Attachment_L-04_Overhaul_Work_Specification_Final.pdf

For Official Use Only Source Selection Information – See FAR 2.101 and 3.104

FA2521-19-R-A007

(REF) FA2521-18-R-0024

Attachment L-04 15 Aug 19

OVERHAUL WORK SPECIFICATION

Overhaul price proposed shall be consistent with overhaul CDRL specification and requirements contained under SOW 4.3.

RANGE

WSMR

SYSTEM

FPS-16 Radar

Note: This sample is used only for Technical Evaluation. Does not apply to pricing in L-11, Cost Workbook.

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IRSP WORK SPECIFICATION

APPENDIX A

AN/FPS-16, AN/FPQ-13,

AN/MPS-25 (MOD 0 Pedestals) and

AN/FPS-105 (Non-Hydraulic)

CDRL A005 Overhaul Work Specification

Classification: Unclassified

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AN/FPS-16, AN/FPQ-13 AND AN/MPS-25

(MOD “O” PEDESTALS)

AND

AN/FPS-105 CAPRI (NON-HYDRAULIC)

PARTIAL OR FULL OVERHAUL

A partial overhaul will consist of the accomplishment of the tasks listed in Section I, Subsystem 1, and selected tasks from Subsystem 2. The successful accomplishment of these tasks will be demonstrated by performing selected tests from Sections II and III.

The completion of Section I, Subsystems 1 – 5, will constitute a full overhaul and will be followed by accomplishment of the actions in Sections II and III.

Work to be performed by the site personnel will be noted on the preoverhaul survey report. Special equipment required to perform the overhaul will be listed on the equipment section of this report.

The parts and materials required to perform the overhaul will be listed on the parts list.

Hazardous waste disposal responsibility will be listed in the Hazardous Waste section of the report.

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SECTION 1

MECHANICAL OVERHAUL ACTIONS

This section is divided into five subsystems and specifies the actions that will be taken on each item to ensure the equipment meets the required system specification.

SUBSYSTEM 1

1.0 PEDESTAL

1.1 BASE AND TURNTABLE

1.1.1 Inspect cabling; refurbish as required

1.1.2 Inspect junction boxes and connectors; refurbish as required

1.1.3 Remove and overhaul / replace leveling jacks

1.1.4 Inspect access panel gaskets and hardware; replace as required

1.1.5 Replace base blowers as required; inspect and refurbish associated circuitry as required

1.1.6 Replace AZ rotary joint as required (verify system configuration)

1.1.7 Replace base flexguide as required

1.1.8 Inspect and refurbish stowlock (AZ & EL) as required

1.1.9 Inspect heaters and thermostats; replace as required

1.2 LUBRICATION SYSTEM (AZ & EL)

1.2.1 Replace oil pump, motor and coupling as required

1.2.2 Replace or refurbish tubing and feeder blocks as required

1.2.3 Replace indicating devices as required

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REVISEDMARCH 1999

1.2.4 Drain, flush and replace oil

1.2.5 Inspect heaters and thermostats; replace as required

1.3 AZ & EL DRIVE GEAR BOXES

1.3.1 Refurbish or replace AZ gear box

1.3.2 Inspect and clean main bull gear; replace and torque hold-down bolts as required.

1.3.3 Refurbish or replace EL gear box

1.4 SLIP RINGS

1.4.1 Inspect slip ring assembly; replace or refurbish as required

1.4.2 Inspect and refurbish coffin wiring

1.4.3 Inspect LO cable; replace as required

1.4.4 Replace entry panel gaskets

1.5 SERVO DRIVE COMPARTMENTS

1.5.1 Replace drive motors and couplings as required

1.5.2 Check drive motor brushes; replace as required

1.5.3 Adjust brakes as required

1.5.4 Refurbish compartment wiring as required

1.6 AZ AND EL HANDWHEEL ASSEMBLY

1.6.1 Refurbish or replace AZ handwheel assembly as required.

1.6.2 Clean and refurbish AZ and EL cursor scale

1.6.3 Clean or replace cursor window as required

1.6.4 Replace gaskets as required

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1.6.5 Replace or refurbish EL handwheel assembly as required

