DVAC-2 CONCEPT DESCRIPTION: PRIME FOCUS DISH …...FINAL【DVAC-2 CONCEPT DESCRIPTION:PRIME FOCUS DISH】 [2011] 2011/06/15 Page 1 of 54 Name Designation Affiliation Date Signature

FINAL【DVAC-2 CONCEPT DESCRIPTION:PRIME FOCUS DISH】 [2011]

2011/06/15 Page 1 of 54

Name Designation Affiliation Date Signature

Additional Authors

Bo PENG, Yuanpeng ZHENG, Yu LU, Chengjin JIN, Zhenguo FENG, Minxiang SHI, Yifan ZHANG, Jianzhai ZHOU, Guoxi LIU,. Feng YAN, Jingnan LI, Shuo LI, Yuhai QIU, Lijia LIU

Submitted by:

Zanming LIANG Director of JLRAT JLRAT 2011.06.15

Accepted by:

Bo PENG Director of JLRAT JLRAT 2011.06.15

Approved by:

Feng WANG VP JLRAT 2011.06.15

DVAC-2 CONCEPT DESCRIPTION: PRIME FOCUS DISH

VERSION D

Document number .................................................................. WP2-XXXXXXXXXXXXXXXX

Revision ............................................................................................................. Version D

Author ................................................................................................................... Biao Du

Date ................................................................................................................ 2011/06/15

Status ......................................................................................................................... Final

FINAL WP2-XXXXXXX Revision : Version D

2011/06/15 Page 2 of 54

DOCUMENT HISTORY

Revision Date Of Issue Engineering Change

Number

Comments

A 2011.03.16 - First draft release for internal review

B 2011.05.31 Open for review

C 2011.06.03 - Open for review

D 2011.06.15 Final

DOCUMENT SOFTWARE

Package Version Filename

Wordprocessor MsWord Word 2003

Block diagrams MsVisio Word 2007

Real Time operating system VxWorks

Calculating radiation patterns of antenna Grasp Grasp 9.7

Calculating radiation patterns of feed Ansoft Ansoft 11.0

3D structure design Pro/E Pro/E4.0

2D structure design CAXA CAXA 2007

Finite element analysis MSC·Patran/Nastran MSC·Patran/Nastran 2007

Other MsProject Word 2003

ORGANISATION DETAILS

Name JLRAT

Physical/Postal

Address

Datun Road, A20, Chaoyang District, Beijing, 100012,

China

Fax. 86 10 64807689

Website www.nao.cas.cn

http://www.nao.cas.cn/


2011/06/15 Page 3 of 54

TABLE OF CONTENTS

1 INTRODUCTION ............................................................................................. 9

1.1 Purpose of the Document ....................................................................................................... 9

2 REFERENCES .............................................................................................. 10

3 CONTEXT .................................................................................................. 11

3.1 SKA Hierarchy........................................................................................................................ 11

3.2 Role of the Prime Focus Dish in the Dish Array .................................................................... 12

3.3 Context diagram ................................................................................................................... 13

4 PHYSICAL DESCRIPTION ................................................................................ 13

4.1 Introduction .......................................................................................................................... 13

4.2 Antenna Design and Manufacture ........................................................................................ 15

4.2.1 Microwave Optical Design Example .................................................................................. 16

4.2.2 Design of the Reflector ..................................................................................................... 18

4.2.3 Reflector Manufacture ...................................................................................................... 18

4.2.4 Back Structure and Feed Support ..................................................................................... 21

4.2.5 Antenna Mount Design ..................................................................................................... 21

4.2.5.1 Pedestal ..................................................................................................................... 23

4.2.5.2 Azimuth Part ............................................................................................................. 24

4.2.5.3 Elevation Part ............................................................................................................ 24

4.2.5.4 Polarisation Part ........................................................................................................ 25

4.2.6 Weight of Dish ................................................................................................................... 25

4.2.7 Packaging and Transportation .......................................................................................... 26

4.2.8 Antenna Servo Control Design .......................................................................................... 26

5 REQUIREMENTS .......................................................................................... 28

5.1 Functional Requirements ...................................................................................................... 29

5.2 Non-Functional Requirements .............................................................................................. 30

6 TECHNICAL PROGRESS TO DATE ...................................................................... 32

7 COST ESTIMATES ......................................................................................... 33

8 PLANS FOR FURTHER DEVELOPMENT ................................................................ 34

8.1 Milestone .............................................................................................................................. 34

8.2 Schedule for Prototype ......................................................................................................... 34

8.3 Phase I Construction ............................................................................................................. 35

8.4 Phase II Construction ............................................................................................................ 35

8.5 Technology Roadmap ........................................................................................................... 36


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9 RISK ANALYSIS AND MITIGATION STRATEGIES .................................................... 36

9.1 Purpose ................................................................................................................................. 36

9.2 References ............................................................................................................................ 37

9.3 Risk Management Group ...................................................................................................... 37

10 OTHER CROSS CUTTING ISSUES .................................................................... 39

10.1 Health, Safety & Environmental Management Plan ............................................................. 39

10.1.1 JLRAT Health Safety and Environment Policy ................................................................... 39

10.1.2 HSE Organization Roles and Responsibilities .................................................................... 40

10.1.3 Antenna Site Overview ..................................................................................................... 42

10.1.4 Health Safety and Environmental Risk Assessment .......................................................... 43

10.1.5 Safety Instructions and Guidelines ................................................................................... 43

10.1.5.1 Safety Instructions and Training ........................................................................... 43

10.1.5.2 Site Condition and Safety Induction at JLRAT ....................................................... 44

10.1.5.3 Safety Induction on Site ........................................................................................ 44

10.1.5.4 Specific HSE Training ............................................................................................. 44

10.1.5.5 Preliminary Set Up for Installation ........................................................................ 45

10.1.5.6 Housekeeping ........................................................................................................ 45

10.1.5.7 Personal Protective and Other Equipment ........................................................... 45

10.1.5.8 Fire Prevention ...................................................................................................... 46

10.1.5.9 Alcohol and Drugs ................................................................................................. 47

10.1.5.10 First Aid ................................................................................................................. 47

10.1.5.11 Hydration / Exposure ............................................................................................ 47

10.1.6 Environmental Hazards and Control Measures ................................................................ 48

10.1.7 HSE Meetings/Reports and Notices .................................................................................. 48

10.1.7.1 HSE Meetings ........................................................................................................ 48

10.1.7.2 Incident Reporting & Recording ............................................................................ 49

10.2 Quality Control ...................................................................................................................... 50

10.2.1 Design Phase ..................................................................................................................... 50

10.2.1.1 Plan Procedure ...................................................................................................... 50

10.2.1.2 Developing Procedure ........................................................................................... 51

10.2.1.3 Review ................................................................................................................... 51

10.2.2 Antenna Manufacturing Phase ......................................................................................... 51

10.2.2.1 Procurement Control ............................................................................................ 51

10.2.2.2 Manufacture Process Control ............................................................................... 52

10.2.2.3 Key Quality Process Point...................................................................................... 52

10.2.3 Assembly, Acceptance Phase ............................................................................................ 52

10.2.3.1 Products Test Control ............................................................................................ 53


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10.2.3.2 Malfunction Revise Control................................................................................... 53

10.2.3.3 Factory Acceptance Testing (FAT) ......................................................................... 53

10.2.4 Delivery Phase ................................................................................................................... 53

10.2.4.1 Storage, Packaging and Transportation ................................................................ 53

10.2.4.2 Site Installation...................................................................................................... 53

10.2.4.3 Site Acceptance Test (SAT) .................................................................................... 53


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LIST OF FIGURES

Fig. 1 Dish Array Hierarchy .................................................................................................................... 12

Fig. 2 Dish Context Diagram .................................................................................................................. 13

Fig. 3 Block Diagram of 15 Meter Antenna System .............................................................................. 16

Fig. 4 Prime Focus Dish Configuration ................................................................................................. 16

Fig. 5 15 Meter Prime Focus Antenna Geometry ................................................................................. 17

Fig. 6 Radiation Pattern in Phi=90ºand Phi=0º Plane at f=1.5GHz ....................................................... 17

Fig. 7 Prime Focus Antenna Reflector ................................................................................................... 18

Fig. 8 Integral Sandwich Structure of the Reflector .............................................................................. 19

