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C2SAT - Installation Manual 4m Radome _501_1730_ 2009a

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Installation Manual 4m Radome _501_1730_ 2009a

Description

Marine Stabilised Antenna System

Version: 09A

Assembly Manual 4m Radome (501-1730)

Assembly Instruction of C-band Radome Uppgjord (även faktaansvarig om annan)

C2SAT Production AB Anders Strömberg Dokansv/Godk

C2SATP-08:011 Uen Kontr

- Checked

C2SAT communication AB Erik Dalin

2009-05-10

File name

Table of Contents 1

GENERAL

RADOME INSTALLATION

PREPARATION FOR INSTALLATION RADOME DOOR ASSEMBLE PANELS OF LAYER 1 BOTTOM RIM SEALING PANEL TO PANEL SEALING TAPE PANEL ASSEMBLY ASSEMBLE PANELS OF LAYER 2 ZENITH PANEL INSPECT THE BOLTS SEALING THE JOINTS WITH SILICONE PANEL TO PANEL SEALING BASE RIM SEALING CLEANUP AFTER INSTALLATION

INSTALLATION PROCEDURE FLOW CHART

PANEL ASSEMBLY SEQUENCE DRAWING

TOTAL DRAWING FOR 4M RADOME

Assembly Instruction of C-band Radome Uppgjord (även faktaansvarig om annan)

C2SAT Production AB Anders Strömberg Dokansv/Godk

C2SATP-08:011 Uen Kontr

- Checked

C2SAT communication AB Erik Dalin

2009-05-10

File name

Introduction The Assembly manual for 4 meter radome provides a description of the procedure of radome assembly

The radome consists of 11 panels which form a rigid sphere shell that protects the antenna from the marine environment

It is composed of pentagonal shaped FRP panels with a foam-sandwich structure

The panels are bolted together to form a truncated sphere with stainless steel bolts

GENERAL       

Radome assembly should be operated by the qualified installation team

The chief of installation team should check the goods (panels,

) in the crates according to the Packing Lists

All workers who work in high altitudes must wear safety belt or safety lines to prevent falling accidents

Define a scaffolding assembly scheme (steel pipes or bamboo poles) according to the installation site

Extinguisher should be putted on site

Smoking or open flames is not allowed on the site

Check the weather forecast in advance

Do not perform the installation if wind velocity is over 20m/sec

Estimated installation time: 2 days Each panel weighs about 35 kg

The weight of the complete radome is 410 kg

The service hatch/door to the radome is 60x100cm

RADOME INSTALLATION

Preparation for installation

Equip the assembling staff

Check that ladders,

scaffolding and crane used for installation is available on site

Check that all parts of radome on the Packing List (panels,

Check that all tools and other materials for radome installation on the Packing List have arrived on site

Assembly Instruction of C-band Radome Uppgjord (även faktaansvarig om annan)

C2SAT Production AB Anders Strömberg Dokansv/Godk

C2SATP-08:011 Uen Kontr

- Checked

C2SAT communication AB Erik Dalin

2009-05-10

File name

Radome door The radome has a door on one side which is used to enter the radome

It is important that you assemble the radome so that the radome door is located towards the stern of the ship

Assemble panels of layer 1 Remove the PVC packing film after taking out of the Base Panels from the crates

Put base panel on sealing gasket,

Assembly Instruction of C-band Radome Uppgjord (även faktaansvarig om annan)

C2SAT Production AB Anders Strömberg Dokansv/Godk

C2SATP-08:011 Uen Kontr

- Checked

C2SAT communication AB Erik Dalin

2009-05-10

File name

sealing rubber gasket Base (Ship Deck)

sealing rubber gasket mm 6 100 mm

Panel-to-panel joint is an overlapping joint

Put 2 pieces of rubber sealing tape on both sides of bolt along panel-to-panel joint

Tightening the bolts will compress the sealing tape

Start with the door panel and than put the panel 1:1 to the left,

Panel bolts

Base bolts

Assembly Instruction of C-band Radome Uppgjord (även faktaansvarig om annan)

C2SAT Production AB Anders Strömberg Dokansv/Godk

C2SATP-08:011 Uen Kontr

- Checked

C2SAT communication AB Erik Dalin

2009-05-10

File name

Tighten base bolts initially with spanner

Apply a momentum to all base bolts of 50Nm Tighten the panel bolts with spanner on the edges of the panels of layer 1

Close up of bolts on the inside

± 10Nm

Close up of joint on outside

Continue assembling all base panels until layer 1 is fully assembled

Layer 1 assembly finished

Assemble panels of layer 2 A fold-up ladder (and/or scaffoldings) will be necessary for the assembly of panels of layer 2 (and the zenith panel)