1.7 UPRIGHT AND TRUNNION

1.7.1 Inspect and lubricate and refurbish elevation cable windups assemblies as required

1.7.2 Inspect trunnion shaft and replace garlock seals and felt rings as required

1.7.3 Inspect pillow blocks

1.7.4 Inspect equilibrator; replace chains and torsion bars as required; adjust and lubricate as required

1.7.5 Torque sector gear hold-down bolts as required

1.7.6 Refurbish or replace boresight telescope mount as required

1.7.7 Refurbish or Replace lens mount as required

1.8 ANTENNA RF PLUMBING

1.8.1 Refurbish or replace comparator as required

1.8.2 Refurbish or replace comparator mount as required

1.8.3 Replace flexguide and gaskets as required

1.8.4 Remove support rods; clean and refinish as required

1.8.5 Refurbish or replace waveguide from RF head to comparator

1.8.6 Replace elevation rotary joint and flexguide as required

1.9 ANTENNA REFLECTOR

1.9.1 Inspect and repair any minor deficiencies

1.9.2 Note any deficiencies that cannot be corrected on-site

1.9.3 Replace and torque drum bolts as required

1.10 RF HEAD

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1.10.1 Inspect all RF head door latches and slides; refurbish or replace as required

1.10.2 Inspect gaskets; replace as required

1.10.3 Inspect and refinish RF head and camera maintenance stands

1.11 AZ & EL DATA COMPARTMENTS

1.11.1 Check synchros; replace as required

1.11.2 Replace encoders as required

1.11.3 Replace secant potentiometer as required

1.11.4 Inspect all couplings; replace as required

1.11.5 Inspect wiring; refurbish as required

1.11.6 Inspect digital blowers; replace as required

1.12 PEDESTAL LEVEL, BALANCE AND FRICTION CHECKS

1.12.1 Measure elevation unbalance; counterweight as necessary

1.12.2 Measure and record azimuth antenna friction

1.12.3 Level pedestal to system specifications

1.13 CORROSION CONTROL

1.13.1 Inspect all areas

1.13.2 Remove all corrosion; apply corrosion preventive.

1.13.3 Refinish pedestal as required

1.13.4 Replace all name plates

1.14 HAZARDOUS WASTE DISPOSAL

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1.14.1 Deposit all hazardous waste in containers provided by the range in accordance with range requirements

1.14.2 Label all containers showing the contents and provide Material Safety Data Sheets for all waste material generated

1.14.3 Complete the hazardous waste receipt form and acquire the signature of the receiving agent

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SUBSYSTEM 2

2.0 ANCILLARY EQUIPMENT

2.5 COMPRESSOR – DEHYDRATOR

2.1.1 Replace as required

2.2 SERVO POWER AMP

2.2.1 Inspect and clean cabinet as required

2.2.2 Replace blowers; check wiring and connectors

2.3 26 VOLT POWER SUPPLY

2.3.1 Replace or refurbish as required

2.4 LOAD CENTER (CABINETS 173, 174, AND 175)

2.4.1 Clean as required

2.4.2 Inspect and tighten all terminal connectors

2.4.3 Inspect circuit breakers; replace as required

2.4.4 Inspect contactors; replace contacts as required

2.4.5 Refurbish inductrol regulators as required (if applicable)

2.4.6 Inspect solid-state AC regulators (if applicable)

2.4.6.1 Replace blowers as required

2.4.6.2 Refurbish or replace regulators as required

2.5 TV CAMERA AND LENS SYSTEM (IF APPLICABLE)

2.5.1 Inspect and refurbish CCTV system as required

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2.6 SAFETY SWITCH AND WARNING LIGHT ASSEMBLY

2.6.1 Refurbish safety switch and warning light assembly as required

3.0 ELECTRICAL

3.1 RF HEAD (ELECTRICAL)

3.1.1 Check heaters and thermostats; replace as required

3.1.2 Replace blowers as required

3.1.3 Check and replace waveguide switches as required

3.1.4 Replace TR tubes as required

3.1.5 Inspect flexguides and feed-thru plate; replace or refurbish as required

3.1.6 Inspect and replace door interlocks as required

3.1.7 Inspect duplexors; replace or refurbish as required

3.1.8 Inspect and refurbish low noise amplifiers as required

3.1.9 Refurbish RF head cables and wiring as required

3.1.10 Replace RF head lamps as required

4.0 TRANSMITTER

4.1 CABINETS 139 AND 140 / STANDARD TRANSMITTER

4.1.1 Strip and clean cabinets as required

4.1.2 Inspect and replace door gaskets and DZUS fasteners as required

4.1.3 Inspect, refurbish, or replace flexguide and gaskets as required

4.1.4 Inspect keyer tube and collets; replace or clean as required

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4.1.5 Check and inspect tubes, resistors, capacitors, and relays; replace as required

