified as a moored training ship (MTS-635) and repurposed for nuclear propulsion and weapons systems training at the Naval Submarine Base New London, serving in that capacity for over three decades until being towed to Puget Sound Naval Shipyard in May 2025 for dismantlement.^[2]^[5]

Design and Construction

Authorization and Keel Laying

The construction contract for USS Sam Rayburn (SSBN-635), the fifth ship of the James Madison-class fleet ballistic missile submarines, was awarded on 20 July 1961 to Newport News Shipbuilding and Dry Dock Company in Newport News, Virginia.^[6] This authorization occurred amid the U.S. Navy's rapid expansion of its sea-based nuclear deterrent force under the Polaris program, following President Kennedy's approval earlier that month for ten improved Lafayette-class/early James Madison variants to enhance strategic capabilities against Soviet submarine and land-based threats.^[7] The keel laying ceremony took place on 3 December 1962 at the Newport News shipyard, marking the formal start of physical construction for the 425-foot-long, nuclear-powered vessel designed to carry 16 Polaris A-3 ballistic missiles.^[1]^[3] This event aligned with the accelerated production schedule for the class, which shared hull and propulsion designs with preceding Lafayette-class boats but incorporated refinements for greater reliability and stealth in submerged operations.^[8] The shipyard, a key contractor for nuclear submarines since the 1950s, assembled the pressure hull using high-strength HY-80 steel to withstand deep diving depths exceeding 800 feet.^[1]

Launch and Commissioning

The USS Sam Rayburn (SSBN-635) was launched on 20 December 1963 at the Newport News Shipbuilding and Dry Dock Company in Newport News, Virginia.^[1] The ceremony was co-sponsored by Mrs. S. E. Bartley and Mrs. W. A. Thomas, sisters of the ship's namesake, the late Speaker of the House Sam Rayburn.^[1]^[9] This event marked the completion of the hull fabrication phase for the James Madison-class fleet ballistic missile submarine, designed for strategic nuclear deterrence under the U.S. Navy's Polaris program.^[1] Nearly one year later, on 2 December 1964, the Sam Rayburn was commissioned into active service at the same shipyard, becoming the 28th U.S. fleet ballistic missile submarine.^[1] Captain Oliver H. Perry, Jr., took command of the Blue Crew, with the vessel entering the dual-crew rotation typical for SSBN operations to maximize patrol availability.^[1]^[4] The commissioning ceremony featured remarks from Under Secretary of the Navy Paul B. Fay and a telephone message from President Lyndon B. Johnson, underscoring the submarine's role in Cold War strategic posture.^[4] Following shakedown operations, the ship prepared for its initial deterrent patrols armed with Polaris A-3 missiles.^[1]

Technical Specifications and Capabilities

Propulsion and Hull Design

The propulsion system of USS Sam Rayburn (SSBN-635) consisted of one S5W pressurized water nuclear reactor, which supplied steam to two geared steam turbines driving a single propeller shaft at 15,000 shaft horsepower.^[2]^[6] This nuclear power plant enabled the submarine to achieve sustained submerged speeds of 22–25 knots and surfaced speeds of 16–20 knots, supporting extended deterrent patrols without refueling.^[2] The hull design adhered to the SCB-216 configuration for fleet ballistic missile submarines, measuring 425 feet (129.6 meters) in length overall, with a beam of 33 feet (10 meters) and a draft of 31.5 feet (9.6 meters).^[2] Displacement was approximately 7,250 tons surfaced and 8,250 tons submerged, reflecting the vessel's robust construction to house 16 vertical launch tubes for Polaris or Poseidon missiles amidships while maintaining hydrodynamic efficiency for stealthy underwater operations.^[10] The pressure hull, fabricated from high-tensile steel, incorporated a streamlined form with anechoic coatings to minimize acoustic detectability, evolutionary improvements over prior classes like Ethan Allen for enhanced submerged performance and strategic deterrence.^[11]