Fig. 9 Reflector Rib Configuration ......................................................................................................... 20

Fig. 10 Back Structure and Feed Support .............................................................................................. 21

Fig. 11 Antenna Mount Structure ......................................................................................................... 22

Fig. 12 Antenna Mount Dimensions ..................................................................................................... 22

Fig. 13 Pedestal ..................................................................................................................................... 23

Fig. 14 Azimuth Part .............................................................................................................................. 24

Fig. 15 Elevation Part ............................................................................................................................ 25

Fig. 16 Block Diagram of the Antenna Control System ......................................................................... 26

Fig. 17 Technology Roadmap ................................................................................................................ 36

Fig. 18 Flow Chart of Employee HSE Responsibility .............................................................................. 40


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LIST OF TABLES

Table 1 Specifications for 15 Meter Prime Focus Antenna ................................................................... 14

Table 2 Weight of 15 Meter Antenna ................................................................................................... 25

Table 3 Cost Estimates .......................................................................................................................... 33

Table 4 Milestones of SKA Project-Dish Subsystem .............................................................................. 34

Table 5 Schedule for Manufacture of Prototype .................................................................................. 35

Table 6 Potential Risk and Its Proposed Mitigation .............................................................................. 37

Table 7 Regulatory Reporting Time Frames .......................................................................................... 49


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LIST OF ABBREVIATIONS

ASKAP .......................... Australian SKA Pathfinder

AZ .................................. Azimuth

CoDR ............................. Conceptual Design Review

DVAC-1 ......................... Dish Verification Antenna China #1

DVAC-2 ......................... Dish Verification Antenna China #2

EL. ................................. Elevation

EMC. ............................. Electro Magnetic Compatibility

FAT ................................ Factory Acceptance Test

FEA………………………Finite Element Analysis

HR. ................................ Human Resource

HSE ............................... Health Safety and Environment

JLRAT ........................... Joint Laboratory for Radio Astronomy Technology

LNA ............................... Low Noise Amplifier

LRU ............................... Line-Replaceable Unit

NCR ............................... Non-Conformed Report

NTP ............................... Network Time Protocol

PAF ............................... Phased Array Feed

POL ............................... Polarisation

PrepSKA........................ Preparatory Study for the SKA

QMG .............................. Quality Management Group

QMS .............................. Quality Management System

RFI ................................. Radio Frequency Interference

r.m.s. ............................. Root Mean Square

S.A. ................................ South Africa

SAT ............................... Site Acceptance Test

SEMP ............................ System Engineering Management Plan

SKA ............................... Square Kilometre Array

SKA1 ............................. Phase I Construction of SKA Project

SKA2 ............................. Phase II Construction of SKA Project

SKADS .......................... SKA Design Studies

SPDO ............................ SKA Program Development Office

SPO ............................... SKA Project Office

SPF ............................... Single Pixel Feed

TBC ............................... To be calculated

TBD ............................... To be decided

UTC ............................... Universal Time Coordinated

WBSPFs ........................ Wideband Single-Pixel Feeds

WMS .............................. Workmanship Manufacturing Specification


2011/06/15 Page 9 of 54

1 Introduction

JLRAT propose two concept designs for the SKA dish: Dish Verification Antenna China #1 (DVAC-1)

and DVAC-2. DVAC-1 refers to an offset Gregorian dish; DVAC-2 refers to axis-symmetric dish (prime

focus reflector antenna).

This document describes the concept design for DVAC-2, a prime focus dish with three axis design,

which has been developed by the Chinese Joint Laboratory for Radio Astronomy Technology (JLRAT)

for potential use in the SKA Dish Array.

This document also discusses the requirements for the dish, technical progress to date, cost

estimates for mass production, plans for further development, risk analysis and mitigation strategies,

and other cross cutting issues.

This document focuses on the concept design and analysis only of a prime focus antenna.

The main attractions of the DVAC-2 design are as follows.

Wideband single-pixel feed (WBSPF) is used to ensure high antenna efficiency and decrease

the number of the feeds.

Integrated modular design is beneficial to accuracy assurance, cost reduction and

convenient maintenance.

One whole reflector surface is used to allow rapid installation with low man power.

Sealed and Lubricated Driving Devices are used for high reliability and low maintenance cost

Mature technology is used to achieve low cost, high reliability, and convenient maintenance.

1.1 Purpose of the Document

The purpose of this document is to describe the dish subsystem, including the following information.

Its context within the Dish Array Element

Discussion of the SKA requirements that the dish subsystem will address

Physical description of the dish subsystem

Target specifications

Description of interfaces


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Details of technical progress to date

Cost estimates for production in SKA quantities

Details of further plans up to production readiness

2 References

[1] System Engineering Management Plan (SEMP) WP2-005.010.030-MP-001Reference 3

[2] Requirements_spreadsheet_v1_20100929(1)

[3] SKA Dish Verification Antenna: Executive Summary

[4] SKA Dish Verification Antenna System Functional Specifications v 0.6

[5] DVAC-2 Antenna Design and Analysis, JLRAT May, 2011

[6] SKA System Requirement Specification (SRS)

[7] 11-MGT-090.010.010-RE-003-C_Risk Register

[8] 14-MGT-040.040.000-MP-001-1_Risk Man Plan

DRAFT WP2-XXXXXXX Revision : Version D

2011/06/15 Page 11 of 54

3 Context

3.1 SKA Hierarchy

The SKA Systems Engineering Management Plan (SEMP)[1] has defined multiple layers of hierarchy:

L7: SKA User

L6: System

L5: Element

L4: Sub-System

L3: Assembly

L2: Sub Assemblies

L1: Components

Although not explicitly stated in the SEMP, the hierarchical approach has the advantage of breaking

down the complexity of the system. Each layer is only concerned about its own functionality and its

interface to the immediately adjacent layers.

Within the hierarchical scheme, the dish array is defined at the element level deriving its requirements

directly from a subset of System level requirements. In turn, the sub-system level allows the dish array

element to be partitioned further into Level 4 functionality, comprising the dish, PAF and single pixel

feed (SPF) sub systems. Dish is further divided into dish structure and servo control assemblies at level 3,

and these two assemblies also can be divided into sub assemblies at level 2 and components at level 1.

Introducing these layers of hierarchy ensures that the complexity of the system is broken down such

that an individual layers only have to deal with their relevant perspective of the system.


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Main

Reflector

Mount

Dish

Array

Dish

PAF

Single Pixel

Feeds

L5

Elements

L4

Sub-Systems

L3

Assemblies

L2

Sub

Assemblies

Dish Structure

Servo Control

Feed

Support

Antenna

Pedestal

Azimuth

Part

Elevation

Part

ACU ADUPower

Distribution

Position

Encoders

Limit and

Safety

Protection

Reflector

L1

Components

Polarisation

Part

Fig. 1 Dish Array Hierarchy

In Fig. 1, dish as one of the sub-systems is divided into 3 layers：

At level 3, dish is divided into dish structure and servo control assemblies;

At level 2, dish structure is divided into 2 sub assemblies: reflector and mount; servo control is

divided into 5 sub assemblies: ACU, ADU, power distribution, position encoders, limit and safety

protection;

At level 1, reflector is further divided into 2 components: main reflector and feed support;

mount is further divided into 4 components: pedestal, azimuth part, elevation part and

polarisation part.

3.2 Role of the Prime Focus Dish in the Dish Array

The prime focus dish that has been studied in depth by the JLRAT team is a potential SKA dish capable of

accommodating currently 3 single pixel feed payloads (however, if more, e.g. 5 corrugated horns are

needed for SKA Phase 2, then the impact of the size and weight of the feeds on structure of the antenna

may need to be further investigated), a phased array feed (SKA Requirements:

Requirements_spreadsheet_v1_20100929(1)[2]). Alternatively, 2 Wideband single-pixel feeds (WBSPFs,

developed by JLRAT team) may be used to replace 3 single pixel feeds.

It is a completely new design that specifically addresses the functional and non-functional requirements

for the SKA; many of these requirements are unique to the SKA and go far beyond what has previously

required for dishes used in ground based radio astronomy.


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3.3 Context diagram

Fig. 2 is a first order system context diagram, which contains a mixture of both science and non-science

influences. The diagram illustrates the large number of influences that must be considered in the Dish

design. These will spawn the development of Dish requirements, both functional and non-functional.

