c2sat - installation manual 4m radome _501_1730_ 2009a

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Marine Stabilised Antenna System

4m Radome (501-1730)Assembly ManualVersion 2009a

Version: 09A

Assembly Manual 4m Radome (501-1730)

Assembly Instruction of C-band RadomeUppgjord (ven faktaansvarig om annan) - Prepared (also subject responsible if other) Nr - No. Datum - Date

2 (12)

C2SAT Production AB Anders StrmbergDokansv/Godk - Doc respons/Approved Kontr - Checked

C2SATP-08:011 UenRev File name

2009-05-10

C2SAT communication AB Erik Dalin

09A Assembly Manual 4m Radome (501_1730).pdf

Table of Contents1 2 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 3 3 3 4 4 4 5 5 6 7 7 7 7 8 8 9 10 11 12

2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.4 2.5 2.6 2.7 2.7.1 2.7.2 2.8 3 4 5 6

INSTALLATION PROCEDURE FLOW CHART PANEL ASSEMBLY SEQUENCE DRAWING TOTAL DRAWING FOR 4M RADOME LADDER

Assembly Instruction of C-band RadomeUppgjord (ven faktaansvarig om annan) - Prepared (also subject responsible if other) Nr - No. Datum - Date

3 (12)

C2SAT Production AB Anders StrmbergDokansv/Godk - Doc respons/Approved Kontr - Checked

C2SATP-08:011 UenRev File name

2009-05-10

C2SAT communication AB Erik Dalin

09A Assembly Manual 4m Radome (501_1730).pdf

IntroductionThe 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.

1

GENERALRadome assembly should be operated by the qualified installation team. The chief of installation team should check the goods (panels, fasteners, washers, etc.) 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.

22.1

RADOME INSTALLATIONPreparation for installationEquip 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, fasteners, washers, etc.) have arrived on site. Check that all tools and other materials for radome installation on the Packing List have arrived on site.

Assembly Instruction of C-band RadomeUppgjord (ven faktaansvarig om annan) - Prepared (also subject responsible if other) Nr - No. Datum - Date

4 (12)

C2SAT Production AB Anders StrmbergDokansv/Godk - Doc respons/Approved Kontr - Checked

C2SATP-08:011 UenRev File name

2009-05-10

C2SAT communication AB Erik Dalin

09A Assembly Manual 4m Radome (501_1730).pdf

2.2

Radome doorThe 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.

2.3

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

2.3.1 Bottom rim sealingPut a piece of hard sealing rubber gasket on the platform where the Base Panels will be placed. Put base panel on sealing gasket, and tighten the base bolts.

Assembly Instruction of C-band RadomeUppgjord (ven faktaansvarig om annan) - Prepared (also subject responsible if other) Nr - No. Datum - Date

5 (12)

C2SAT Production AB Anders StrmbergDokansv/Godk - Doc respons/Approved Kontr - Checked

C2SATP-08:011 UenRev File name

2009-05-10

C2SAT communication AB Erik Dalinbase panel bolt

09A Assembly Manual 4m Radome (501_1730).pdf

sealing rubber gasket Base (Ship Deck)

sealing glue

sealing rubber gasket6 m m

2.3.2 Panel to panel sealing tapeApply sealing rubber tape on the joint edges the Base Panels when they are assembled together.

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.

2.3.3 Panel assemblyAssemble the Base Panels according to the Panel Assembly Sequence Drawing in chapter 4. Start with the door panel and than put the panel 1:1 to the left, continue with 1:2 etc.

Base bolts

mm 001

Panel bolts

Assembly Instruction of C-band RadomeUppgjord (ven faktaansvarig om annan) - Prepared (also subject responsible if other) Nr - No. Datum - Date

6 (12)

C2SAT Production AB Anders StrmbergDokansv/Godk - Doc respons/Approved Kontr - Checked

C2SATP-08:011 UenRev File name

2009-05-10

C2SAT communication AB Erik Dalin

09A Assembly Manual 4m Radome (501_1730).pdf

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.

10Nm.

Close up of bolts on the inside

Close up of joint on outside

Continue assembling all base panels until layer 1 is fully assembled.

Layer 1 assembly finished

2.4

Assemble panels of layer 2A 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 RadomeUppgjord (ven faktaansvarig om annan) - Prepared (also subject responsible if other) Nr - No. Datum - Date

7 (12)

C2SAT Production AB Anders StrmbergDokansv/Godk - Doc respons/Approved Kontr - Checked

C2SATP-08:011 UenRev File name

2009-05-10

C2SAT communication AB Erik Dalin

09A Assembly Manual 4m Radome (501_1730).pdf

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 Drawingin chapter 4.

Tighten panel joint bolts with spanner. Apply a momentum to all bolts of 10Nm

1Nm.

2.5

Zenith PanelAssemble the zenith panel with the same procedure until last layer is fully assembled. You may need a crane for this placement.

2.6

Inspect the boltsTighten all panel bolts with a momentum of 10Nm 1Nm from bottom to top. Re-tighten all base bolts with a momentum of 50Nm 10Nm.

2.7

Sealing the joints with silicone

2.7.1 Panel to panel sealingAfter the whole radome is assembled, installers climb on the outside of the radome and apply sealing glue to the exterior joint from top to bottom.sealing glue stainless bolt exterior surface

sealing tape

interior surface

mm

4 01

mm

Assembly Instruction of C-band RadomeUppgjord (ven faktaansvarig om annan) - Prepared (also subject responsible if other) Nr - No. Datum - Date

8 (12)

C2SAT Production AB Anders StrmbergDokansv/Godk - Doc respons/Approved Kontr - Checked

C2SATP-08:011 UenRev File name

2009-05-10

C2SAT communication AB Erik Dalin

09A Assembly Manual 4m Radome (501_1730).pdf

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, and after it has hardened, apply glue on the seam again. 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.

2.7.2 Base rim sealingApply sealing glue to the exterior joint between base panel and platform.base panel bolt

sealing rubber gasket Base (Ship Deck)

sealing glue

2.8

Cleanup after installationDisassemble scaffoldings inside the radome, dont touch the panel laminates and antennas. After completing the installation, remove dirt, stain and oil on the radome inside or outside surface, remove all rubbish on site, and keep the environment clean.

Assembly Instruction of C-band RadomeUppgjord (ven faktaansvarig om annan) - Prepared (also subject responsible if other) Nr - No. Datum - Date

9 (12)

C2SAT Production AB Anders StrmbergDokansv/Godk - Doc respons/Approved Kontr - Checked

C2SATP-08:011 UenRev File name

2009-05-10

C2SAT communication AB Erik Dalin