NDGPS RFP - Atth I - PWS Enclosure 3 - Maintenance Procedures Manual.pdf

Nationwide Differential Global Positioning System (NDGPS)

Maintenance Procedures Manual

16 JULY 2012

(This edition supersedes all previous versions)

NDGPS Maintenance List of Effective Pages Procedure Manual

LIST OF EFFECTIVE PAGES

Dates of issue for original and changed pages are:

Original ..................... 0 ........... 20 January 2012

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 102 CONSISTING OF THE FOLLOWING.

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

i - vi 1-1 - 1-8 2-1 - 2-8 3-1 - 3-10 4-1 - 4-4

5-1 - 5-18 6-1 - 6-6 7-1 - 7-4 8-1 - 8-6 9-1 - 9-6

10-1 - 10-2 11-1 - 11-6 12-1 - 12-12

*Zero in this column indicates an original page.

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List of Effective Pages NDPGS Maintenance

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NDGPS Maintenance Table of Contents

Table of Contents

List of Effective Pages ................................................................................................................... i

Paragraph Title Page No.

Section 1 – NDGPS Maintenance Organization and Concepts ............................................. 1-1

1.1 Levels of Electronic Equipment Maintenance ............................................................................... 1-1

1.1.1 Organizational Level Maintenance ................................................................................. 1-1

1.1.2 Depot Level Maintenance ............................................................................................... 1-1

1.2 Types of Organizational Maintenance ........................................................................................... 1-1

1.2.1 Preventive Maintenance (PM) ........................................................................................ 1-1

1.2.2 Corrective Maintenance (CM) ........................................................................................ 1-1

1.2.3 Coast Guard Depot Maintenance .................................................................................... 1-2

1.2.4 Coast Guard System Management Engineering Facility (SMEF) .................................. 1-2

1.2.5 Installation of Time Compliance Technical Order (TCTOs) or Authorized Equipment

Modifications .................................................................................................................. 1-4

1.2.6 Responsibility ................................................................................................................. 1-5

1.2.7 Procedure ........................................................................................................................ 1-5

1.2.8 Tools and Test Equipment Required ............................................................................... 1-5

1.2.9 Materials Required .......................................................................................................... 1-6

Section 2 – Safety ...................................................................................................................... 2-1

2.1 NDGPS Shelter Safety and Fire Program ...................................................................................... 2-1

2.1.1 Safety Program ............................................................................................................... 2-1

2.1.2 Background ..................................................................................................................... 2-1

2.1.3 Responsibilities ............................................................................................................... 2-1

2.1.4 Procedures ....................................................................................................................... 2-2

2.1.5 Summary ......................................................................................................................... 2-3

2.2 NDGPS Hazardous Material (HAZMAT) Program ....................................................................... 2-3

2.2.1 Hazardous Material Program .......................................................................................... 2-3

2.2.2 Background ..................................................................................................................... 2-4

2.2.3 Responsibilities ............................................................................................................... 2-4

2.2.4 Procedures ....................................................................................................................... 2-4

2.2.5 Summary ......................................................................................................................... 2-5

2.3 Radio Frequency (RF) Radiation Hazard Program ........................................................................ 2-5

2.3.1 RF Radiation Hazard (RADHAZ) Program ................................................................... 2-5

2.3.2 Background ..................................................................................................................... 2-5

2.3.3 Responsibility ................................................................................................................. 2-5

Section 3 – Back-up Power Group (BUPG) ............................................................................. 3-1

3.1 Battery and Charging System......................................................................................................... 3-1

3.1.1 Batteries and Charger ...................................................................................................... 3-1

3.2 Back-up Generator Preventive Maintenance .................................................................................. 3-2

3.2.1 BUPG Pre-Operational Checks....................................................................................... 3-2

3.2.2 Test Engine-Generator and Ventilation .......................................................................... 3-3

3.2.3 Test and Adjust Automatic Transfer Switch (ATS) ........................................................ 3-5

3.2.4 Renew Fluids and Filters ................................................................................................ 3-5

3.2.5 Inspect and Test BUPG Ventilation, Heaters, and Alarms ............................................. 3-7

3.2.6 Measure and Sample Fuel Levels ................................................................................... 3-8 iii

Table of Contents NDGPS Maintenance

3.2.7 Fueling Operations ......................................................................................................... 3-9

3.3 Visual Inspection of the BUPG ..................................................................................................... 3-9

Section 4 – GCF-W-1216-DGPS Differential Global Positioning System Equipment .......... 4-1

4.1 GCF-W-1216-DGPS Differential Global Positioning System (DGPS) Equipment Rack ............ 4-1 4.2A Uninterrupted Power Supply – APC MATRIX 5000 (1 kW Broadcast Sites) ............................. 4-1 4.2B Uninterrupted Power Supply – APC Smart-UPS RT (CRIA Sites) .............................................. 4-2 4.2C Uninterrupted Power Supply – IQ1100SXR (2.5 kW Broadcast Sites) ........................................ 4-2