Armament and Missile Systems

The primary armament of USS Sam Rayburn (SSBN-635) consisted of 16 vertical launch tubes positioned amidships for submarine-launched ballistic missiles (SLBMs), designed for steam ejection from submerged positions to support strategic nuclear deterrence.^[1] These tubes were integral to the James Madison-class design, enabling the submarine to carry a full load of missiles compatible with the Polaris and Poseidon systems without structural modifications beyond backfit conversions.^[12] Upon commissioning in December 1964, Sam Rayburn was armed with 16 UGM-27C Polaris A-3 missiles, each with a range of approximately 2,500 nautical miles (4,630 km) and an accuracy of about 3,000 feet CEP, typically fitted with a single W58 thermonuclear warhead of 200 kilotons yield, though capable of three reentry vehicles for improved targeting flexibility.^[13] The Polaris A-3 represented an advancement over prior variants with its constant-diameter solid-fuel motors that maximized launch tube efficiency, allowing submerged launches from depths up to 100 meters via compressed air and steam generation systems.^[14] In 1971, Sam Rayburn underwent conversion to carry the UGM-73A Poseidon C-3 missile, with the Blue Crew successfully launching a test missile on October 14, 1971, followed by an operational deterrent patrol equipped with 16 Poseidon missiles by March 1972.^[15] The Poseidon C-3 extended capabilities with multiple independently targetable reentry vehicles (MIRVs), accommodating up to 10-14 W68 warheads of 40-50 kilotons each, a range of about 2,800 nautical miles, and enhanced penetration aids against Soviet anti-ballistic missile defenses, reflecting upgrades to the missile fire control and guidance systems without altering the submarine's hull.^[15] This backfit maintained the 16-missile loadout through the remainder of active service until decommissioning in 1989.^[4] Secondary armament included four 21-inch (533 mm) bow torpedo tubes for anti-submarine and anti-surface warfare, typically loaded with up to 12 reserve torpedoes comprising Mk-48 heavyweight guided torpedoes for wire-guided attacks against submarines and surface ships, alongside earlier Mk-37 electric torpedoes and Mk-14/16 steam-gas propulsion types for versatility across threats.^[2] The Mk-48, introduced progressively in the 1970s, featured acoustic homing, depth control, and a 650-pound warhead, enabling runs exceeding 30 nautical miles at speeds over 40 knots, while the tubes supported swimmer defense with smaller Mk-45 nuclear-tipped options if required.^[12] No deck-mounted guns or other external ordnance were fitted, prioritizing stealth and missile-centric operations.^[7]

Crew and Operational Features

The USS Sam Rayburn (SSBN-635) operated with two alternating crews, designated Blue and Gold, each consisting of approximately 13 officers and 122 enlisted personnel, enabling continuous deterrent patrols without extended downtime.^[4] This dual-crew system, standard for U.S. Navy ballistic missile submarines (SSBNs), allowed one crew to conduct at-sea operations while the off-duty crew underwent training, maintenance support, or rest, maximizing the vessel's operational availability during the Cold War era.^[16] Crew rotations typically followed a cycle of about 100-day patrols, with a brief 3-day turnover period at the end of each deployment for handover of the vessel, ensuring seamless transitions and high readiness.^[16] Operational features emphasized stealth and endurance, supported by nuclear propulsion that permitted submerged patrols lasting 60 to 90 days or longer, during which the crew managed missile systems, navigation, and life support in confined quarters designed for minimal noise and maximal reliability.^[1] The submarine's design incorporated redundant systems and rigorous qualification standards for crew members, who underwent specialized training in nuclear operations, sonar, and weapons handling to maintain strategic deterrence postures.^[4] Living conditions aboard featured hot-bunking arrangements to optimize space for the 135-person crew per shift, with berthing areas, galleys, and recreational facilities adapted for prolonged isolation, contributing to the psychological and physical demands of extended underwater missions.^[2] These features underpinned the Sam Rayburn's completion of multiple Polaris and later Poseidon missile patrols, demonstrating the crew's capacity for sustained, independent operations in support of national security objectives.^[1]

Operational History

Initial Deterrent Patrols and Cold War Role (1964–1970)