Other elements of the context will be identified in the next phase of the project. At this high level, the

context diagram for SKA1 and SKA2 are identical.

Health

and

Safety

Operations

Maintenance

and support

Human

Factors

Natural

Environment

Technology

Dish

Manufacturing

and installation

Security

Evaluation

during

Construciton

External RFI

Environment

SKA System

Transitioning

between

phases

Commercial

Industry

Power

Provision

Radio

Propagation;

Troposphere,

Ionosphere

Existing

Infrastructure

Regulatory

Transportation

Fig. 2 Dish Context Diagram

4 Physical Description

This chapter gives a description of the dish subsystem, with diagrams, CAD drawings, and photographs

etc., Including details of how the sub system will interface with other parts of the Dish Array.

4.1 Introduction

The SKA is expected to need about 3300 15-metre dishes, to be installed in Australasia or Southern

Africa. Essential features of the antennas are as follows [3].


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Ease of installation, using minimal manpower and tools

Low manufacturing cost

Ease of transportation

Minimal routine maintenance requirements

Lifetime: minimum 30 years, up to 50 years

Main specifications for the DVAC-2 antenna are given in Table 1[4].

Table 1 Specifications for 15 Meter Prime Focus Antenna

Items Specification

Antenna type Prime Focus Antenna

Diameter 15 meter

Focal length / Diameter

ratio (f/D) 0.4

Mount type AZ-EL-POL mount（AZ, POL: Gear , EL: Screw）

Frequency switch

manner Feed switch（within 30s）

Surface accuracy 1.1mm r.m.s. (at night and no wind)

TBC(at daytime, with wind)

Pointing accuracy 10 arcsec r.m.s. (at night and no wind)

TBC(at daytime, with wind)

Travel range

AZ：-270°270°

EL：15°85°

POL: -180°180°

Slew rates (Max)

Acceleration (Max)

AZ：3°/s, EL：1°/s, POL: 3°/s

AZ：3°/s2, EL：1°/s2, POL：3°/s2

Feed type 2 wide-band SPF (see note 2)and a PAF

Frequency band(GHz) 0.31.5 1.510


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Items Specification

Wavelength（cm） 20100 320

Antenna aperture

efficiency （%）

0.3 GHz 0.9 GHz 1.5 GHz 1.5 GHz 6 GHz 10 GHz

60 60 65 65 60 50

First sidelobe level

（dB） -20 -20

Polarisation Dual-CP Dual-LP Dual-CP Dual-LP

VSWR 1.5 2 1.5 2

Ambient temperature -10°C50°C

Wind velocity Drive to stow at zenith: 70 km/h

Survivable at zenith: 160 km/h

Design lifetime 30 years

Notes: This table is based on the following conditions, if the requirement changed, further investigation will be needed.

1. At night, windless, 2. Two wideband single-pixel feeds (WBSPFs, developed by JLRAT team)

4.2 Antenna Design and Manufacture

The 15 meter antenna design includes microwave optical design, structural design and servo control

design. Its design characteristics are given in the following.

Wideband single-pixel feed (WBSPF) is used to ensure high antenna efficiency and decrease the

number of the feeds.

Integrated modular design is beneficial to accuracy assurance, cost reduction and convenient

maintenance.

One whole reflector surface is used to allow rapid installation with low man power.

Sealed and Lubricated Driving Devices are used for high reliability and low maintenance cost

Mature technology is used to achieve low cost, high reliability, and convenient maintenance.


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Fig. 3 Block Diagram of 15 Meter Antenna System

The prime focus dish configuration is shown in Fig. 4. The design shows single piece reflector supported

by a minimal spar structure. The mount is a turning head design with a lead screw elevation actuator

and POL axis. The design also includes a support and interchange mechanism of PAF and 3 SPFs or 2

WBSPFs.

Mount

Wrap

Room

Feed Support

Truss

Reflector

Feed

Switch

Fig. 4 Prime Focus Dish Configuration

4.2.1 Microwave Optical Design Example

The antenna adopts a parabolic reflector. The ratio of focus over diameter (F/D) is 0.4, equivalent to the


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half angle of 64 degrees subtended to the reflector. The blockage by the feed is φ 1600 mm. Geometry

of prime focus antenna is shown in Fig. 5.

The electrical parameters: DM=15000mm, FM=6000mm,Φ*=64°.

Fig. 5 15 Meter Prime Focus Antenna Geometry

Efficiency and radiation patterns of the antenna are calculated by the simulation software GRASP9.7.

The calculated radiation pattern and efficiency for the antenna are shown in Fig. 6.

-10 -8 -6 -4 -2 0 2 4 6 8 10-70

-60

-50

-40

-30

-20

-10

0

Angle [deg]

Rela

tive P

ow

er

[dB

]

Freq=1.5 [GHz] Gain=46.02 [dBi] Aeff=72.0 [%]

phi=0°

phi=90°

Fig. 6 Radiation Pattern in Phi=90ºand Phi=0º Plane at f=1.5GHz

Further details can be found in section 4.1.2 in [5].


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4.2.2 Design of the Reflector

The antenna reflector subsystem mainly consists of the reflector surface, back structure, feed support as

well as feed switch device as shown in Fig. 7.

The reflector surface design adopts single sandwich panel. The back structure adopts simple truss

structure and feeds are supported by four legs.

Fig. 7 Prime Focus Antenna Reflector

4.2.3 Reflector Manufacture

Two draft designs are provided for main reflector manufacture. One adopts aluminum skin and the

other carbon fibre.

Design 1. Aluminum sandwich structure

The main reflector surface consists of two aluminum skins and Z-shaped ribs between the two skins,

composing integral sandwich structure, shown in Fig. 8


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Al Skin

Z-type Rib

Gluing &

Riveting

Gluing

Al Skin

Fig. 8 Integral Sandwich Structure of the Reflector

Two aluminum skins and Z-shaped ribs are glued and riveted on the mould. The space between the

skin and the ribs may be stuffed by polystyrene foam to increase rigidity. The aluminum skin is

2mm(up)/1mm(down) in thickness and 2m in width, and its length varies with the arc length of the

reflector. Z-shaped ribs are laid at the joints of adjacent skins and the aperture edge of the main

reflector surface. In central area, some ribs are placed in cross direction. Some ribs are also placed

at the joints of the back structure and the surface ribs in order to enhance the local rigidity. On the

mould, the skin of operating surface and the ribs are glued through the negative pressure method,

the back skin and ribs are glued and riveted together. Total surface accuracy σ≤0.8mm (r.m.s.).

Fig. 9 shows the main reflector rib configuration.


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Fig. 9 Reflector Rib Configuration

All the components of skins and ribs will be produced in the factory, and then transported to the

site for the shaping of the main reflector with helps of the mould, and assembly.

Design 2. Carbon fibre sandwich structure

Compared with design 1, the aluminum skins are replaced by carbon fibre skins and Z-shaped ribs

are not used. The space between two skins is stuffed by polystyrene foam.

We have done some research work reaches on these two designs for offset Gregorian dish. From

the results of FEA for these two types of reflector, the carbon fibre panel has lighter weight and less

deformation. The details can be found in section 4.2.1 in [5]. From technical process, we think that

carbon fibre is easier to be shaped on the mould and the surface accuracy will be better than

0.8mm (r.m.s.). We will do further research work to decide which design will be adopted eventually.

Our practice shows that the surface reflectivity of the carbon fibre reflector is the same as that of

aluminum reflector, better than 99% at 10 GHz.


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4.2.4 Back Structure and Feed Support

The reflector adopts a minimal spar back structure and a feed support with four thin steel trusses, as

shown in Fig. 10.

Fig. 10 Back Structure and Feed Support

4.2.5 Antenna Mount Design

The antenna mount adopts the AZ-EL-POL type structure, with gear drive in AZ, POL and screw drive in

EL. It is composed of pedestal, AZ part, EL part and POL part, shown in Fig. 11. The mount has a strong

bearing capacity, compact structure and is easy to manufacture and transport.

The elevation driving device adopts the planetary reducer with ball screw driving, without

counterweight. The azimuth and elevation angular encoder mounting mechanism adopts flexible-axis

driving technique with high rotational rigidity. The azimuth cable wrap device adopts the double-layer

ring structure suitable for cables bending. The polarisation cable wrap device adopts a special single-

layer ring structure suitable for elevation motion.

