HAL Summer Training Report

HINDUSTAN AERONAUTICS LIMITED

S R INSTITUTE OF MANAGEMENT AND TECHNOLOGYA SUMMER TRAINING REPORTOF

HINDUSTAN AERONAUTICS LIMITEDSUBMITTED BY:-Mo Meraj(B.Tech ME)1148540052

Under the Guidance ofMr. O P Tiwari Mr.AnuragSrivastav

ASummer Training ReportOf

Hindustan Aeronautics LimitedIn partial fulfillment of requirements for the Degree ofBachelor of Technology in Mechnical EngineeringSUBMITTED BY:MO Meraj1148540052Under the Guidance ofMr. O P Tiwari Mr.Anurag Srivastav

S.R INSTITUTE OF MANAGEMENT & TECHNOLOGY LUCKNOWACKNOWLEDGMENT

I am indebted to my respected teachers and supporting staffs of Division of Mechnical Engineering for providing as my inspiration and guidance for my Summer Training . I am grateful to Mr.AnuragSrivastav Head of Division of Mechnical Engineering for giving such an opportunity to utilize all resources needed for the training. I am highly obliged to my guide Mr. O P Tiwari for their valuable instructions,guidance and corrections in my training period and its presentation.I would like to express my greatest gratitude to the people who have helped & supported me throughout my Summer Training. I am grateful to my teacher for his continuous support for the Summer Training, from initial advice & contacts in the early stages of conceptual inception & through ongoing advice & encouragement to this day. A special thank of mine goes to my colleague who helped me in completing the Summer Training& she/he exchanged her/his interesting ideas, thoughts & made this Summer Training easy and accurate. I wish to thank my parents for their undivided support and interest who inspired me and encouraged me to go my own way, without whom I would be unable to complete my Summer Training. At last but not the least I want to thank my friends who appreciated me for my work and motivated me and finally to God who made all the things possible...

Mo MerajRoll No- 1148540052

CONTENTS

BRIEF HISTORY/INTRODUCTION OFINDUSTRY/ORGANIZATION

ORGANISATIONAL CHART..

SYSTEMS/PLANT LAY OUT.

PRODUCTS &SPECIFICATIONS/ACTIVITES/SALIENT FEATURES .

PRODUCT FLOW CHART/PROCEDURES..

CHRONOLOGICAL TRAINING DAIRY (WEEKLY DETAILS OFOBSERVATION/STUDIES IN DIFFERENT SECTIONS)..

PRODUCTIONPROCESSES/PROJECT/CONSTRUCTIONAL/STRUCTURALDETAILS.

MARKETING STRATEGIES.

DIVERSIFICATIONS..

SUGGESTIONS.....

CONCLUSIONS

REFERENCES

history of halHindustan Aeronautics Limited has blossomed into a major player in the global aviation arena, and today is among the elite Navratna companies. The history of Indian aircraft industry can be traced to the foundation ofHindustan Aircraft Limited at Bangalore in December 1940 in associationwith the erstwhile princely state of Mysore and lateShri SethWalchandHirachand, an industrialist of extra-ordinary vision. Govt. of India became one of its shareholders in March 1941 and took over the management in1942. Hindustan Aircraft Limited was merged with Aeronautics India Limited and Aircraft Manufacturing Department Kanpur to form HAL on1-october-1964.Today HAL has got 18 production divisions & 9 research &design enters spread out in 7 different locations in India. Its product track record consists of 12 types of aircraft from in house R & D and 13 types by licenseproduction. HAL has so far produced about 3352 aircraft (which include 11type of indigenous design), 3583 engines & overhauled over 8141aircraft &27267 engines. HAL has engaged & succeeded in number of R & D programs forboth the military and civil aviation sectors. Substantial progress has been made in the current project like Dhruv Advanced Light Helicopter (ALH),Tejas-Light Combat Aircraft (LCA), Intermediate Jet Trainer (IJT) &various military and civil upgrades. The deliveries of Dhruv were affected to Indian Army, Navy, Air force & Cost Guards in March 2002, in its first yearof production which is a unique achievement. The Government of India decided to set up a factory Lucknow Division in 1969 to undertake License manufacture of accessories and instrument for Hindustan Fighter HF-24 and Hindustan jet trainers HJT-16, aircrafts. The factory building is ready by October 1973 and full fledged manufacturing of the accessories to cover Ajeet,MIG-BIS Aircrafts, aero engines and Helicopters.HAL Accessories Division Lucknow was established in 1970 withprimary objective of manufacturing systems and accessories for varies aircrafts and engines. At present it is turning out over 1100 different types ofaccessories. The division manufactures various systems viz. Hydraulics; engine Fuel systems, Air-conditioning Pressurization, Gyro and Barometric Instruments, Electrical system items Undercarriage, Electronic items all under one roof to meet the requirements of the aircrafts, helicopters and engines being produced by HAL.HAL has played a significant role for Indias space program in the manufacturing of satellite launch vehicle like PSLV (Polar Satellite Vehicle), GSLV (Geo Stationary Launch Vehicle), IRS (Indian Remote Satellite) & INSAT (Indian National Satellite).HAL has joint ventures companies BAEHAL, Software Limited & Indo-Russian Aviation Limited (IRAL),Snecma-HAL Aerospace Pvt Ltd. Apart from these, other major diversification project & industrial marine gas turbine & airport services. Several co-production & joint ventures with international participation are under consideration.HALs supplies / services are mainly to Indian Defense services, Coastguard & Border Security Force. Transport Aircraft & Helicopters have alsobeen supplied to Airlines as well as State Government of India. The company has also achieved a foothold in export in more than 30 countries, having demonstrated its quality & price competitiveness