4.3 4000IM Integrity Monitor Receiver .............................................................................................. 4-3

4.4 Cisco Router (1A6) ....................................................................................................................... 4-3

4.5 Z-12-R Reference Station Receiver .............................................................................................. 4-3

4.6 GPS and MSK Antennas ............................................................................................................... 4-4

4.6.1 Safety Precautions .......................................................................................................... 4-4

4.6.2 Clean and Inspect Antennas ........................................................................................... 4-4

Section 5 – CDWP-SC1000-DGPS-USCG 1 kW Broadcast System ...................................... 5-1

5.1 Clean, Inspect and Align the Broadcast Transmitter ..................................................................... 5-1

5.1.1 Preparation ..................................................................................................................... 5-4

5.1.2 Check and Record Transmitter Parameters .................................................................... 5-4

5.1.3 Clean and Inspect the Broadcast transmitter .................................................................. 5-5

5.1.4 Duty Cycle Verification and Adjustment ....................................................................... 5-5

5.1.5 Front Panel Output Power Meter Verification and Adjustment ..................................... 5-7

5.1.6 Monitor PWB Shutdown Function Verification ............................................................ 5-8

5.1.7 RSIM Transmitter Interface Calibration Verification and Adjustment ......................... 5-10

5.1.8 Perform Alternate Transmitter Alignment ..................................................................... 5-11

5.1.9 RSIM Battery Interface Verification and Adjustment ................................................... 5-11

5.1.10 Thermal Shutdown Check and Alignment ..................................................................... 5-13

5.1.11 Power Supply Checkout ................................................................................................. 5-14

5.1.11 Troubleshooting Aids ..................................................................................................... 5-15

Section 6 – RCA 2.5 kW Transmitter ....................................................................................... 6-1

6.1 Clean MSK-5SS Transmitter Filters ............................................................................................. 6-1

6.2 Verify Transmitter Operating Parameters ..................................................................................... 6-1

6.3 Perform Broadcast Transmitter Alignment ................................................................................... 6-2

6.3.1 Preliminary Equipment Setup ........................................................................................ 6-2

6.3.2 Verify and Adjust ........................................................................................................... 6-3

Section 7 – Nautel Vector Transmitter .................................................................................... 7-1

7.1 Nautel Vector Inspection ............................................................................................................... 7-1

7.2 Verify Transmitter Operating Parameters ..................................................................................... 7-2

Section 8 – Antenna Tuning Units ........................................................................................... 8-1

8.1 Nautel ATU-HP............................................................................................................................. 8-1

8.2 Starlink CP-3000 and CP-3000S ................................................................................................... 8-5

8.3 Antenna Matching/Static Drain Assembly .................................................................................... 8-6

Section 9 – Broadcast Antenna and Towers .......................................................................... 9-1

9.1 Material Condition ........................................................................................................................ 9-1

9.2 Lighting System ............................................................................................................................ 9-3

9.3 Reference Masts ............................................................................................................................ 9-4 iv

NDGPS Maintenance Table of Contents

Paragraph Title Page No.

9.3.1 Reference Mast Nos. 1 and 2 Ground Connections ........................................................ 9-5

9.3.2 Reference Mast Conduit ................................................................................................. 9-6

9.3.3 Reference Mast Cabling .................................................................................................. 9-6

9.3.4 Safety Accessories .......................................................................................................... 9-6

Section 10 – Electronic Equipment Shelter .............................................................................. 10-1

10.1 Electronic Equipment Shelter ........................................................................................................ 10-1

10.2 Air Conditioning/Heating System .................................................................................................. 10-1

10.2.1 Clean or Replace Air Filters ........................................................................................... 10-1

10.2.2 Clean System .................................................................................................................. 10-2

10.2.3 Test the Air Conditioning and Heating System .............................................................. 10-2

Section 11 – Security, Grounds, and Miscellaneous ............................................................... 11-1

11.1 Locks and Site Security .................................................................................................................. 11-1

11.2 Fences ............................................................................................................................................ 11-1

11.3 Grounds Maintenance .................................................................................................................... 11-2

11.4 Soil Treatment ................................................................................................................................ 11-3

11.5 Signage ........................................................................................................................................... 11-3

11.6 Roads and Gravel Areas ................................................................................................................. 11-3

Section 12 – NDGPS Site QA Procedures ................................................................................. 12-1

12.1 Arrival Procedures ......................................................................................................................... 12-1

12.2 Site Inspection ................................................................................................................................ 12-1

12.3 Site Departure ................................................................................................................................ 12-2

List of Figures

Figure Title Page No.