Following her commissioning on 2 December 1964, USS Sam Rayburn completed post-shakedown operations and training before embarking on her inaugural Polaris A-3 ballistic missile deterrent patrol during the summer of 1965.^[1] This patrol marked the submarine's entry into the U.S. strategic nuclear deterrent force, where she carried 16 Polaris missiles capable of delivering multiple independently targeted reentry vehicles over intercontinental ranges, ensuring a survivable second-strike capability against Soviet targets.^[1] In August 1965, Sam Rayburn transferred to Submarine Squadron 16, based at Rota, Spain, to conduct forward-deployed operations in the Atlantic and Mediterranean.^[1] From this base, she executed seven successive deterrent patrols through December 1966, each lasting approximately 60-90 days submerged, during which the crew maintained continuous readiness to launch missiles in response to national command authority while evading detection to preserve operational secrecy.^[1] These missions contributed to the Navy's "41 for Freedom" campaign, whereby ballistic missile submarines provided unbroken at-sea deterrence, with Sam Rayburn's patrols overlapping those of other James Madison-class boats to sustain persistent coverage amid escalating Cold War tensions, including the Soviet naval buildup in the region.^[1] Returning to Submarine Squadron 18 at Charleston, South Carolina, in December 1966, Sam Rayburn resumed East Coast-based patrols, completing her 8th through 11th deterrent missions in 1967 and her 12th through 14th in 1968.^[1] By 1969, she conducted additional patrols—numbered 15 through 17—while operating continuously with the squadron until entering overhaul at the Portsmouth Naval Shipyard in December.^[3] These operations underscored the submarine's role in the broader Polaris fleet, which by the late 1960s comprised over 30 SSBNs forming the sea-based leg of the nuclear triad, designed to counter the Soviet Union's expanding land-based missile arsenal through stealth and mobility rather than fixed-site vulnerability.^[1] Throughout 1964–1970, Sam Rayburn's patrols exemplified the Cold War doctrine of mutual assured destruction, where the assured survivability of submerged SSBNs deterred preemptive strikes by guaranteeing retaliatory devastation; each patrol involved rigorous drills for missile launches, navigation under ice-free polar approaches when applicable, and acoustic evasion tactics against growing Soviet anti-submarine warfare capabilities.^[1] The submarine's contributions helped maintain strategic stability during crises such as the 1968 Soviet invasion of Czechoslovakia, with her Polaris loadout providing approximately 3-megaton yield potential per missile salvo, calibrated for high-confidence targeting of hardened Soviet command centers and silos.^[1] Overhaul preparations in late 1969 extended into 1970, temporarily halting patrols but preserving the boat's deterrence posture through preserved hull integrity and systems readiness.^[1]

Mid-Career Refits and Extended Service (1971–1980)

Following the completion of a major overhaul at Portsmouth Naval Shipyard on 27 May 1971, USS Sam Rayburn resumed operations along the eastern United States coast, conducting training exercises and preparations for renewed deterrent patrols.^[1] This refit, which had begun in December 1969, incorporated upgrades enabling the submarine to carry the Poseidon C3 missile system, with full conversion certified on 2 September 1971 as the eighth SSBN in the fleet to achieve this capability.^[15] The enhancements included modifications to the missile launch tubes and fire control systems to accommodate the larger, multiple independently targetable reentry vehicle (MIRV)-equipped Poseidon missiles, replacing the earlier Polaris A3 configuration and increasing payload flexibility for strategic deterrence.^[15] In February 1972, Sam Rayburn departed Groton, Connecticut, for her homeport shift to Charleston, South Carolina, where she commenced her first post-refit deterrent patrol on 7 March, armed with 16 Poseidon C3 missiles.^[1]^[15] This marked the submarine's integration into the Poseidon force, emphasizing submerged stealth patrols in support of national nuclear deterrence amid escalating Cold War tensions. Throughout the mid-1970s, she maintained a cycle of extended patrols from Charleston, interspersed with local operations and crew certifications; by June 1974, the vessel was engaged in special operations, though details remain classified.^[1] On 8 November 1975, her Blue Crew conducted a successful operational test launch of two Poseidon C3 missiles, validating system reliability.^[15] Extended service continued without major interruptions until May 1980, when Sam Rayburn entered a refit at Kings Bay, Georgia, focusing on maintenance, system inspections, and minor upgrades to sustain operational readiness amid the fleet's aging infrastructure.^[4] These mid-career interventions ensured the submarine's propulsion, sonar, and missile systems met evolving strategic requirements, allowing her to complete over a dozen patrols in the decade while contributing to the U.S. Navy's sea-based nuclear triad.^[1]

Final Active Deployments and Strategic Contributions (1981–1985)

During the early 1980s, USS Sam Rayburn (SSBN-635), assigned to Submarine Squadron 14 at Holy Loch, Scotland, continued conducting strategic deterrent patrols in the Atlantic as part of the U.S. Navy's sea-based nuclear triad. These patrols involved extended submerged operations carrying Poseidon C3 submarine-launched ballistic missiles (SLBMs), with crews alternating between Blue and Gold teams to maximize operational tempo. A notable event occurred between September 1981 and January 1983, when the submarine crossed the Arctic Circle and participated in a COMSUBLANT-arranged test as the first SSBN to surface through polar ice, demonstrating enhanced capabilities for northern latitudes but necessitating dry-docking repairs in Holy Loch afterward due to hull damage.^[4]^[3] Patrols during this period included port visits to Rotterdam, Netherlands; Portsmouth, England; and Faslane, Scotland, supporting forward-deployed logistics and allied interoperability. By 1985, the submarine's final active operations commenced with the Blue Crew departing Holy Loch in February for a deterrent patrol, culminating in turnover at Kings Bay, Georgia. The Gold Crew then completed the 60th overall patrol, after which the vessel arrived in New London, Connecticut, for crew consolidation ahead of inactivation.^[4] These deployments underscored Sam Rayburn's role in sustaining continuous at-sea deterrence amid escalating Cold War tensions, including Soviet naval expansion and U.S. strategic modernization under the Reagan administration. Operating with up to 16 Poseidon missiles capable of multiple independently targetable reentry vehicles (MIRVs), the submarine contributed to the credibility of mutual assured destruction, deterring potential aggression by providing survivable second-strike options. Deactivation on September 16, 1985—while still in commission—involved filling missile tubes with concrete to comply with strategic arms limitation guidelines, reflecting fiscal and treaty-influenced force structure adjustments despite SALT II's non-ratification.^[4]^[15]