4.1.6 Inspect all interlocks; replace as required

4.1.7 Inspect and replace or refurbish wiring and cables as required

4.1.8 Replace blowers and vane switches as required

4.1.9 Inspect contactors; replace contacts or contactors as required

4.1.10 Inspect power programmer; refurbish or replace as required

4.1.11 Inspect variable transformer; refurbish or replace as required

4.1.12 Check operation of load isolator; replace as required

4.1.13 Check clipper diodes; replace as required

4.2 3 MEGAWATT TRANSMITTER

4.2.1 Transmitter (general)

4.2.1.1 Check door gaskets and metex; replace as required

4.2.1.2 Clean high voltage insulators and replace as required

4.2.1.3 Check high voltage wiring; replace all black wire and any discolored white wire

4.2.1.4 Disassemble waveguide; clean or replace as required

4.2.1.5 Clean interior of cabinets

4.2.2 Attenuator

4.2.2.1 Replace attenuator and dummy loads as required

4.2.2.2 Replace waveguide switch as required

4.2.2.3 Replace all “O” rings and defective hardware

4.2.3 RF Amplifier and Modulator

4.2.3.1 Repair or replace cooling system flow switch as required

A-

4.2.3.2 Replace relay contacts as required

4.2.3.3 Check, clean and lubricate Z302 variac as required

4.2.3.4 Check spark gap; replace as required

4.2.3.5 Check time delay relay; replace as required

4.2.3.6 Rebuild or replace tube collets

4.2.3.7 Inspect water coil and fittings for electrolysis and corrosion (Note: Metal fittings should be replaced with PVC types)