2-1 RADHAZ Burn Hazard Warning Sign .......................................................................................... 2-6 2-2 Personnel Hazard Warning Sign .................................................................................................... 2-7 3-1 Lubrication Points .......................................................................................................................... 3-9 5-1 SC1000 Transmitter Drawer .......................................................................................................... 5-3 5-2 RF Driver PWB .............................................................................................................................. 5-6 5-3 RF Driver Duty Cycle Waveform .................................................................................................. 5-6 5-4 AMTR 2 PWB ............................................................................................................................... 5-7 5-5 Monitor PWB ................................................................................................................................. 5-8 5-6 Transmitter Interface PWB ............................................................................................................ 5-10 5-7 Battery I & V Sample PWB ........................................................................................................... 5-12 5-8 Comparator PWB ........................................................................................................................... 5-13 6-1 Control Logic Board A3A1 ............................................................................................................ 6-3 7-1 Vector Control Panel with Panel System Diagram ........................................................................ 7-1 7-2 Vector Status Menu Flow Diagram ................................................................................................ 7-2 11-1 Standard NDGPS Site Sign Location ............................................................................................. 11-4 11-2 Standard NDGPS Site Signage ...................................................................................................... 11-5 v

Table of Contents NDGPS Maintenance vi

List of Tables

Table Title Page No.

3-1 RSIM/RTCI BUPG Status ............................................................................................................ 3-8 6-1 Low Voltage Power Supply Readings........................................................................................... 6-2 8-1 ATU Lightning Ball Gap Settings ................................................................................................. 8-2 9-1 Tower Deviation 9-2 Tension for Guys and Top Loading Radials – Stainless Inc. Tower ............................................. 9-3 9-3 Tension for Guys and Top Loading Radials – Rohn 65GSR Tower ............................................. 9-3 9-4 Tension for Guys and Top Loading Radials – Utility Tower ........................................................ 9-3

Forms Addendum

Form Reference Number Title

SC1000-001 1 kW Broadcast System (V)1 Configuration SC1000-002 1 kW Broadcast System (V)2 Configuration MSK-5SS-001 2.5 kW Broadcast System VECTOR-001 V4, V5 or V6 Broadcast System NDGPSEQP-001 DGPS Equipment (V)1 Configurations NDGPSEQP-002 DGPS Equipment (V)2, (V)3 Configurations BUPG-001 Semi-Annual Back-Up Power Group BUPG-002 Annual Engine/Generator NDGPSSITE-001 Equipment Shelters and Site Condition (Operational) NDGPSSITE-002 Equipment Shelters and Site Condition (Caretaker) NDGPSTWR-001 Tower Vertical Alignment Inspection NDGPSSafety-001 NDGPS Site Safety Equipment Checklist DGPSBATT-001 (V)4 Battery System Inspection DGPSBATT-002 (V)1 Battery System Inspection

NDPGS Maintenance Section 1 – NDGPS Maintenance Procedure Manual Organization and Concepts

Section 1 NDGPS Maintenance Organization and Concepts

1.1 Levels of Electronic Equipment Maintenance

Nationwide Differential Global Positioning System (NDGPS) electronic equipment maintenance is accomplished at two levels as discussed in this section.

1.1.1 Organizational Level Maintenance

Defined as on-site maintenance performed on the unit’s equipment using qualified maintenance personnel. The level of maintenance will vary from repairing the failure to only reporting the failure. In the case of the NDGPS, Organizational Level Maintenance will be performed by a qualified contractor or Coast Guard personnel operating under the technical guidance of the DGPS Product Line (DGPS PL) located at the Command, Control and Communications Engineering Center (C3CEN). Optional Depot Level Maintenance maybe provided via contractor, or other Center (s) of Excellence, for selected components.

1.1.2 Depot Level Maintenance

Depot Level (D-level) activities normally are defined as “any maintenance performed at, or by, other than at the Organizational Level (O-level). D-level activities provide direct support in situations beyond the technical scope of O-level maintenance. For the NDGPS Program, the Depot Level Maintenance support is provided via Coast Guard C3CEN.

1.2 Types of Organizational Maintenance

1.2.1 Preventive Maintenance (PM)

PM consists of a schedule of tests, adjustments, inspections, cleaning, lubrication, and preservation to maintain equipment performance at design standards. During any NDGPS site visit by an NDGPS technician, upcoming PM procedures should be accomplished given time and material support.

1.2.2 Corrective Maintenance (CM)

The NDGPS Program has an established Casualty Response Instruction that addresses actions taken in response to any CM requirements. The maintenance contractor is responsible for employing technicians trained in NDGPS equipment on staff. CM follows a logical progression of:

a. Symptom recognition.

b. Symptom enhancement.

c. List probable causes.

d. Localizing probable causes.

e. Localizing trouble to the circuit/module.

1. Waveform analysis.

2. Voltage checks.

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Section 1 – NDGPS Maintenance NDGPS Maintenance Organization and Concepts Procedure Manual

3. Resistance checks.

4. Logic level tests.

f. Failure analysis.

g. Failure correction.

h. Failure reporting and equipment log entries.

1.2.3 Coast Guard Depot Maintenance (liaison and responsibilities)

There is a direct liaison between the Coast Guard SFLC and the maintenance contractor. This direct liaison enables the maintenance contractor to have direct access to needed parts and eliminates days of delay while the request for equipment finds its way through other channels. The result is expedited transfer of RFI equipment.

