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HartRAO 26m Telescope repair


The large bearing at the South end of the main polar shaft of the 26m radio telescope failed on 2008 October 03. Observing was immediately shut down to prevent further damage. After extensive engineering investigation and consultation, the decision was taken to repair the telescope - the only one of its type in Africa. The photographs below summarise how this was accomplished.

Prime contractors for the repair were General Dynamics Satcom Technologies in the United States. Local contractors were Stratosat Datacom, and the local engineering subcontractor was Tass Engineering.

polar shaft
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Schematic diagram of an antenna similar to the HartRAO 26m telescope, showing the polar shaft (NASA). The failed bearing was at the upper end of the polar shaft.

Slab
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2010-03-09 Cutting the concrete slab and removing the old airconditioning chiller foundation in preparation for casting the concrete supports for the box beam and A-frame that will hold up the 200 tonne telescope during the bearing replacement

soil
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2010-04-09 Testing the soil hardness to ensure it will properly support 200 tonnes.

2010-04-19 Pouring concrete
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2010-04-19 Pouring concrete

2010-05-14_concrete_curing_in_the_mist
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2010-05-14 Concrete curing in the mist

2010-05-26_box_girder+parts
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2010-05-26 Box girder parts constructed at Tass Engineering. The large box beam will support an A-frame (bipod) that will be attached to the polar shaft just behind the failed bearing.

2010-05-27_Ludwig_surveying_26m_polar_shaft
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2010-05-27 HartRAO Associate Director for Space Geodesy Ludwig Combrinck surveying the 26m polar shaft before work begins, to determine its shift during the repair

2010-06-10_placing_box_beam
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2010-06-10 Placing the box beam on the concrete pads

2010-06-15_bearing_puller
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2010-06-15 The red polar shaft end cap puller is in place. The bearing is behind the end cap. Spot the person in the structure!

2010-06-18_polar_shaft_collar+A-frame_top_pivot
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2010-06-18 Polar shaft collar and A-frame top pivot have been installed on the polar shaft just behind the bearing. Viewed from the west side.

2010-06-22_East_A-frame_upper_leg_installed
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2010-06-22 The A-frame upper legs have been installed. At this stage the two upper legs hang from the collar around the polar shaft.

2010-06-23_HA_gearwheel_bracing_and_scaffolding_05888
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2010-06-23 The large gear wheel for driving East-West Hour had to be braced with temporary struts to prevent it moving during the repair

2010-06-24_East_bipod_leg_lift
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2010-06-24 Lifting the lower East A-frame leg into position. The lower West leg is already in place.

2010-06-24_inserting_pivot_pin_East_bipod_leg
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2010-06-24 Inserting the pivot pin in the East A-frame leg to lock it in place

2010-06-28_A-frame_work
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2010-06-28 Working on the A-frame

2010-06-30_first_lift-east_jack
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2010-06-30 First lift of the East A-frame leg using a 200 tonne hydraulic jack. The polar shaft had sagged as the bearing failed, and had to be moved back into the correct position to replace the bearing.

2010-07-01_end_cap_puller_and_splice_plate_removal
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2010-07-01 The red puller is in place for removing the end cap. The bolts holding the splice plates between the end cap and support legs are being removed. The 200 tonne antenna is now supported on the A-frame.

2010-07-01_bearing_cover_removal_with_jack_inside_puller
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2010-07-01 Bearing cover removal with jack inside puller

2010-07-01_bolts_that_used_to_hold_the_telescope_together
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2010-07-01 Bolts that used to hold the telescope together

2010-07-02_polar_shaft_end_cap_is_off
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2010-07-02 The polar shaft South end cap is off! 200 tons of force was required from the hydraulic jack to shift it, after 49 years in place.

2010-07-02_south_polar_shaft_bearing_exposed
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2010-07-02 The south polar shaft bearing exposed. Fragments of broken bearing fall out.

2010-07-02_extracting_rollers_from_damaged_inner_race
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2010-07-02 Extracting rollers from the damaged inner race of the south bearing.

2010-07-06_arc_gouging_in_action_1634.jpg
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2010-07-06 Arc gouging being used to cut through inner bearings to get them out.

2010-07-13_Andrew_preparing_endcap
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2010-07-13 HartRAO antenna technician Andrew Masiteng preparing the polar shaft end cap for re-installation

2010-07-14_1000_bearing_pusher_installation
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2010-07-14 The new bearing is on the end of the shaft and the pusher is being installed

2010-07-14_1010_bearing_preparing_for_push
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2010-07-14 Preparing to push the new bearing onto the shaft. Heating and cooling (with liquid nitrogen) was used to cause differential expansion and provide sufficient clearance to push the new bearing into place.

2010-07-15_the_bearing_is_in
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2010-07-15 The new bearing is in!

2010-07-14_1044_bearing_in_and_Pieter_happy
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2010-07-14 HartRAO antenna specialist Pieter Stronkhorst is happy.

2010-07-15_06144_end-cap_approaches_polar_shaft
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2010-07-15 The end cap is brought to the polar shaft for refitting

2010-07-16_A-frame_removal
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2010-07-16 The end cap is on, the splice plates have been bolted back on to rejoin the end cap to the support legs, and the A-frame is being removed.

2010-07-20_Hart26m_telescope_drives_with_new_bearing
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2010-07-20 The HartRAO 26m telescope drives for the first time with new bearing, closely watched by technical staff

2010-07-22_first_observation_log
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2010-07-22 Exactly one year after the decision by the President of the NRF to repair the telescope, the first observation was carried out successfully. The observing log is shown; the observation was to begin the process the establishing a new pointing model for the telescope.

2010-07-22_first_observation_plot
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2010-07-22 Plot of the scans across radio galaxy 1253-05 in the first observation after the repair. Multiple scans are plotted superimposed, as the observing programme iteratively finds the pointing errors in this direction. This receiver has two feeds alongside each other collecting the signal. The software takes the difference between the two signals. This causes the apparent "positive" and "negative" radio sources in the scans - they are actually from the same object. The upper plot shows left-circular polarization data, the lower plot righ-circular polarization. The are recorded separately by the receiver.

2010-07-22_testing_the_west_limit
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2010-07-22 Testing the West limit switches that prevent the antenna from driving off the end of the gearwheel

2010-07-23_Hart26m+XDM_both_observing_Vela_pulsar
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2010-07-23 The process of recommissioning all the receivers and data capture system for different observing modes continued. Here the HartRAO 26m telescope and the 15m XDM prototype for the Karoo Array Telescope are both observing the Vela pulsar. This collapsed star undergoes sudden jumps in its rotation rate, called 'glitches', every few years. After a wait of four years, it glitched a few days after observing resumed with the 26m telescope.

2010-07-28_Marisa_preparing_for_VLBIs
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2010-07-28 A big milestone was resuming VLBI observing, working together with radio telescopes on other continents. Here Marisa Nickola prepares for the first VLBI.

The first post-repair VLBI was a 24-hour astrometric experiment named CRF60. It was undertaken on 2010 August 11. In this experiment the (ex-NASA) HartRAO 26m telescope combined with the University of Tasmania 26m telescope (also ex-NASA) at Mount Pleasant near Hobart and NASA's DSS-45 34m antenna at Tidbinbilla near Canberra. CRF60 is one of a continuing series astrometric VLBIs run by the International VLBI Service for Astrometry and Geodesy (IVS) aimed at establishing, maintaining and improving the International Celestial Reference Frame in the Southern Hemisphere. The ICRF provides the framework for astronomers to accurately locate other celestial objects.

A timelapse movie of the repaired telescope in action can be seen here, courtesy of "Carolune".