4.2.3.8 Replace keyer tubes “O” ring seals and clean water chambers

4.2.3.9 Replace all RFI filters as required

4.2.3.10 Inspect cooling plumbing for signs of leakage; repair as required

4.2.4 Trigger Pulse Amplifier

4.2.4.1 Replace blowers and vane switch as required

4.2.4.2 Replace all questionable vacuum tubes

4.2.4.3 Rebuild or replace tube collets

4.2.5 Control Power Supply

4.2.5.1 Replace spark gap as required

4.2.5.2 Replace relay contacts as required

4.2.5.3 Clean and lubricate Z101 variac as required

4.2.5.4 Check diodes on rectifier banks; replace as required

4.2.6 RF Oscillator

4.2.6.1 Replace blowers as required

4.2.6.2 Replace all questionable tubes

4.2.6.3 Clean and lubricate variac assembly

4.2.6.4 Check/replace relay contacts as required

4.2.7 Fluid Cooler

4.2.7.1 Rebuild or replace motor pump assembly as required

4.2.7.2 Inspect, repair or replace fan motor and pillow blocks

4.2.7.3 Clean reservoir sight glass

4.2.7.4 Flush system with citric acid; replace filters and add new coolant

4.2.7.5 Replace fan belt as required

4.2.7.6 Inspect and replace contactor contacts as required

4.2.7.7 Replace heaters and thermostat as required

4.2.7.8 Replace liquid level switch and alarm as required

4.2.7.9 Replace pressure gauge and differential gauge as required

4.2.7.10 Refinish entire unit as required

4.2.8 Load Center – 3 Megawatt Transmitter

4.2.8.1 Check operation of circuit breakers; replace as required

4.2.8.2 Check and replace regulator relays as required

4.2.8.3 Tighten all power terminations as required

4.2.8.4 Check operation of AC regulators; repair/lubricate as required

4.2.8.5 Check operation of low voltage power supply; repair as required

4.2.8.6 Check A/C volt meters; replace as required

5 OPERATIONS ROOM

5.1 CONSOLE

5.1.1 Replace blowers as required

5.1.2 Replace synchros as required

5.1.3 Inspect and refurbish power supplies as required

5.1.4 Inspect control units and tach drive assemblies; repair or replace as required

5.1.5 Inspect modules; refurbish or replace as required

5.1.6 Inspect all meters, indicators, readouts, controls and switches; replace as required

5.1.7 Replace all defective lamps

5.1.8 Inspect console wiring; refurbish as required

5.1.9 Replace CRTs as required

5.2 CABINET 101

5.2.1 Replace meters as required

5.2.2 Replace relays as required

5.2.3 Inspect circuit breakers and connections; replace and refurbish as required

5.2.4 Inspect and replace lamps and lamp sockets as required

5.2.5 Inspect and refurbish cabinet wiring as required

5.3 MODE SWITCH

5.3.1 Replace defective relays and diodes

5.3.2 Inspect and refurbish wiring as required

5.4 CHASSIS AND ASSOCIATED COMPONENTS

5.4.1 Inspect and refurbish all system low voltage power supplies; replace components

5.4.2 Inspect and refurbish all contactor panels; replace contacts and time delay relays

5.4.3 Inspect meter selector and sequencing panels; refurbish as required

5.4.4 Inspect range chassis; refurbish as required

5.4.5 Inspect angle chassis; refurbish as required

5.4.6 Inspect data chassis; refurbish as required

5.4.7 Inspect receiver chassis; refurbish as required

5.4.8 Inspect noise figure and power monitor; refurbish as required

5.4.9 Inspect LO assembly and power supplies; refurbish as required

5.6 CABINETS

5.6.1 Inspect cabinet wiring; refurbish as required

5.6.2 Inspect all lamps and indicators; replace as required

5.6.3 Inspect base board outlets and covers; replace as required

5.7 OVERHEAD WIRING

5.7.1 Inspect wiring, connectors and lacing; refurbish as necessary

SECTION II

ELECTRICAL OVERHAUL AND CHECKOUT

1.0 LOAD CENTER

1.1 POWER DISTRIBUTION

1.1.1 Check operation of all power distribution circuit breakers; correct any discrepancies

1.1.2 Check operation of AC line voltage regulators; adjust and correct any discrepancies

1.2 26 VOLT POWER SUPPLY

1.2.1 Check for proper rectification, filtering and regulation

1.2.2 Check volt/amp meter for proper indication; ensure that voltage can be adjusted

1.3 SERVO POWER AMP

1.3.1 Check circuit breakers and blowers for proper operation

1.4 SYSTEM AIR CONDITIONER (AN/MPS-25 ONLY)

1.4.1 Adjust air conditioner for proper operation

1.5 COMPRESSOR-DEHYDRATOR

1.5.1 Adjust for proper operation

1.5.2 Leak-test system and check for proper air flow indication with correct pressure applied to waveguide

1.5.3 Test to insure proper operation of switching circuitry

1.5.4 Test moisture alarm system

1.5.5 Correct any discrepancies noted in above tests

2.0 RANGE SYSTEM

2.1 Check range system power supplies for proper operation; adjust to correct voltages and loading

2.2 Align range system to system specification

2.3 Perform range subsystem tests; correct any discrepancies

3.0 RECEIVER SYSTEM (INCLUDING LOW NOISE AMPLIFIERS)

3.1 Check receiver power supplies for proper operation; adjust for correct voltages and loading

3.2 Align receiver and low noise amplifiers to system specifications

3.3 Check operation of noise figure and power monitor; correct any discrepancies