The Coast Guard will provide the capability for the maintenance contractor to order parts and material directly from Government supply sources. (These procedures are currently under review and will be published as procedures are finalized).

1.2.4 Coast Guard System Management Engineering Facility (SMEF) (liaison and responsibilities)

The designated SMEF for the NDGPS is the Coast Guard Command, Control and Communications Engineering Center (C3CEN) and is generally responsible for performing the following functions:

a. Maintenance Management. The SMEF must actively participate in the maintenance management process to perform specific SMEF functions. A maintenance contractor, whose sole responsibility is to respond to and correct system failures as they occur, will perform equipment, shelter and facility maintenance for the NDGPS network. The contractor may be responsible for infrastructure and back-up power maintenance at those sites primarily supported by government personnel.

b. Configuration Management. A major responsibility of the SMEF is Configuration Management, which provides a means for managing technical engineering documentation, determining the differences between the documentation and the “as-built” product, and controlling changes affecting both. The SMEF will perform the following configuration management functions:

1. Management and control of the master technical data and the master equipment suite which define the Configuration Baseline (CB), less the Provisioning documentation required to develop APLs, MICAs, etc.

2. Evaluation of all proposed changes to the CB including parts substitution.

3. Management of the implementation of all approved changes to the set of approved configurations.

4. Configuration status accounting.

5. Monitoring of the field configuration.

c. Performance Monitoring. The SMEF will monitor the technical performance of specified equipment.

1. Review of all technical and operational data and reports for that equipment which are submitted to the SMEF. Further analysis will be required for reports that identify potential problem areas.

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2. Where problem areas have been reported and the equipment is not achieving specified performance standards, compare actual field performance against specified technical performance standards and identify problem areas.

3. Evaluate all beneficial suggestions for equipment assigned.

4. Development of a proposed configuration change to correct problems identified or changes required by approved beneficial suggestions.

d. Technical Liaison. The SMEF is the prime point of contact for technical liaison and information for the NDGPS equipment. The technical liaison function may also include coordination and engineering services necessary to provide technical advice and information to:

1. Headquarters acquisition managers: e.g., provide technical advice to specification writers and assist in specification review; provide technical assistance in reviewing proposals; provide technical advice in the drafting and review of proposed technical approaches.

2. The Inventory Control Point to assist in managing the logistics support for the NDGPS equipment.

3. The Depot Level Repair activity for the equipment.

4. Project engineering activities.

5. Command, Control and Engineering Center (C3CEN).

6. Commercial manufacturers and suppliers as appropriate.

7. Other government agencies.

8. Training activities.

9. Foreign governments as specifically authorized.

e. Dissemination of Technical Information. It is necessary and useful for the SMEF to disseminate technical information concerning support of the NDGPS equipment. This technical information will be provided to maintenance activities and contractors supporting NDGPS equipment.

f. Configuration Management Procedures. Configuration management is a discipline that applies technical and administrative direction to:

1. Identify and document the functional and physical specifications of electronic systems, and/or equipment.

2. Control changes to those specifications.

3. Record and report configuration changes.

g. Implementation of Configuration Changes. The SMEF is responsible for the engineering, management, and administration of configuration changes. This responsibility includes:

1. Development of implementation schedule and plans.

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2. Coordination with logistic and support elements.

3. Providing required technical documentation to appropriate procurement activities.

4. Providing technical direction and quality assurance of manufacturing or fabrication efforts.

5. Printing of required technical documentation.

6. Providing technical guidance to supply activities on distribution and development of appropriate support for the change.

7. Updating the master configuration baseline.

h. Configuration Status Accounting. The SMEF is responsible for documenting, recording, and reporting information on the configuration baseline; the history of changes to the baseline; the status of pending baseline changes; and implementation status information.

i. Monitoring of Field Configuration. The SMEF for a NDGPS system or equipment has responsibility for monitoring the installed configuration of that system or equipment.

1.2.5 Installation of Time Compliance Technical Order (TCTOs) or Authorized Equipment Modifications

a. Definitions:

1. General. A TCTO is a modification to a specific type of Coast Guard equipment. It is a universal change to all equipment of that specific type within the Coast Guard.

2. Modification. TCTOs are issued to modify electronic equipment to meet a change in operational requirements, remove hazards, correct design deficiencies, improve reliability and maintainability, and correct technical documentation. Technical manuals and formal operating and maintenance instructions are treated as an inherent part of the equipment for TCTO purposes.

3. Alteration. All authorized equipment alterations are documented by TCTOs. In urgent situations, MESSAGE TCTOs are used for rapid dissemination of maintenance actions or configuration changes that are of an urgent nature due to safety or severe operation degradation. Message TCTOs are not appropriate for complex changes with man design and logistic elements since the TCTO may bypass key portions of the TCTO process that are intended to address these elements.

4. Frequency Determining Circuits. Any modification that affects the frequency determining circuits of any equipment will not be accomplished without first receiving specific authority from the Commandant, U.S. Coast Guard.