DIVISIONS

MISSION

To become a global player in theaerospace industry

HAL LUCKNOW (ACCESSORIES DIVISION):-

The manufacturing range of this division can be grouped under three categories:1.) Mechanical and hydro-mechanical accessories,2.) Engine Accessories3.) Instrument accessories.

In addition, the division also manufactures the wide variety of ground support equipment like Ground Power Unit, hydraulic trolley, weapon loading trolley ,Test equipment etc.

The Aerospace & equipment research & design Centre is involved in the design and development of hydraulic pumps, actuators, wheels andbrakes etc.

ORGANIZATIONAL CHART

ChairmanManaging Director General Manager

AGM(Fuel) AGM(Design) AGM(Instrument) AGM(Mechanical)DGMDGMDGMDGMChief Manager Chief Manager Chief Manager Chief ManagerSenior Manager Senior Manager Senior Manager Senior ManagerManagerManagerManagerManagerDeputy Manager Deputy Manager Deputy Manager Deputy Manager EngineerEngineerEngineerEngineer EmployeeEmployeeEmployeeEmployee

SYSTEM LAYOUTHead of HAL Lucknow division is General Manager. The factory is divided into five sub Divisions: Instrument factory Mechanical factory Fuel factory Design and Development Sukhoi-30INSTRUMENT FACTORYThis is further divided into two shops1. Assembly shop2. Manufacturing shop

Assembly shopis divided into: -1. SHOP12. SHOP 23. SHOP 34. SHOP 45. ALH

Manufacturing shopis divided into: -1. NGL Shop2. Smiths shop3. Gyro shop4. Press Shop

Following systems or instruments are manufactured in Instrument factory.1. Barometric instrument2. Gyroscopic instruments3. Electrical and Electronics equipment4. Fuel gauging systems5. Ground level navigation systems

All the above products are manufactured in specially designed rooms called clean rooms. Following conditions are essential for the clean rooms for production.

STANDARD CLEAN ROOMS CONDITIONSTEMPERTURE: -15 to 25oCHUMIDITY: - 45 TO 55%DUST COUNT: - Less than 100,000 for class C shop (unmonitored)Less than 100,000 for class B shopLess than 10,000 for class A shop

PRODUCTS

Initially production of accessories was planned for Marut and Kiran aircrafts in 1972 which later expanded to include accessories for MIG-21 series and helicopters during the late 1970s in Lucknow Division.

The current products of HAL are- DO-228 Kiran MK II HPT-32 Cheetah Chetak MIG-21 MIG-27 Jaguar Engine Test beds Radars

There are some new products- ALH LCA HTT-35 Industrial/marine Gas Turbine Modern Instruments GSE

The division today has prime name in the Aviation market and various international companies are interested to join hands it for future purpose. The division has also made steady progress in the area of export.

PRODUCT PROFILE of hal1950s & 1960s

1970s & 1980s

1990s to till date

Products Of HAL Lucknow Division

Instruments Sensors, GyrosFlight instruments, electrical indicators, Fuel Gauge probes, Gyros,sensors and Switches

Electrical power generation and controlAC/DC Generator, Control and protection units, inverters, Transformers Rectifier units, AC/DC Electrical system, Actuators.

Land navigation system

Microprocessor controller

Under carriage, wheels and breaks

Hydraulic system and power controlPumps, Accumulators, Actuators Electro-Selectors, BootstrapReservoirs and various types.

Environmental control systemPneumatics and oxygen system, cold air unit, water Extractors, valves.

Ejection systemEjection Seats, Release Units

Engine fuel control systemBooster pumps, main and Reheat Fuel systems, Nozzle Actuators.

SERVICES-

MANUFACTURE & OVERHAUL OF AIRCRAFTThe division has manufactured more than 700 Aircraft & overhauled morethan 1300 Aircraft in last 3 decades. Having state-of-the-art technology &facilities, the division is fully geared up to take the challenge future tasksuch as manufacture of SU-30 MK 1 & Advanced Jet Trainer.

CUSTOMER SERICES

The division has established full fledge infrastructure, facilities & system forensuring optimum level for customers satisfaction on the products &services rendered. The major area includes

Overhaul/ Repair of RotableThe Division takes up over/repair of entire range of Electrical,instrument, Mechanical & Armaments Rotables.