Fig. 11 and Fig. 12 show the proposed mount structure for the prime focus antenna. Further details are


2011/06/15 Page 22 of 54

in section 4.2.2 in [5].

Fig. 11 Antenna Mount Structure

φ 2900

8413

6103

2695

Fig. 12 Antenna Mount Dimensions

The elevation part of antenna mount and the reflector are in integratived design, which may effectively

improve the rigidity, ensure the accuracy of the reflector and reduce the weight of the whole antenna.


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The azimuth part adopts dual-motor electrical anti-backlash driving with high driving precision. The

polarisation part adopts single-motor driving.

Modular design is adopted for all the rotation parts of the mount. The design of Line-Replaceable Unit

(LRU) is applied in reducer, motor, encoder and limit device, azimuth cable wrap, elevation lock device,

which is not only easy for replacement and maintenance, but also suitable for batch production.

The AZ drive adopts external gear bearing and is installed on the AZ rotation table which is better than

adopting internal bearing located in the inner box. It is easy to maintain and achieves high drive rigidity.

A seal cover is used to avoid dust and sands.

All of the structural parts of antenna mount are welded with steel plates, which allow for fast scale

production and may reduce the weight.

4.2.5.1 Pedestal

The pedestal is the supporting body of the antenna mount, as shown in Fig. 13. It is a low-cost cylinder

welded with steel plates and it is designed for easy manufacturing.

Fig. 13 Pedestal


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4.2.5.2 Azimuth Part

The azimuth part is comprised of azimuth pedestal, azimuth disc bearing, azimuth rotation table,

azimuth encoder and limit device, azimuth cable wrap device, azimuth reducer, azimuth motor, etc., as

shown in Fig. 14.

Four-point-contact ball bearing (external-tooth) with high load-carrying capability and high rotation

accuracy is adopted in azimuth part.

Double-layer ring structure is adopted in azimuth cable wrap device to support the cable. This device is

suitable for more cables and larger bending radius.

Fig. 14 Azimuth Part

4.2.5.3 Elevation Part

The elevation part is comprised of elevation box, elevation axis bearers, elevation axes,

elevation driving bracket, reducer, motor, lead screw, antenna support, encoder ,limit device

and elevation cable towline, etc., as shown in Fig. 15.


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Left and right elevation yokes and azimuth rotation table are welded into a one-box-type

structure(elevation box), which can greatly increase the supporting rigidity of the azimuth

rotation table and elevation axis.

Fig. 15 Elevation Part

4.2.5.4 Polarisation Part

The polarisation part is comprised of a base pedestal on the bottom of reflector hub, disc bearing,

driving, encoder and limit device, cable wrap device, etc., as shown in Fig. 15

4.2.6 Weight of Dish

The weight of the 15 meter antenna is listed in Table 2.

Table 2 Weight of 15 Meter Antenna

ITEM WEIGHT（aluminum, Kg）

WEIGHT（carbon fibre, Kg）

Reflector 6800 6550

Mount 12500 12500

TOTAL WEIGHT OF DISH 19300 19050


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4.2.7 Packaging and Transportation

All the structural components in the antenna except for the reflector surface can be disassembled and

assembled easily, and they can be disassembled into many parts suitable for transportation in a

container.

4.2.8 Antenna Servo Control Design

The antenna servo control system consists of Antenna Control Unit (ACU), Antenna Drivers and motors,

power distribution devices, encoders, local control pendant, limit and safety protection device. The ACU,

Drivers and power distribution devices are placed inside a RFI-shielded cabinet. The block diagram of the

antenna control system is shown in Fig. 16.

AZ ADU

Feed System

Mount

RFI -Tight

Servo Cabinet

Power

Distribution

POL- Driver

ACU

Remote

Comput

er

EL Motor

Limit&

Safety

Switches

AZ

Encoder

EL Encoder

AZ Motor1

AZ Motor 2

POL Motor

AC

Power

Supply

EL-Driver

AZ-Driver1

AZ-Driver2

Local

Control

Pendant

Networks

MotorFeed

ControlSensor

POL

Encoder

Fig. 16 Block Diagram of the Antenna Control System

The main advantages of the control system are:

State-of-the-art components

Improved performance because of fully digital control system

Very high reliability


2011/06/15 Page 27 of 54

Modular design, easy for maintenance

No maintenance required for brushless motors

Good spare part availability

The design of antenna control system is based on the feedback control theory, which controls the

rotation of the azimuth axis and elevation axis simultaneously. With a typical closed-loop control system

of current, velocity and position loops are adopted; it has the advantages of steady rotation and

accurate position control of the antenna.

The ACU is mainly composed of an industrial computer and peripheral control circuit, etc. The ACU

communicates with the remote computer via Ethernet, receives M&C commands and data, and reports

antenna status and position. It also receives the UTC time signal sent through the NTP client by the

station timing device and sets the time of the ACU. An operator pendant providing basic controls at the

pedestal (stop, start, drive) will also be provided.

The operating modes below are available for azimuth and elevation axes:

STANDBY

The standby mode is the power-on default operation mode or return-on-fault mode of the antenna

drive control system

PRESET

Moving to predefined position. Active position control is maintained.

RATE

Moving at user-defined constant velocity.

PROGRAM TRACK

Tracking of an object along a pre-defined path. The path is defined by a sequence of

time/position/velocity samples.

STOW

The ACU automatically controls the antenna to rotate to a preset stow position and lock the stow

pin.

The azimuth axis will be equipped with two AC drivers and two brushless motors, the elevation axis

and polarisation axis will be equipped with single AC drivers and single brushless motors.


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Synchronous motors with permanent magnets will be used. Each motor includes a position sensor

which is used for electronic commutation and for measuring the motor velocity. Also, each motor

will include a magnetic brake.

To ensure high positioning accuracy, the AZ axis is equipped with torque bias drives to compensate

for the gearbox backlash.

The absolute position encoder is used for each axis, which resolution is better than 25 bits .The

azimuth axis is equipped with a turn-differentiating sensor to resolve the azimuth ambiguity in the

overlap range.

The interlock system formed by the safety protection devices and the sensor on the antenna mount

is used to ensure the safety of the antenna. The interlock system consists of safety device, brake,

limit switch, emergency stop switch, etc.

The function of the feed control devices is to select feed when the antenna works in different bands.

The principal function of the power distribution unit is to supply power and provide power

distribution protection for the whole equipment. The power supplying can be controlled by the

contactor either remotely or locally. The power on/off of the antenna drive system is under the

control of the ACU.

5 Requirements

This section of the document will describe how the proposed sub system will address the requirements

for the Dish Array, which are derived from the system requirements [6] and ultimately the science

requirements. These include both the functional and non-functional requirements. Some of the key

requirements that need to be addressed are as follows.

• Imaging dynamic range

• Mass manufacture

• Operating cost

• Feed flexibility

• Rapid installation

• Maximising A/T per unit system cost (i.e. including signal transport, signal processing, computing

etc.)

• Minimising maintenance cost


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• Electromagnetic compatibility

5.1 Functional Requirements

Describe which requirements are being addressed and how the proposed sub system is expected to

meet them.

Aperture efficiency

Antenna aperture efficiency: ≥50% at 10GHz; ≥60% at 0.3GHz,0.9GHz,6GHz; ≥65% at 1.5GHz .

Details of the analysis and investigation can be found in [5], in Section 5.2.

First sidelobe level

The first sidelobe level -20dB.

Details of the analysis and investigation can be found in [5], in Section 4.1.2.

Maximising A/T per unit system cost (i.e. including signal transport, signal processing, computing

etc.)

Comparing various schemes of the design, demonstration and optimization; the best A/T could

be reached after the prototype and verification.

Surface accuracy

The total surface accuracy at night and no wind 1.1mm r.m.s.


Pointing accuracy

Pointing accuracy no wind and at night 10 arcsec r.m.s.

Details of the analysis and investigation can be found in [5], in Section 5.4.

Travel range

AZ：-270°270°; EL： 15°85°; POL：-180°180°


Slew rates (Max)

AZ：3°/s, EL：1°/s, POL：3°/s



2011/06/15 Page 30 of 54

Feed flexibility

The dish shall accommodate three single pixel feeds and PAF payloads. Feeds can be remote

selectable with a changeover time of 30 seconds maximum.