5. Maintenance Hints. Maintenance hints are not to be confused with TCTOs. A TCTO involves the changing of components, physical alteration of cabinets or housing, changing of operational tolerances or capabilities, and changes to the technical manuals. In contrast, a maintenance hint involves procedures not formerly documented that are useful in servicing electronic equipment. For example, a maintenance hint may involve a revised method for disassembly and re-assembly of a complicated servomechanism that simplifies the procedure or decreases the time involved.

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1.2.6 Responsibility

C3CEN and the designated maintenance contractor are responsible for acquisition and installation of applicable NDGPS Time Compliance Technical Order (TCTO).

1.2.7 Procedure

Coast Guard TCTOs are issued by the DGPS Product Line except those authorized to be issued by the C4IT Service Center, however, information necessary to implement an TCTO must come from all levels of command.

The required TCTO shall be published by Surface Force Logistics Center (SFLC) and necessary TCTO parts kits are assembled for distribution. Wherever possible, a trial installation is made for evaluation prior to service-wide distribution of a TCTO.

1.2.8 Tools and Test Equipment Required

Standard hand tools are required for performance of Operational/Depot Level Maintenance. In addition, the below listed test equipment is necessary for proper measurement, performance analysis, and adjustment of the equipment.

a. Digital multimeter.

b. Through-line wattmeters with appropriate frequency and power elements.

c. Scopemeter for duty cycle measurement and general troubleshooting.

d. PC laptop with USCGCTRL service software.

e. Extender board for SAC 1000 transmitter.

f. DB-9 male to DB-9 female straight-through RS232 cable.

g. Tuning tool (“tweaker”).

h. Connector kit.

i. Miscellaneous test cables.

j. Battery tester.

k. Battery brush.

l. Electrolyte tester (optional in lieu of vendor services).

m. Coolant tester (optional in lieu of vendor services).

n. Vacuum cleaner.

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1.2.9 Materials Required

The following is a list of materials required for performance of Intermediate Level Maintenance:

a. Rags, lint free.

b. Brush, cleaning.

c. Detergent, all-purpose.

d. Water.

e. Self-vulcanizing rubber tape.

f. Vinyl electrical tape.

g. Scotchcoat.

h. Lubricating oil.

i. Cleaning solvents as approved for use with electronic equipment.

j. Conductive anti-seize.

k. Battery terminal compound.

l. Engine oil per specifications (as required).

m. Engine coolant per specifications (as required).

n. Standard hand tools.

o. Oil absorbent pads (as required).

p. Oil filters – two types (as required).

q. Fuel filters.

r. Oil filter wrenches (large and small).

NDPGS Maintenance Section 2 Procedure Manual Safety

Section 2 Safety

2.1 NDGPS Shelter Safety and Fire Program

2.1.1 Safety Program

The designated maintenance contractor shall have an established and on-going Safety Program. All employees shall be required to read and comply with their company’s Safety Program. The Safety program shall comply with OSHA standards and generally accepted safety practices.

2.1.2 Background

The NDGPS shelter and installed equipment presents some unique safety situations. This NDGPS Shelter Safety and Fire Program addresses these situations.

Most injuries and fatalities caused by energized electrical equipment can be attributed to human error. Some common errors to avoid are:

a. Failure to observe standard safety precautions.

b. The installation of unauthorized equipment modifications.

c. Using unauthorized or inappropriate test equipment for repair work.

d. Failure to secure and repair unsafe equipment.

e. Failure to fully test the equipment following repairs.

Note

Safety shall not be sacrificed in order to expedite equipment repair

2.1.3 Responsibilities

The Maintenance Contractor will train all repair technicians in the electrical and physical configurations associated with each of the NDGPS installations. NDGPS training will include repair of the electronic equipment, as well as specific safety training for equipment repair in the confined space of the shelter. Only those technicians that have successfully completed both of these training requirements will be designated as NDGPS Casualty Repair Technicians.

The NDGPS casualty repair technician will be technically qualified to perform casualty repair on the NDGPS equipment. The technician must successfully complete the NDGPS Shelter Safety and Fire Program. While performing preventive or corrective maintenance on NDGPS equipment, the technician will observe all general and specific safety precautions (listed in Paragraph 2.1.4 Procedures). Should the technician encounter a safety hazard that cannot be immediately resolved, the repair may be delayed or abandoned pending resolution of the hazard.

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Section 2 NDGPS Maintenance Safety Procedure Manual

2.1.4 Procedures

a. General

1. Repair and testing of energized equipment with cabinets open and/or interlocks defeated will be kept to a minimum, and then only when no other measures will suffice. A Safety Observer shall be present whenever work is performed on open energized equipment, or when climbing towers.

2. No metal or dangling jewelry will be worn during equipment maintenance.

3. Ensure the equipment and the surrounding area is dry.

b. Shelter Specific

1. The NDGPS shelter is defined as a “confined space” due to the small physical size of the shelter and the amount of equipment operationally required.

2. The NDGPS shelters are not occupied working spaces and are only occupied during maintenance operations. At all other times the shelters are locked.