Conversion and Training Service

Decommissioning and Refit as Moored Training Ship

The USS Sam Rayburn was deactivated while still in commission on September 16, 1985, marking the initial step toward its transition from active ballistic missile submarine service.^[2] This deactivation occurred as part of the U.S. Navy's phase-out of older James Madison-class submarines amid strategic shifts and the drawdown of the Cold War-era fleet.^[2] The vessel arrived at the Norfolk Naval Shipyard for conversion on February 1, 1986, where it underwent extensive modifications to transform it into a moored training ship.^[17] Key alterations included the removal of the missile compartment to reduce length and eliminate strategic weapon systems, followed by welding the bow and stern sections together to create a compact platform suitable for shore-based nuclear operations training.^[18] The reactor was refueled during this refit to support prolonged instructional use, preserving the submarine's nuclear propulsion systems for hands-on sailor qualification without underway mobility.^[4] Following completion of these modifications, the Sam Rayburn was formally decommissioned and stricken from the Naval Vessel Register on July 31, 1989, and immediately reclassified as Moored Training Ship MTS-635.^[4]^[2]^[3] This refit established it as the U.S. Navy's first dedicated moored training ship, assigned to the Naval Nuclear Power Training Unit at Goose Creek, South Carolina, for prototype reactor training.^[4]

Training Operations and Nuclear Instruction (1989–2024)

Following decommissioning on 31 July 1989, ex-USS Sam Rayburn (SSBN-635) underwent conversion to become the U.S. Navy's first moored training ship designated MTS-635, stationed at the Nuclear Power Training Unit (NPTU) in Charleston, South Carolina.^[2] The refit process, which began prior to full decommissioning, entailed demilitarization by removing ballistic missile launch tubes, torpedoes, and associated weaponry while retaining the S3G nuclear reactor and propulsion machinery to enable operational training scenarios.^[6] This configuration allowed for live-reactor evolutions, including initial criticality achieved on 29 July 1989, marking the start of its instructional role.^[6] As MTS-635, the vessel primarily supported the Naval Nuclear Propulsion Program by delivering practical, at-sea-like instruction in nuclear power plant operations, emphasizing reactor physics, heat transfer, fluid systems, and radiological controls.^[19] Training focused on engineering qualifications for enlisted personnel, officers, and civilian technicians, including shift supervision, casualty response drills, and maintenance procedures on primary coolant pumps, steam generators, and turbine systems.^[20] These evolutions complemented classroom and simulator-based learning at NPTU, with the moored platform providing immersion in a fleet-representative environment to build proficiency for submarine service.^[5] Over its 32-year tenure from 1989 to 2021, MTS-635 facilitated the qualification of nuclear operators for the submarine force, operating alongside land-based prototypes and team trainers to maintain high standards in propulsion reliability and safety.^[21] The ship's role evolved with program updates, incorporating advancements in monitoring instrumentation and procedural standardization, though it remained anchored and non-self-propelled throughout.^[22] By 2021, as newer converted submarines like ex-USS La Jolla (SSN-701) and ex-USS San Francisco (SSN-711) augmented NPTU capacity, MTS-635 concluded active training on 1 April 2021 prior to transfer for defueling and disposal.^[4]