Various feed installation interfaces are preserved, with a positioning design.


Imaging dynamic range

To achieve high imaging dynamic range, the dish shall have stable beam shape and pointing.

For the design of prime focus dish with 3-axis, a stable dynamic range could be achieved.

Because of the environmental load influences (e.g. gravity and wind loads), the beam shape and

pointing of the antenna will be changed in motion. Therefore, in structural design, we need to

analyse the effect of the surface accuracy and pointing accuracy caused by loads, then reduce

the error by optimize the structure design. By measured results, system error could be modified.

5.2 Non-Functional Requirements

There are many non-functional requirements that will need to be met if the Dish Array is to operate

successfully; a few of these are listed above. Describe here how some of the critical requirements are

expected to be met.

Mass manufacture

On site mass manufacture of the main reflector panels are proposed as follows:

1) Our design is fully considerate on mass production line, can meet the SKA project schedule

by increasing the equipment and facility.

2) In terms of antenna manufacturing

Manufacture Technology adopts negative pressure shaping method.

The material of main reflector panel and other raw material will be transported to site and

manufactured, for other structure parts will be manufactured in factory and transport to

site.

Operating cost

There are several factors have been considered in the analysis of operating cost, for example:

power supply, cost of regular inspection, cost of replacement of damageable parts, cost of

lubricating oil supply, un-manned operating and failure detection.

Rapid installation


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The dish shall be designed for rapid installation with a minimum of manpower and equipment.

This requirement can be met as follow:

1） Reflector panel is shaped as a whole, no assembly is required

2） LRU design in all structure

3） Fast and fine location re-assembly of all structure parts on site, free adjustment

Minimising maintenance cost

1） Using lubricant oil, maintain the antennas each year.

2） Structural design (outside located motors, sealed lubricated driving devices) can reduce the

maintenance cost.

3） Changeable units are used, and so it is convenient to replace them, and the maintenance

cost is reduced.

Electromagnetic compatibility

1） The antennas are to be designed to preserve the RFI environment on site, and this requires

that all cables, motors, terminal boxes and other electrical devices are to be shielded and

made RFI-tight. Furthermore, the use of instruments or tools which generate RFI during on-

site construction, installation or commissioning will be discouraged.

2） The entire control system is to be housed in RFI-tight cabinet(s).

3） A complete drive and control system (motors, encoders, limit switches and controller(s) in

their RFI-tight cabinet(s)) must pass the test.

4） The door seal should provide RFI isolation. Servo cabinet must be sealed.

The dish shall be designed for 30 year minimum lifetime.

Life of some parts like bearing and gear etc. can be evaluated and might be given an accelerated

life test; some damageable parts must be chosen carefully and optimized.

The routine maintenance interval for each dish shall be more than 1 year.

Analyze the reliability of each component, by choosing and optimizing the components and

parts, and optimizing the design of antenna, ensure the routine maintenance interval for each

dish shall be more than 1 year.

Dishes shall incorporate lightning protection to TBD standard.

After making sure the local standard, design the lightning protection according to relative

requirements; and professional company can supply some technical support.

Dishes in the array shall be provided with security systems to prevent access by unwanted

visitors.


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All components of the antenna should be waterproof and can be protected from destroying by

the animals, e.g. snake, goat, cattle, spider and parrot. We are considering adding mesh cover at

the vent hole to keep off birds and spiders etc.

6 Technical Progress to Date

Give a brief description of development work to date, together with critical results where appropriate.

More substantial reports on technical progress can be included as appendices.

Up to now, we have a good command of 3-axis technology (alt-AZ antenna mount with the addition of a

third axis that rotates the entire reflector), cable wrap technology (capable of handling a large amount

of cables across the third axis in any elevation angle), wideband feed technology (excellent transmitting

and radiating performances in several octave bands), sandwich panel (a honeycomb sandwich structure

with two aluminum alloy or carbon fibre panel skins) and LRU design, etc.

JLRAT has capabilities in manufacturing and testing of carbon fibre reflector, which is successfully used

in 2.4m offset carbon fibre sandwich antenna (surface accuracy is 0.3mm).

JLRAT has the experience in design and manufacturing long life antennas, which are continuously and

smoothly operating in 24 h/d, over ten years, with the rotation speed of 4 runs per minute.

A matured EMC technology has been successfully used, for example, 80dB isolation of servo cabinet and

40dB isolation of mount have been achieved in ASKAP Antenna project.

Software used in design is given below.

Software used in the servo system is as given below.

Operating system: Real Time operating system VxWorks

Programming languages according to IEC61131−3: IL, LAD, FBS, ST, SFC, CFC

Programming system: Rexroth IndraWorks

Programming interface: Ethernet or RS232


2011/06/15 Page 33 of 54

Development environment : Microsoft Windows XP or Windows2000

Software used in microwave optical design is as given below.

Calculating radiation patterns of antenna : Grasp 9.7

Calculating radiation patterns of feed : Ansoft 11.0

Software used in structure design is as given below.

3D structure design : Pro/E4.0

2D structure design : CAXA 2007

Finite element analysis : MSC·Patran/Nastran 2007

7 Cost Estimates

This chapter provides initial cost estimates for manufacture of the proposed sub system in quantities

applicable to the SKA pre-construction phase, phases 1 and 2.

The budget for prototyping (including feed subsystem) and verification in pre-construction phase is

approx. € 3.5 million. The feed subsystem is for test only.

Initial investment for phase I including verification is approx. € 3 million, while for phase II is TBD.

The unit price of antenna in phase I and phase II is shown in Table 3.

Table 3 Cost Estimates

ITEM UNIT PRICE (aluminum, k €)

1-250S

UNIT PRICE (carbon fibre, k €)

1-250S

UNIT PRICE (aluminum, k €)

251-3300S

UNIT PRICE (carbon fibre, k €)

251-3300S

Reflector 65 75 63 72

Pedestal 108 107 103 102

Servo System 38 38 36 36

Total 211 220 202 210

Notes: 1) The exchange rate CNY and EUR is 9.5:1

2) The price is based on price index in 2010, and without any tax.

3) The feed subsystem is not included in this cost estimates.


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8 Plans for Further Development

8.1 Milestone

Describe the plans to further develop the proposed sub system up to the point where it can be mass

manufactured. Include time lines and details of resources that will be available to carry out the work.

Based on the ‘SKA Project’ study logic as outlined in overall requirement, the following master schedule

shows all work packages in the frame of the overall schedule plan. The master schedule for the SKA

Project—Dish subsystem is showing in Table 4.

Table 4 Milestones of SKA Project-Dish Subsystem

8.2 Schedule for Prototype

The schedule for manufacture of prototype is listed in Table 5

MILESTONE TIME

Pre-construction 2011.7-2015.12

Concept Design -2011.7

Primary Design and Feasibility Study 2011.8-2012.1

Final Design of Prototype 2012.2-2012.4

Finish Manufacture of Prototype 2012.5-2013.2

Test Verification of Prototype 2013.3-2013.5

Design Review and Design Change 2013.6-2013.8

Finish Manufacture of the Second Prototype 2013.9-2014.1

Test Verification of the Second Prototype 2014.2-2014.4

Further Design Review and Design Change 2014.5-2014.8

Mass Manufacture Preparation 2014.9-2015.12

Phase I Construction Dishes ~250s 2016-2019

Phase II Construction Dishes~3000s 2019-2023


2011/06/15 Page 35 of 54

Table 5 Schedule for Manufacture of Prototype

8.3 Phase I Construction

This part aims to give a period budget of JLRAT or JLRAT coordinated parties manufacturing schedule,

however the project plan in Gantt chart is expected to be given after prototype manufacturing.

Period: 2016-012016.12，

Installation on site and preparation for manufacture

Period: 2017.012017.12

9 antennas/month, 1-100 sets to be finished in manufacturing and installation.

Period: 2018.012018.10


Period: 2018.112018.12

For contingency.