3. An Emergency Cutoff switch is located just inside the NDGPS shelter on the right. Activating this switch secures ALL power to the shelter.

4. Ample fluorescent and incandescent lighting is provided inside the shelter.

5. A telephone is available inside the shelter.

6. Smoke, temperature, humidity, and intrusion alarm sensors are included in the overall NDGPS monitoring system and are linked to NAVCEN/NAVCEN Western Operations at the 1 kW transmitter sites. A dial-up intrusion alarm is being incorporated at other sites.

7. A five-pound CO2 fire extinguisher is located on the inside wall to the right of the doorway.

8. A Safety Board is installed in a conspicuous location within the shelter and contains a shorting probe rated at 25,000 volts, a pair of rubber insulating gloves providing 5,000 volts protection, a face shield, a length of rope, and a wooden cane.

9. A first-aid kit is attached to the inside of the shelter door.

10. The floor of the shelter, the wall behind the transmitter, and the wall under the power panel are protected with MIL-M-15562D compliant electrical matting.

c. Personal Safety

De-energize the equipment BEFORE connecting test equipment. Be wary of exposed terminals, especially when the equipment is not de-energized.

d. Equipment Safety

1. A Plexiglas™ cover is installed over the exposed power terminals in the rear of the Southern Avionics Corporation (SAC) transmitter and within the Zenith Automatic Transfer Switch (ATS) located in the

BUPG.

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2. Repair parts installed shall be of the same specifications as those removed. In no case will any parts be installed that are not direct replacements unless authorized by the SMEF and maintenance COTR.

3. The NDGPS Repair Technician shall perform only Government authorized repairs, maintenance, or modifications.

e. Reference Mast Safety

1. IN ALL CASES, A SAFETY OBSERVER WILL BE PRESENT WHEN IT IS NECESSARY TO

CLIMB A MAST. NO EXCEPTIONS.

2. Climber’s safety rails are normally provided on all masts over 20 feet in height and should be used.

3. Where a climber’s safety rail is installed, ensure it is properly installed, all connections are tight, and there is an end-stop at the top of the rail.

4. On installations where Reference Station (REFSTA) towers are 20 feet or more, ensure anti-climb guards are in place and do not crush or penetrate antenna cables.

5. All climbing harnesses and safety belts shall conform to CFR1926.500 and 1910.159. A full body harness is normally required for personnel involved in tower climbing.

6. Inspect the ‘parachute’ climbing harness before each use. The safety observer will check the proper placement of all straps after the climber has put on the harness.

7. In general, all personnel engaged in climbing must be trained in the use of the equipment and be qualified in writing to climb by their employer. Climbers must be qualified in first aid and at least one in CPR.

2.1.5 Summary

Personnel and equipment safety are paramount. All actions by technicians must be approached from the safety aspect. This plan is in no way all-inclusive.

REMEMBER

Be careful! Do not take chances! Take the time to do the job safely!

2.2 NDGPS Hazardous Material (HAZMAT) Program

2.2.1 Hazardous Material Program

Within the NDGPS Program there is a limited amount of hazardous material that requires special handling.

Currently the only equipment that has parts that require special HAZMAT handling are the battery packs associated with the Uninterruptible Power Source (UPS) units. There is currently no requirement to use any toxic chemicals in the maintenance of NDGPS system equipment.

NDGPS site maintenance requires the routine replenishment of fuel oils and coolants in the engine-generator set.

Old fuel, lubricants, coolants and cleaning fluids shall be disposed of in accordance with the applicable state, county, or other local jurisdiction requirements. Absolutely no dumping is permitted. The use of licensed, local venders to receive and dispose of these fluids is encouraged.

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2.2.2 Background

The NDGPS equipment has minimal equipment requiring the use of hazardous material. A complete understanding of the proper handling of lead-acid batteries is imperative for any technician performing NDGPS site maintenance. Each Uninterruptible Power Supply (UPS) unit has two battery packs and each battery pack contains four sealed lead-acid batteries with a life expectancy of six years.

2.2.3 Responsibilities

The Contractor shall train all repair technicians in the proper handling of lead-acid batteries. Only those technicians that have successfully demonstrated a complete knowledge of the procedures for handling lead-acid batteries will be authorized to handle the battery packs used in association with the UPS units.

2.2.4 Procedures

a. Any person handling lead-acid batteries must use:

1. Goggles.

2. Rubber gloves.

3. Rubber apron.

4. Remove all metal jewelry.

b. The hydrogen gas generated by the battery is highly explosive, persons working around lead-acid batteries shall adhere to the following:

1. Do Not smoke.

2. Do Not light a flame.

3. Do Not generate sparks with hand tools or electric tools.

4. Do Not dispose of batteries in a fire, they may explode.

5. Do Not open or mutilate the battery. The batteries contain an electrolyte, which is toxic and harmful to the skin and eyes.

c. Battery Disposal.