Make sure that the ladder is long enough to reach the top layer

Make sure that the ladder can be extracted through the service door in the radome after the assembly is finished

See chapter 6 for suggested ladder dimensions

Assembly Instruction of C-band Radome Uppgjord (även faktaansvarig om annan)

C2SAT Production AB Anders Strömberg Dokansv/Godk

C2SATP-08:011 Uen Kontr

- Checked

C2SAT communication AB Erik Dalin

2009-05-10

File name

Assemble the panels according to the corner label of the panels,

use the same principle as layer 1 regarding placement,

sealing tape and bolt tightening

see the Panel Assembly Sequence Drawing´in chapter 4

Tighten panel joint bolts with spanner

Apply a momentum to all bolts of 10Nm

Zenith Panel Assemble the zenith panel with the same procedure until last layer is fully assembled

You may need a crane for this placement

Inspect the bolts Tighten all panel bolts with a momentum of 10Nm ±1Nm from bottom to top

Re-tighten all base bolts with a momentum of 50Nm ±10Nm

Sealing the joints with silicone

installers climb on the outside of the radome and apply sealing glue to the exterior joint from top to bottom

4 10 mm

Assembly Instruction of C-band Radome Uppgjord (även faktaansvarig om annan)

C2SAT Production AB Anders Strömberg Dokansv/Godk

C2SATP-08:011 Uen Kontr

- Checked

C2SAT communication AB Erik Dalin

2009-05-10

File name

Seal the panel joints with white silicone from the top

Seal the panels inside the radome first and then seal the outside seam

Apply the sealing glue into the joints evenly with the use of tools or fingers

Protect the hands by wearing soft plastics gloves

When sealing the seam of base panels,

if the seam width is too large to apply one lay of glue,

you can apply one lay of glue on both sides of the seam first,

Before the silicone has hardened clean off the remains on tools or fingers

During sealing,

if you need to step on the radome when climbing outside the radome,

please place your feet on the panel joints

Do not step on the middle of a panel since that is the weakest point and also most prone to surface damage and/or coating damage

Ensure that the panels or surface is not damaged

Please wear shoes with a soft rubber sole

Base (Ship Deck)

Cleanup after installation Disassemble scaffoldings inside the radome,

don’t touch the panel laminates and antennas

After completing the installation,

stain and oil on the radome inside or outside surface,

and keep the environment clean

Assembly Instruction of C-band Radome Uppgjord (även faktaansvarig om annan)

C2SAT Production AB Anders Strömberg Dokansv/Godk

C2SATP-08:011 Uen Kontr

- Checked

C2SAT communication AB Erik Dalin

2009-05-10

File name

INSTALLATION PROCEDURE FLOW CHART Chapter Installation team enters the site ↓ Prepare for installation

↓ Check items on packing list

Equip team with tools,

↓ Place sealing rubber gasket for base rim on platform

↓ Assemble base panels (layer 1) Place sealing tape between panels

2 and 2

↓ Erect scaffoldings ↓ Assemble layer 2 Place sealing tape between panels

↓ Tighten all bolts when the assembly of each layer is complete ↓ Assemble zenith panel

↓ Make a primary inspection when radome is assembled

↓ Sealing of panel to panel joints with silicone

↓ Sealing of bottom rim with silicone

↓ Disassemble scaffoldings ↓ Clean the site ↓ Radome installation is finished

Assembly Instruction of C-band Radome Uppgjord (även faktaansvarig om annan)

C2SAT Production AB Anders Strömberg Dokansv/Godk

C2SAT communication AB Erik Dalin

C2SATP-08:011 Uen Kontr

- Checked

2009-05-10

File name

PANEL ASSEMBLY SEQUENCE DRAWING

10 (12)

Assembly Instruction of C-band Radome Uppgjord (även faktaansvarig om annan)

C2SAT Production AB Anders Strömberg Dokansv/Godk

C2SAT communication AB Erik Dalin

C2SATP-08:011 Uen Kontr

- Checked

2009-05-10

File name

TOTAL DRAWING FOR 4M RADOME

11 (12)

Assembly Instruction of C-band Radome Uppgjord (även faktaansvarig om annan)

C2SAT Production AB Anders Strömberg Dokansv/Godk

C2SAT communication AB Erik Dalin

C2SATP-08:011 Uen Kontr

- Checked

2009-05-10

File name

LADDER Suggested dimensions of ladder that can be used inside the radome

12 (12)