8.4 Phase II Construction

Period: 2018-12018-12

Installation on site and preparation for manufacture

Period: 2019-12023-12



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8.5 Technology Roadmap

Technology roadmap is shown in Fig. 17

Preconstruction2011.7-2015.12

Phase I Construction

2016-2019

Dishes ~250s

Phase II Construction

2019-2023

Dishes~3000s

Concept Design

-2011.7

Primary Design and

Feasibility Study

2011.8-2012.1

Final Design of Prototype

2012.2-2012.4

Finish Manufacture of

Prototype

2012.5-2013.2

Test Verification of

Prototype

2013.3-2013.5

Design Review and

Design Change

2013.6-2013.8

Finish Manufacture of the

Second Prototype

2013.9-2014.1

Test Verification of the

Second Prototype

2014.2-2014.4

Further Design Review

and Design Change

2014.5-2014.8

Mass Manufacture

Preparation

2014.9-2015.12

Fig. 17 Technology Roadmap

9 Risk Analysis and Mitigation Strategies

9.1 Purpose

This part describes the Risk Management Plan for the SKA Project, based on DVAC Design. The purpose

of risk management is to identify possible threats to project success and mitigate or eliminate the

negative impacts on the project.


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9.2 References

The plan is developed based on 11-MGT-090.010.010-RE-003-C_Risk Register [7] and 14-MGT-

040.040.000-MP-001-1_Risk Man Plan [8]. However, the intention of this part is the dish and relative

crossing cutting issues only, the whole risk for SKA project is beyond the scope of JLRAT consideration.

9.3 Risk Management Group

Systematic risk management comprises of the following distinct steps:

Risk identification---the process of determining the specific risk factors that can be reasonably

expected to affect the project.

Analysis of probability and consequences---the potential impact of these risk factors, determined

by how likely they are to occur and the effect they would have on the project if they do occur.

Risk mitigation strategies---steps taken to minimize the potential impact of those risk factors

deemed sufficiently threatening to the project.

Control and documentation---creating a knowledge base for future projects based on lessons

learned.

Table 6 lists the potential risk and its proposed mitigation in dish part ONLY.

Table 6 Potential Risk and Its Proposed Mitigation

No. Risk Brief description Impact Proposed mitigation

1 Environment protection

Dishes are installed in rural or original area, to protect the local environment during installation period and waste disposal after the life cycle.

The lessons in failure to protect the environment are obviously. Any offended of site environmental regulation may cause delay or termination of the project.

Well cooperated with the selected country, make a fully understand of local regulation and cultural. Consider the waste disposal (during installation/after dish life cycle) in design phase. Lessons earned shall be transferred to SKA dish subsystem

2 Cost Exceed As a long-term project, the conflict between budget and real expense could easily happen. esp for raw material outsourced project, the price index variation is common. Any delay may also cause the extra cost.

Underestimation of the cost will lead to an increase in the budget, which will effect the whole project operation in some degree.

Cooperate with a reliable supplier with good reputation,


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3 Scope of logistics and support

Logistics from China to selected site

It requires a large number of people, tools, equipment, facilities arrangement, any failure of each section will terminate or delay the project schedule

A logistics group need to be formed in charge of each section. Each cooperated country/group/organization requires a smooth information communication.

4 Schedule control

Most refers to manufacturing and installation schedule control

The base of whole project schedule.

Key parts are manufactured by the contractor. Subcontract/external supply backup (A/B or A/B/C role) The principle of using different places for back ups will be applied. There will be a recovery plan using rapid manufacturing.

5 Main reflector manufacture

The diameter of whole shaped reflector with high accuracy is extremely large, so the techniques process would be a challenge.

Difficult in manufacturing, and hard to meet accuracy requirement. Failure to achieve the expected accuracy will lead to suboptimal antenna efficiency.

Feasibility study will be done on the reflector manufacturing. Cooperation with international groups.

6

High dynamic range

To perform the imaging and spectral dynamic range requirement.

Failure to achieve the expected

high dynamic range will lead to

a suboptimal system not able

to achieve the science goals.

This will involve analysis and

measurement of dish.

7 Surface accuracy

Surface accuracy is affected by reflector and its support structure, which have close relationship with cost. So to balance the low cost and high accuracy is a challenge

Failure to achieve the expected accuracy will lead to suboptimal antenna efficiency.

Reflector mitigation refers to 5. Support structure design will be realized by optimal design.

8 Pointing accuracy

Pointing accuracy mainly is affected by random error.

Failure to achieve the expected accuracy will lead to low dynamic range.

System error would be modified by servo system System optimization to reduce random error.

9 EMC and RFI environment

High sensitive receivers,

covering wide frequency

range, will be co-located

with high speed digital

equipment, local

oscillators, dish controllers,

external RFI from satellites.

The RFI will significantly

influence performance of the

SKA.

Identify EMC aspects of designs.


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10 Other Cross Cutting Issues

10.1 Health, Safety & Environmental Management Plan

The following discussion is based on assuming JLRAT takes the SKA dish contracts.

JLRAT has the obligation to ensure the health and safety of its engineers and workers during the course

of their work at their workplace and the living accommodation in antenna installation site (esp. aboard),

it also has an obligation to ensure the health and safety of others that JLRAT’s work may impact upon.

The purpose of the Heath Safety and Environmental (HSE) Management Plan is to address JLRAT’s

obligation to ensure the health and safety of persons at their workplaces .The HSE management plan is a

working document designed to effectively manage and minimize health safety and environmental risks,

reduce hazards for the SKA project-dish subsystem and its related equipment facilities, material and

supports. This part aims to cover the requirements of the accident prevention rules and safety program

to be applied to the antenna installation. Please note that, JLRAT has the experience in antenna

installation in West Australia, part of this plan is referenced from Australia experience, for the

environment of two potential sites are deemed similar.

10.1.1 JLRAT Health Safety and Environment Policy

At JLRAT, a commitment to occupational health, safety and the environment is part of the business.

This is achieved through:

complying with statutory requirements, codes, standards and guidelines;

setting up objectives and targets with the aim of minimizing risk in relation to our activities,

products and services;

defining roles and responsibilities for occupational health, safety and environment.

Strategies will include:

ensuring occupational health, safety and environment management principles are included in all

organisational planning activities;

providing ongoing education and training to all of our employees;


2011/06/15 Page 40 of 54

consulting with employees and other parties to improve decision-making on occupational health,

safety and environment matters;

ensuring incidents are investigated and lessons are learnt within the organisation;

distributing occupational health, safety and environment information, including this policy, to all

employees and interested parties;

providing enough resources to ensure occupational health, safety and environment;

ensuring effective injury management and rehabilitation is provided to all employees.

10.1.2 HSE Organization Roles and Responsibilities

The flow chart of HSE management roles and responsibility is shown in Fig. 18, the broken line parts are

the suggestion by JLRAT:

JLRAT Project

Manager

Antenna & Servo

Department Safety

Committee

JLRAT Site Manager

SKA Project HSE

Manager

(dish-subsystem)

Employees

JLRAT HSE

Supervisor

SKA Project Manager

(Dish-subsystem)

Fig. 18 Flow Chart of Employee HSE Responsibility

The key personnel and their roles and responsibilities for safety management are shown as follows

Project Manger:

Provide financial, material, and employee support of safety related activities.

Provide an environment where safety in the workplace is of utmost importance.


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responsible for incidents/accidents within 24 hours of occurrence, holding regular HSE

discussions with staff during the project weekly etc

Antenna & Servo Department Safety Committee:

Encourage employees to report safety related issues.

Identify and report safety related issues.

Review and develop corrective actions.

Ensure and assist in the correction of safety related issues.

Develop safety management and policies as needed to provide a safe workplace.

Assure compliance with all applicable Australian/SA, Chinese, Local, safety policies.

Review accident reports as requested.

Facilitate safety training in JLRAT.

JLRAT site manager

Ensure employees on site have completed all applicable training.

Provide equipment and materials to support safety activities on site.

Provide support and suggest to JLRAT and SKA project manager (dish subsystem) in specific

safety issues.

Provide assistance during emergency response.

Ensure all incidents and accidents are reported as quickly as possible (within 24hours at least) to

the SKA Site Manager, to enable timeframes for compliance reporting requirements to be met if

necessary and to facilitate incident investigations

Ensure compliance within their team to all applicable Australian/SA, Chinese, local policies and

regulations.

Conduct safety report to SKA project HSE manager (dish subsystem) and JLRAT headquarter

weekly.

Hold weekly HSE meeting on site with site manager

Ensure harm reports daily to Site Manager and all team signed in.