1. The batteries used in the UPS unit are recyclable.

2. Refer to local codes for proper disposal requirements or,

3. Return the unit to a factory authorized Service Center for battery replacement or disposal.

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2.2.5 Summary

Personal safety and environmental concerns are paramount in regard to lead-acid batteries. All technicians must be thoroughly familiar with the HAZMAT Program.

REMEMBER

Be careful! Do not take chances! Take the time to do the job safely!

2.3 Radio Frequency (RF) Radiation Hazard Program

2.3.1 RF Radiation Hazard (RADHAZ) Program

The Contractor shall establish an on-going RADHAZ program. All NDGPS repair technicians are required to read and comply with established Coast Guard and company policies regarding radiation hazards.

2.3.2 Background

The NDGPS radiates RF energy using the MF frequency range (300 kHz +/-). There are two undesirable effects of prolonged exposure to this radiation. 1) RF, which is an induced voltage that accumulates in ungrounded structures and other metal objects, will cause shock or produce open sparks upon contact. 2) Personnel Biological Injury is caused by internal heat generated in the body by exposure to RF energy for a period of time.

An instrumented RF energy boundary, known as the Permissible Exposure Limit (PEL) Boundary, is established around each radiating antenna. The maximum Permissible Exposure Limits (PEL) to Radio Frequency Radiation (RFR) has been established as no more than six minutes of exposure to RFR within the PEL Boundary during any given hour.

2.3.3 Responsibility

The Maintenance Contractor shall ensure all repair technicians are aware of the hazards involved with working around RF energy. Safety precautions to guard against any Induced Voltage Effects (IVE) would be to ensure combustible materials or any ordinance is kept well outside the RF Radiation Hazard Area.

The Contractor is responsible for checking all RADHAZ warning signs and placing or replacing any signs that are not present, are missing or art not suitable for the intended purpose of providing a warning of know hazard of radiation. Figure 2-1 is an example of the type of Burn Hazard warning sign that must be displayed. Figure 2-2 is an example of the type of Personnel Hazard warning sign that must be displayed. Any time maintenance is required in a RADHAZ area, transmitting activity will be terminated. NDGPS Repair Technicians are trained in the dangers associated with exposure to RF energy.

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WARNING RADIO FREQUENCY HAZARD

BURN HAZARD

MAY EXIST ON METALLIC OBJECTS

IN THIS

AREA

Figure 2-1. RADHAZ Burn Hazard Warning Sign

2-6

WARNING RADIO FREQUENCY HAZARD

PERSONNEL HAZARD

EXISTS

IN THIS AREA

KEEP MOVING

Figure 2-2. Personnel Hazard Warning Sign

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NDPGS Maintenance Section 3 Procedure Manual Back-up Power Group

Section 3 Back-up Power Group (BUPG)

3.1 Battery and Charging System

Equipment: Starting Batteries and Charger

Type of Maintenance: Test, Clean, Visual Inspection, Replacement as necessary

Periodicity: Semi-annual, annual (caretaker) or As Required

Responsibility: Maintenance Contractor

Required Documentation:

Maintenance Action Form (MAF) BUPG001, BUPG Semi-Annual Back-Up Power Group, for semi-annual PMs or BUPG002, Annual Engine/Generator, for annual PMs – see Forms Addendum for MAF examples.

Procedure:

3.1.1 Batteries and Charger

a. Record the Elapsed Time Meter reading from the engine control panel. If there is a label designating a previous meter reading, add the number to the existing meter number and record the SUM of the two numbers.

b. Remove power from the battery charger at CB8 on the BUPG panel board. Turning off the charger will generate LED 29, BUPG Battery Charger Fail on the RSIM/RTCI, which can be annotated on NDGPSSITE-

001. Remove the metal covers from the two battery boxes.

For convenience, battery #1 is the battery on the left (looking toward fuel tanks) with the charger connections.

b. With charger power off, disconnect batteries as follows: remove the negative lead from each battery and set aside. Remove the positive lead from each battery and set in a position that will not touch any metal.

Measure the voltage and, if above 13 volts, load test each battery per tester instructions.

c. Perform a visual inspection of the batteries paying special attention to anode corrosion, bulges in the battery, frayed wiring etc.

d. Make note of the battery date and record. Batteries should be replaced at years of operation even if testing is satisfactory.

e. If a serviceable battery type, check electrolyte level and test electrolyte. Add distilled water, if needed. If a sealed battery type, observe status indicator (green). Replace if defective and properly dispose of old battery.

f. If needed, clean terminals and seal battery connections.

g. Open the front panel of the wall-mounted battery charger and perform a visual inspection. If excess dirt is present, clean out the charger with a brush and vacuum.

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Section 3 NDPGS Maintenance Back-up Power Group Procedure Manual

Note: prior to closing the battery boxes, review step 3.2.1 (c.3) concerning battery heater operation.

h. Reconnect the batteries at this time by connecting the anodes first and then the negative terminals. Ensure the charger lines are connected to battery #1.

i. Turn on the battery charger at CB8. Observe the charger front panel. The voltmeter on the charger should read above 13 Vdc for fully charged batteries. The current meter should initially indicate a fast charge (approximately 6 amps) then drop to a small trickle charge or negligible amperage for fully charged batteries.

j. Return the metal covers on the batteries being careful not to touch the metal cover to the battery terminals.