3.4 Perform receiver subsystem tests; correct any discrepancies

4.0 MODULATOR/TRANSMITTER

4.1 Check all safety and interlock circuits for proper operation; correct any

4.2 Align modulator and transmitter to system specifications

4.3 Test system in both high and low power operation (if applicable); correct any

4.4 Check operation of power programmer and other RF components; correct any discrepancies

4.5 Check waveguide for pressure leaks and arcing

4.6 Check fluid coolant system; correct any discrepancies (3 megawatt transmitter only)

5.0 ANGLE SERVO SYSTEM

5.1 Check angle system power supplies for proper operation; adjust for correct voltage and loading

5.2 Align angle servo system to system specifications

5.3 Perform test on angle servo system; correct any discrepancies

6.0 DIGITAL DATA SYSTEM

6.1 Check digital system power supplies for proper operation; adjust to correct voltages

6.2 Test digital system as required; correct any discrepancies

6.3 Check all data devices for proper data-to-data handling equipment and indicators

6.4 Check performance of the digital data system by running plotting board circle checks and/or slew checks if available

7.0 LOCAL OSCILLATORS

7.1 Check operation and stability of LO power supplies; correct any discrepancies

7.2 Check local oscillators for proper operation, frequency stability, and adequate LO power to the RF head; correct any discrepancies

SECTION III

OVERALL SYSTEM PERFORMANCE TESTS

I. SYSTEM EVALUATION TESTS

A. PRIMARY POWER AND REGULATED SUPPLIES

1. Compressor-dehydrator check

2. Check and record unregulated line voltages

3. Check and record regulated line voltages

4. Check and record 26 V power supply voltage and current

5. Check and record low voltage power supply voltages and currents

B. RECEIVER

1. Check and record AZ, EL and REF noise figure

2. Check and record MDS in AZ, EL and REF channels

3. Check and evaluate skin and beacon AFC operation; record evaluation

4. Check all crystal currents, both SKIN and BEACON (console)

C. ANGLE SERVO SYSTEM

1. Check and record error gradients

2. Check and record tachometer gradient

3. Check and record closed tach loop response, AZ & EL

4. Check and record closed track loop response, AZ & EL

5. Check and record noise on tach lines

6. Check and record AZ and EL slew speeds, fast and slow

7. Check synchro designate and nulls, noting quality of nulls

D. RANGE SYSTEM

1. Check and record slew speeds

2. Check and evaluate RANGE DESIGNATE operation

3. Check auto target detection function

4. Check and evaluate track response in all bandwidths

E. DIGITAL DATA SYSTEM

1. Verify correct AZ, EL and range count

2. Perform slew check to verify digital data linearity

F. STANDARD TRANSMITTER CHECKS

1. Check modulator power supplies and record voltages

2. Check modulator waveforms and record amplitudes

3. Check and record transmitter high voltage and high voltage power supply and magnetron currents

4. Check and record magnetron filament voltages

5. Check magnetron filament schedule; record magnetron current each change

6. Check transmitter waveforms and record amplitudes

7. Check transmitter pulse widths, spectrum and power out

8. Check the operation of the power programmer in MANUAL and AUTO;

record results

G. 3 MEGAWATT TRANSMITTER CHECKS

1. Cabinet 141

a. Check waveforms and record results

b. Record voltages and currents

(1) 2 KV supply

(2) 15 KV supply

(3) Check line voltages

(4) Check 1st RF amplifier current

(5) 2nd RF amplifier current

2. Cabinet 142

a. Line voltages

b. High voltages

c. Record high voltage current

d. Record klystron current

e. Observe ripple voltage at J20105 and record results

f. Record time meter reading

3. Cabinet 143

a. Observe waveforms at Jacks 20410, 20415, 20418, and 20419; record results

b. Record power supply voltages and current

c. Record time meter reading and filament voltage

4. Cabinet 144

a. Observe waveshapes at Jacks 20202, 20203, 20212, and 20213;

record results

b. Record power supplies voltages

c. Record water coil current or resistance, as applicable

d. Record filament voltages

e. Record time meter reading

f. Record water flow

5. Cabinet 145

a. Measure and record TX power output

b. Measure and record TX pulse widths

c. Measure and record TX pulse rise time

d. Observe waveforms at Jacks 20318 and 20319

e. Record focus coil current

f. Record time meter reading

g. Record klystron tuning control positions

h. Record klystron filament current

i. Measure and record klystron relative power

j. Record water flow

II. SYSTEM PERFORMANCE EVALUATION

1. Record survey data to boresight tower and range target

2. Perform boresight tower checks for collimation and survey data; record results

3. Check depth of null and record results

4. Perform range calibration target survey data checks and record results

5. Level radar pedestal to system specification and record readings

6. Perform receiver AGC gain tracking calibration and record results

7. Track sphere and record information necessary to verify loop gain