Produces monthly progress report of site work including HSE issues to site manager


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JLRAT HSE Supervisor

Ensure the work is carried out in accordance with the safety standards required for the

minimum risk to employees and property.

Know the safety requirements stipulated in the safety program.

Check each work procedure from the safety point of view and advise the site manager before

commencement of work and, or while working

Make sure that suitable personal protective equipment is available and in use.

Check on the use of all types of personal protective equipment, evaluate effectiveness and

suggest improvements to site manager.

Conduct daily visual inspections of safe work practices and avoidance of environmental harm

Investigate and provide a written report on any HSE incidents/accidents within 7 days of the

event

On Site Employees:

Complete all applicable safety training.

Report safety related hazards, incidents and accidents immediately to JLRAT site safety officer

Work safely at all times; ensure no harm to the environment; ensure cultural sensitivity to the

site environment.

Use the correct tools and equipments for the job.

Keep tools in good condition.

Use proper personal safety equipment provided at all times.

10.1.3 Antenna Site Overview

Before access to site, no matter Australia or S.A., we will get acquaintance with the following notice

Site Access notice

Environmental conditions

Site cultural awareness


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10.1.4 Health Safety and Environmental Risk Assessment

The risk assessment process involves 6 steps as follows:

Identify OHS hazards and environmental aspects using this process and documenting the

information of the Job Safety and Environment Assessment Form.

Rate the risk associated with each hazard/aspect according to JLRAT internal Job Safety

Guidance. For each hazard/aspect, adopt the risk rating that is given by JLRAT document

For each hazard/aspect, to rate the likelihood of an incident that will lead to the consequences

you have determined. Consider all of the options for each rating and use the most likely rating

that is possible for the defined consequences.

Use the Risk Matrix to analysis the consequence against the likelihood to determine the

inherent risk category associated with each hazard/aspect. These are the risks posed by the

hazards in the absence of any consideration of risk control strategies.

Use the same Risk Matrix to consider the Residual Risk - plot the inherent risks against your

perceptions of the effectiveness of the risk management controls implemented so you can

estimate the residual risk associated with each hazard/aspect.

Deal with high residual risks as a matter of urgency, ensuring appropriate controls are in place

prior to the commencement of any work activities. See significant inherent and residual risks

and expectations around further action and/or controls that are needed to ensure risk levels

remain acceptable.

10.1.5 Safety Instructions and Guidelines

10.1.5.1 Safety Instructions and Training

The whole team must undertake all necessary inductions and task-specific training at JLRAT and antenna

installation site.

The team has been involved in on-the-job training as the antenna has been built at JLRAT test range. This has familiarized the team with the work required at antenna installation site, this works include

Use of tools and equipments

The team member has trained to use personal protective equipments, antenna installation tools

antenna testing instruments etc

Electrical installation safety


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Electrical engineer in the team has trained about electrical safety during cabling, testing, and

trouble shooting etc.

More general HSE procedures during antenna installation

Trained engineers

10.1.5.2 Site Condition and Safety Induction at JLRAT

All JLRAT team members are required to undertake a site safety induction at JLRAT headquarter before

going to antenna installation site, which includes the general site condition introduction and explains

particular safety issues related with working on site. The team will be familiar with JLRAT HSE plan.

The site manager will distribute a translation of safety induction material, which will be supplied by the

local host, to all employees. The JLRAT team members are required to read this material carefully to

ensure their behaviour complies with local rules, customs and culture.

10.1.5.3 Safety Induction on Site

The JLRAT team will undergo a full site safety briefing run by installation site manager prior to

commencing work at the site. This explains particular safety issues relating to working in a hot, remote

location, as well as outlining emergency and communication procedures.

10.1.5.4 Specific HSE Training

Based on the risk assessment, the following safety trainings have provided to JLRAT employees

Use of personnel protective equipments

Working expose to heat and sun

Working at height

Crane lift safety issues

Working at night

Working at confined space

Electrical installation safety

Manual handling during antenna installation

Other works involved in antenna installation


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10.1.5.5 Preliminary Set Up for Installation

All equipment, machinery and tools for use on the job site must be approved by SKA Project manager-

dish subsystem, and shall be subject to initial and periodic inspection by Site Manager.

Prior to commencing Installation, the planned arrangement of all equipment to be placed on the

location should be reviewed to eliminate potentially hazardous conditions. Changes to the site set up

are to be recorded in the site installation plan

10.1.5.6 Housekeeping

Work areas should be maintained reasonably clean and free of debris to remove slip and trip

hazards.

Hazardous leaks or spills should be promptly cleaned up to reduce the risk of falls,

contamination of surface waters and fire hazards.

Equipment operators shall only operate machinery for which they are authorized.

A tag-out security system shall be established for the isolation of equipment or during

maintenance and repairs.

Any spill of liquids will be cleaned up immediately to minimize harm to the environment,

cleaning equipment and an emergency response will be kept within the work site.

10.1.5.7 Personal Protective and Other Equipment

All JLRAT employees are to be supplied with personal protective equipment and must use it where

required. This equipment will include but is not limited to:

safety helmet, with wide brim for sun protection

Safety boots with toe protection;

Gloves

Full length cotton breathable clothing.

Safety glasses or face shields

Safety belt

Water


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First aid kit (remote use)

Sunscreen

The equipment that is worn by each employee at any time will depend on the job at hand. Employees

shall wear protective clothing and protective equipment when working under conditions where there is

reasonable potential for injury, illness or death that can be prevented by use of such equipment.

The guidelines for appropriate use of safety equipment for JLRAT employees on site are outlined as

follow:

Safety helmet, safety boots should be worn by JLRAT team members within antenna site during

installation or maintenance activities;

When handling antenna parts that may cause injuries, team members will wear gloves,

protective apron, or other protective equipment as appropriate;

Loose or poorly fitted clothing should not be worn;

Employees with hair of such length as to be a hazard in work area should keep it contained in a

suitable manner while performing their duties

10.1.5.8 Fire Prevention

Fire constitutes a significant hazard for operations personnel. Consequently, the recognition and

minimisation of fire risks, i.e., sources of ignition and fuel, is essential for the safe operation of the Site.

Sources of fuel on site are: paints, grease and flammable wastes.

Sources of ignition include: sparks, spontaneous combustion, grinding, electrical faults, cigarette

smokers and lightning. Sparks may be generated mechanically from friction (striking of metal), electricity

(loose or faulty connections, overloading, improper grounding, short circuits, incorrect fuses, etc.) and

from engine exhausts.

General Precautions

The JLRAT team will be conversant with the safety regulations governing fire prevention;

Naked flames, smoking will be prohibited within the workplace except for a designated area.

Electrical work will only be carried out by certified electricians;


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Flammable waste including part package, rope, etc., will be collected and stored safely prior to

removal from site according to site manager arrangement.(waste is handled by local host)

Fire extinguishes and other equipment will be setup on the antenna site by local host.

10.1.5.9 Alcohol and Drugs

Alcohol

Any person is prohibited to consume alcohol while on duty

The driving of any vehicle while under the influence of alcohol is prohibited

Prescription Drugs and Illness

Any person on site who is required to take prescription drugs, which may affect his or her work

performance, must notify the site manager. List of prescription drugs that will bring into site for

Customs approval, accompanied by doctor’s certificate.

Any person on location who has either a contagious illness or an illness or condition which may

affect his or her work performance or the safety and or efficiency of those around that person,

must inform the JLRAT Site Manager.

10.1.5.10 First Aid

JLRAT will provide First Aid support for its employees on the site. A First Aid kit will be kept in the work

site all the time.

10.1.5.11 Hydration / Exposure

Since the site is usually dry, very hot, and usually sunny. All JLRAT employees need to be aware of the

dangers of heat stress, sun burn and dehydration.

So, when working on site, JLRAT staff should

wear a wide brimmed hat, sunglasses and 30+ SPF sunscreen, loose long-sleeved cotton shirts

and long pants.

have their water bottles and must be readily accessible at all times. 4 litres of water per person

per day is recommended.

try to work in the cooler parts of the day and avoid working when temperature over 38 degree.

have rest breaks according to local conditions.