Inactivation and Disposal

Final Inactivation Process

Norfolk Naval Shipyard (NNSY) welcomed the Moored Training Ship Sam Rayburn (MTS-635) on April 3, 2024, marking the commencement of its inactivation, the first such process for a Navy moored training ship.^[20] The effort involved coordinated preparations between NNSY and personnel from the vessel's prior base in Charleston, South Carolina, to ensure safe transit and initial setup for the multi-phase disassembly.^[20] The core of the inactivation centered on defueling the reactor, a complex operation necessitating five precise hull cuts to access internal components, temporary removal of the superstructure, and subsequent extraction, handling, and reinstallation of specialized equipment to facilitate fuel transfer.^[19] Hull preservation efforts addressed extensive corrosion accumulated over the ship's 60-year lifespan, including the installation of more than 250 lap plates and comprehensive welding repairs to maintain structural integrity during the process.^[19] Additional tasks encompassed the installation and rigorous testing of towing fittings and related systems in preparation for post-inactivation transit. At peak, the project engaged up to 400 shipyard personnel under the supervision of Project Superintendent Mike Garrelts.^[19] Inactivation concluded successfully on November 6, 2024, with all ship systems rendered inert and the defueled hull certified ready for towing to Puget Sound Naval Shipyard for recycling.^[19] This milestone provided critical lessons for future inactivations, such as that of MTS Daniel Webster, scheduled to begin planning in 2025.^[19]

Towing and Current Status

Following the completion of inactivation at Norfolk Naval Shipyard on November 6, 2024, MTS Sam Rayburn (ex-SSBN-635) underwent preparations for long-distance towing, including structural reinforcements and removal of non-essential components to ensure seaworthiness during transit.^[19] The vessel departed Norfolk on April 2, 2025, under tow by commercial tugs, initiating a multi-leg journey westward via the Panama Canal to its final destination at Puget Sound Naval Shipyard and Intermediate Maintenance Facility (PSNS & IMF) in Bremerton, Washington.^[5] The towing route included passage through the Panama Canal, where the submarine was observed southbound on April 13, 2025, handled by the tug Gary Chouest amid the canal's lock system constraints for oversized vessels.^[23] En route along the U.S. West Coast, it was sighted under tow near West Seattle on May 6, 2025, approaching the Puget Sound region.^[18] Arrival at PSNS & IMF occurred by May 9, 2025, marking the end of active towing operations spanning over 3,000 nautical miles from the Atlantic Coast.^[5] As of October 2025, MTS Sam Rayburn remains in storage at PSNS & IMF pending entry into the Navy's Ship-Submarine Recycling Program (SRP), which systematically dismantles decommissioned nuclear-powered vessels by first removing reactor compartments for specialized disposal, followed by recycling of conventional hull sections per environmental regulations.^[19]^[5] No public timeline for full disassembly has been released, consistent with SRP protocols prioritizing radiological safety and material recovery, with the submarine's hull expected to yield significant scrap steel after defueling and decontamination completed prior to towing.^[19]

References

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Sam Rayburn - Naval History and Heritage Command
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USS Sam Rayburn (SSBN 635) - Navysite.de
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The stretch was not considerable, but they went from 410 ft 4 in (125.07 m) to 425 ft (130 m) for a totalk displacement at 7,325 long tons (7,443 t) Submerged: ...Missing: length | Show results with:length
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May 7, 2024 · Weight: 36,000 Ibs (16,329 kg) ; Speed: Supersonic; ; Range: 500 (926 km) - 2,500 n.miles (4,630 km) ; Accuracy: 3,000 ft (900 m) C.E.P..
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Mar 24, 2024 · 30 SEPTEMBER 1986. USS SAM RAYBURN (SSBN 635) completed dismantlement availability at Charleston Naval Shipyard, Charleston, SC. 27 ...
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Aug 11, 2017 · The Blue and Gold crews rotate on approximately 100 – day intervals for the ship to remain on a continuous patrol. There was usually a 3-day ...
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Jan 7, 2021 · The USS Sam Rayburn was converted into a training platform - Moored Training Ship (MTS-635). The Sam Rayburn arrived for conversion on February 1, 1986.Missing: refit details
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May 6, 2025 · In converting the submarine to a moored training ship, they removed the missile section and welded the bow and stern sections together. Keen ...
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Nov 6, 2024 · Norfolk Naval Shipyard (NNSY) successfully completed the inactivation of the Moored Training Ship Sam Rayburn (MTS 635) Nov. 6.Missing: construction history<|control11|><|separator|>
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May 17, 2025 · MTS Sam Rayburn (MTS. 635), formerly USS Sam. Rayburn (SSBN 635), arrives at PSNS & IMF,. May 6, 2025, for storage and eventual recycling. (U.S. ...Missing: authorized | Show results with:authorized
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In April 2014, the. Navy awarded the largest submarine construction contract in history for ten more ... SSBN 635 627 Newport News. 1962. 12/03/62 12/20/63 12 ...
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MTS-635 (moored training ship) (ex-USS Sam Rayburn SSBN-635
Apr 14, 2025 · James Madison-class fleet ballistic missile submarine being towed by Gary Chouest southbound in the Panama Canal to be scrapped - April 13, 2025.<|control11|><|separator|>