3.2 Back-up Power Group (BUPG) Preventative Maintenance

Equipment: Engine Generator System

Type of Maintenance: Inspect, Test, Renew Fluids, Clean

Periodicity: Semi-Annual, Annual (Caretaker) or As Required

Responsibility: Maintenance Contractor

Procedure:

3.2.1 BUPG Pre-operational Checks

Complete Maintenance Action Form BUPG001 (Semi-Annual) or BUPG002 (Annual) while performing this procedure.

WARNING

To prevent injury, this inspection must be performed with TRANSFER DISCONNECT switch and the engine RUN/OFF/AUTO switch to the OFF position.

a. Turn the engine control panel RUN/OFF/AUTO switch to OFF.

WARNING

Do not check or adjust when engine is running.

b. Check the fuel delivery hose (Pre-heated fuel line) by feeling it for warmth. Note: This is NOT part of the winterization system. The hose should have some warmth any time of the year.

c. Check the winterization system. This system is temperature dependent and during the warmer times of year it is best inspected first thing in the morning. At some times, due to high local temperatures, it will not be operational, which in itself indicates proper operation. Check the winterization system BEFORE test running the engine or the engine will be too warm for the system to operate.

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1. Check the vertical hose from the coolant tank heater (hydraulic hose on the left side of the engine) for warmth.

2. Check the engine block on the right side of the engine just above the crankcase heater for warmth.

3. Check the battery heater pads for warmth by feeling under the battery boxes. These may be difficult to definitively determine by feel. A resistance check can be made if in doubt.

d. Check belts for looseness, damage, or wear. Tighten or replace belts as necessary.

e. Check hoses for looseness, or damage such as holes, and leaks.

f. Tighten or replace hoses as necessary.

g. Check engine oil level with dipstick. For the Allis-Chalmers engine use the side marked STOPPED.

h. Check oil reservoir level using the reservoir dipstick. Ensure the reservoir valve is ON.

WARNING

Ensure engine is cold before checking coolant. Bleed off pressure prior to removing radiator cap. Failure to allow coolant to cool could result in second and third degree burns.

i. Check coolant level, add coolant if necessary. Use only coolant suitable for use in diesel engines. Coolant samples will be taken for lab analysis once a year, typically during vendor annual engine service.

j. Check air cleaner service indicator. A red indicator indicates air flow blockage. Check the dust cap and baffle in air cleaner, empty and clean if necessary.

k. Check radiator for cleanliness, clean if dirty.

l. Check alternator and water pump drives.

m. Check floor drain for fluid accumulation. Open external drain valve and empty fluid into suitable container.

n. Note the status of the BUPG blower and louvers. Their initial state is dependent on the temperature and whether the engine is running. Prior to starting the engine, the recirculation louver is open. If approximately 75 degrees or higher, the intake blower will be running and the exhaust louvers will be open. If below 75, the blower will be off and the exhaust louver closed.

The operation of the vents observed in a later step will be tied to the temperature of the BUPG. When making observations, it’s most important to observe that system operates in the sequence described.

3.2.2 Test Engine-Generator and Ventilation

a. Turn engine control panel RUN/OFF/AUTO switch to ON. Engine will start.

b. After engine reaches normal operating temperature, check oil level with side of dipstick marked RUNNING (Allis-Chalmers).

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c. Check control box for the following:

1. Check oil pressure – should be between 30 and 55 psi (207 to 270 kpm) at full rpm.

2. Check DC amperes – should be 5 amps or less with full charged battery.

3. Check water temperature – should be approximately 180°F under operation.

4. Check oil temperature – should be approximately 190°F under operation.

5. Check elapsed time meter – should show movement on the 1/10 hour dial as the engine is running.

6. Check AC volts – should be between 190 and 220 Vac. Generator output should be matched to commercial power to avoid site output power fluctuations when transferring power sources.

7. Check AC amperes – Amperes will be zero when operating in standby. When tested on line in the next section, amperes should be between 0 and 87 amps depending on load conditions.

8. Check frequency meter – should indicate between 59 and 61 Hz under load – typically, broadcast operational and one heater or AC unit running. The frequency may be up to one hertz high operating under no load conditions.

9. Check that all fault indicating lights are out.

10. Check for oil and coolant leaks during and after operations.

d. Observe operation of the ventilation system as the BUPG warms up. The beginning status of the system will depend on seasonal conditions (temperature).

1. If 65 degrees or lower; blower off, recirculation louver open, exhaust louver closed.

2. As the BUPG warms further (approximately 70 to less than 75 degrees) the recirculation and exhaust louvers will open. The blower remains off.

3. At approximately 75 to less than 80 degrees, the recirculation louver closes.

4. Finally at approximately 80 degrees the blower will active, the…