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When the following signs have been experienced or observed

1) Heat rashes – hives, sunburn

2) Heat cramps – painful muscle spasms, heavy sweating

3) Blurred vision

4) Dizziness, exhaustion

5) Slurred speech

6) Difficulty in thinking clearly

JLRAT staff should stop working and take the following suggestions:

1) Reduce or stop work, seek shade,

2) Replace lost fluids (drink water – avoid caffeine),

3) Rest,

4) Contact First Aid without delay.

10.1.6 Environmental Hazards and Control Measures

The main area of environmental hazard is waste. The control measures for this factor are presented

below.

Wastes generated during installation activities should

Avoid contamination of land or water;

Minimize health risks;

Minimize impacts to visual amenity;

Minimize impacts to native flora and fauna.

No operation on site will create dust

Any spill of liquids and garbage will be cleaned up immediately to minimize harm to the environment,

cleaning equipment and an emergency response will be kept within the work site.

10.1.7 HSE Meetings/Reports and Notices

10.1.7.1 HSE Meetings

A routine HSE meeting shall be held on a weekly basis and attended by all team and chaired by site

manager


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All team members prior to holding a meeting shall conduct a joint site safety inspection and the

inspection results shall be discussed at the meeting.

10.1.7.2 Incident Reporting & Recording

All incidents associated with the contract involving, but not limited to, personal injury, medical

treatment or property damage should be recorded and investigated.

Any incidents that may meet the Comcare reporting criteria listed below must be reported to the SKA

Project HSE Manager-dish subsystem in sufficient time to meet the regulatory reporting time frames

listed in Table 7.

Table 7 Regulatory Reporting Time Frames

Incident Notification time Frame

Death By phone within 2 hours

Serious Personal Injury Fax or online within 24 hours

Dangerous Occurrence Fax or online within 24 hours

Note: Time frames commence as soon as a site supervisor becomes aware of an incident.

The following should be documented:

details of incident, who was involved, what was the outcome (e.g. first aid, medical treatment

required, environmental incident) must be completed within 24 hours of the incident or of

becoming aware of the incident

investigations must be completed in 48 hours and corrective actions put in place as soon as

practicable and appropriate

Incident Investigation should be conducted in a timely manner by a site manager, HSE supervisor,

involving personnel involved in the incident and others who have knowledge or experience that will

have bearing on the outcomes of the investigation. The investigation should identify:

The incident(i.e. what happened, not how);

Quick fixes(i.e. the immediate actions to mitigate the impact);

Root causes (finding the underlying reasons for the incident);


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Corrective actions(to ensure the root causes do not recur),also identifying who should carry out

the actions and by when; and

Follow-up actions (to ensure the corrective actions are in place by the nominated time and are

working as planned; and, if not, then additional/alternative corrective actions and follow-up

actions may be required).

Notices for Corrective Actions

If team member fails or refuses to fulfil his safety responsibility or to correct unsafe conditions or

practices, he will be ordered to take the necessary corrective action.

When any negligence of safety and/ or unsafe practices are detected, HSE supervisor shall immediately

advice and or instruct the team member to correct them.

If the team member fails to heed the instruction or advice or neglects fire precautions described in the

work permit, the unsafe work should be stopped. The work will not commence again until corrective

action has been taken.

10.2 Quality Control

JLRAT has its own Quality Management System (QMS) followed China national standard upon

established. We passed and our quality management system is followed with the government standard

9001B-2009 (idt ISO 9001:2008)

QMS of SKA project is proposed into design phase, manufacturing, assembly, acceptance and delivery

phase. Each phase is proposed as follow:

10.2.1 Design Phase

Design Phase is divided into two steps, Plan Procedure and Design & Development Procedure. In each

step, the QM Activities will emphasize on the follow procedure control.

10.2.1.1 Plan Procedure

The Project Management Office will nominate the Quality Manager, who will organizes the specialists to

authorize the quality plan, including quality purpose, quality criteria, test outline and technics

specification etc,


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approve the quality plan of project in accordance with quality requirements of each phase in

Quality Statement,

authorize the Key processes plan, which need the special control, such as assembly technics of

reflector

10.2.1.2 Developing Procedure

This procedure includes Developing inputs and output. Quality Manager will assist Project Manager to

timely and accurate complete inputs and outputs.

Inputs relate to antenna requirements shall be determined and records maintained. These will include:

functional and performance requirements,

previous similar designs.

The outputs of Developing will be provided in a form that enables verification against the input and shall

be approved prior to release. The outputs cover the following items.

Drawings, Workmanship Manufacturing Specification, Test Outline, Test Planning, and other

reference files,

Purchasing File which list appropriate information for purchasing production and for service

provision,

10.2.1.3 Review

Reviews will occur at corresponding opportunities based on the project plan. Participants in such

reviews include representatives of two parties, who concerned with the design phase being reviewed. If

the work is not passed during the review, the work will not be passed to the next phase; necessary

questions must be supervised to put forward and solved by Quality Manager. Records of the conclusion

of the reviews and any necessary actions will be maintained.

10.2.2 Antenna Manufacturing Phase

10.2.2.1 Procurement Control

The Purchase Manager will assist Quality Manager to perform the Procurement Control. Purchase

Manager is responsible for provide the adequacy and quality of materials, parts, and services for the


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project. Procurement Control is described in QMS documentation. Such activity performs actions for

product-quality control and planning schedules.

10.2.2.2 Manufacture Process Control

Manufacture Process Control includes processing control, planning control, inspection procedure

control, periodicity measurement control of test tools, operating environment control.

The Quality Manager will review and approve related engineering and manufacturing documents,

including Drawings, Workmanship Manufacturing Specification (WMS), Test Outline and other reference

files, which assure production compliance with QMS and satisfaction quality requirements. A WMS will

be released for each working procedure operation, where the following information will be, as a

minimum, identified:

Sequential steps for manufacture and assembly

Applicable technical guide

Mandatory inspection points

10.2.2.3 Key Quality Process Point

QMG will emphasize on monitoring Quality Process Point, in accordance with the Key Process plan in

Design Phase. For example in the assembly technics of reflector, Quality Test Engineer will check

following points.

Technics Engineer authorize particular assembly technics guide.

The position among the hub, ribs, plate.

The joint among the hub, ribs, plate

Regular operator with technical experience

10.2.3 Assembly, Acceptance Phase

Assembly, Acceptance Phase is subjected to QM in order to ensure that the product is compliant with

the design. The main activities during this phase will consist of:

planning all the activities in accordance with the Test Outline and Product Acceptance

standard/Criteria,


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approving product configuration changes

reviewing the entire delivered documentation,

10.2.3.1 Products Test Control

Quality Control Engineer need report to the Quality Manager on the results and progress of quality

management activities, including human resources, equipment requirement, and test data record.

10.2.3.2 Malfunction Revise Control

In the Non-Conformed Report (NCR), the Quality Control Engineer will report the reason. In according to

the analysis of the technical engineer, the drawings will be revised or parts will be exchanged/ replaced.

10.2.3.3 Factory Acceptance Testing (FAT)

In the FAT, QMG will perform the acceptance with the representation of two parties, in according to the

contract requirement. Achieving the function and performance, the products pass through the

acceptance, and be issued the Certification of Factory Quality Acceptance.

10.2.4 Delivery Phase

10.2.4.1 Storage, Packaging and Transportation

Finishing the FAT and certified by inspector, the products will prepare for delivery complying the

relevant standards for storage, packaging, and transportation.

Specified storage environmental conditions will be defined. Before shipping, the QMG will perform final

packaging and shipping inspections of antenna. It will be ensured that each product is shipped complete

and fully assembled, with the necessary documents, under the special requirements for shipping needed

by each one.

10.2.4.2 Site Installation

The products will be installed and tested by JLRAT technical engineers on site. During the installation

and test procedure, an initial training will be occurred, in accordance with the test plan.

10.2.4.3 Site Acceptance Test (SAT)

In the SAT, JLRAT will test the antennas following the buyer requirement in the contract and approved


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Engineering and Test Plan. JLRAT will invite buyer to witness all Acceptance Testing activities. Achieving

the function and performance the products will be issued the Quality Acceptance Certification to certify

the SAT close out.

Documents

DVAC-2 CONCEPT DESCRIPTION: PRIME FOCUS DISH …...FINAL【DVAC-2 CONCEPT DESCRIPTION:PRIME FOCUS DISH】 [2011] 2011/06/15 Page 1 of 54 Name Designation Affiliation Date Signature