Supply of Spares &oth Ground support equipments and rigs Ground power unit, hydraulics trolley and power packs, dedicated testRigs, custom- build Fuel/ Hydraulics Test rigs.

Site RepairThe Division undertakes site repair of Aircraft at IAF bases by deputing site repair teams. Defect Investigation/Failure AnalysisThe aggregate which was received on premature withdrawal from the units are studied & the causes for defects /failures are investigated. Repetitive cases are taken up for in the depth study &modifications are incorporated in the unit to minimize the recurrence of such defects/failures in future.

Product TrainingThe Division has positioned Service Engineers at various IAF bases to closely liaise and to access the requirement of the customer. Based on thefeedback received from Service Engineers, the division renders adequate support for fully exploiting the products

.

PRODUCT FLOW CHART

The instrument factory is divided into-

Assembly shop Manufacturing shop

Assembly shopis divided into: -

SHOP 1 SHOP 2 SHOP 3 SHOP 4 ALH

Manufacturing shopis divided into: -

NGL Shop Smiths shop Gyro shop Press Shop

Following systems or instruments are manufactured in Instrument factory. Barometric instrument Gyroscopic instruments Electrical and Electronics equipments Fuel gauging systems Ground level navigation systems

Process of product preparation follows certain steps. When the customerplaces the order and it approved by the authorities the planning of steps forpreparations are to be layer by authorities now assembly of the material is done and stored in stored. Now these are collected as required and expertsprepare unit. Now the important step comes of testing. Testing is done underspecified conditions and assurance is done in all respect then certificate is raised of being tested. Now the last step comes of proper packing and storing. These are supplied to costumer under followed terms and conditions.

Product Flow Chart

Request of costumer

Planning of steps

Assembly of material

Manufacturing of units

Testing of unit under for conditions

Collecting and proper packing of unit

ADVANCED LIGHT HELICOPTERAdvanced Light Helicopter is a multi-role, multi-mission helicopterdesigned & developed by HAL. The design of this 5.5 ton class, twin-engine helicopter incorporates several state of the art technologies. Extensive use ofcomposites high cruise speed, long range & endurance, excellent high-altitude performance & capability to operate in hot & humid environment are the key to design features. ALH has been designed for both civil &military application in large variety of roles overland &sea.

Performance: -Maximum cruise speed at maximum load: - 250 km/hr. Maximum rate of climb: - 10 m/sec.Range with 20 min reserve: - 650 km.Endurance: - 4 hrs.Hover in ground effect: - 1500 m.Hover out of ground effect: - 1000m.

Leading Particulars: -Overall length: - 15.87 m.Overall height: - 4.91 m.Width: - 3.91 m.Empty weight: - 2500 kg.Fuel capacity: - 1100 kg.Maximum take-off weight: - 5500 kg.Maximum under slung weight: - 1500 kg.Maximum height: - 2500 HT.

ROLES: -Military Role (Unarmed): - Hellebore attack. Reconnaissance Logistic support Casualty evacuation Air observation post

Military Role (Armed): - Anti tank Close air support Anti-submarine warfare Anti surface vessel warfare

Civil Role: - Commuter/ VIP Search & rescue Disaster relief Air ambulance Offshore operation

Salient Features: - Ergonomically designed cockpit Extensive use if composites, reduced radars signature Large cabin volume Ballistic damage tolerant Greater system redundancy Provisions for weapons hard points Twin engine with fully authority digital electronic control Adequate safety margin for single engine operation Four axis automatically flying control system Crash worthy crew seats, under floor and fuel tank Hinge less main rotor & bearing less tail rotor Excellent handling qualities at low as well as high speeds Low maintenance cost & high fuel efficiency Skid version & retractable wheel version available

INTRODUCTION TO SU-MKI AIRCRAFT

1. Aircraft SU-30MKI is a multipurpose twin seated supersonic fighter designed to destroy air target in free space and against the earth background both by day and at night under visual and adverse weather conditions and to engage ground and surface targets within tactical and operational depths under heavy noise conditions as well.2. To destroy aerial targets, a provision is made for employment of allangle medium-range missiles (active, semi-active radar and infra-red guided missiles) and short-range missiles (infra-red guided missiles) capable of high target hit probability.3. To destroy ground targets, use is made of unguided bombs, guidedbombs and missiles. The aircraft is also equipped with a rapid-fire gun mount with calibre of 30mm.4. The aircraft is also intended for training, acquisition (perfection) ofskills in flying techniques, air navigation and combat employment including participation in group combat actions.Main Features

Fuselage: The fuselage of SU-30MKI aircraft is an integrated aerofoil body that provides 40% of aircrafts total lift. The fuselage isbuilt up of three sections; Nose sections, tall section and wing centresection. Fuselage Nose Section: It is an all-metal semi monologue construction. It includes nose cone, two cabins, and nose LG well and equipment compartment. For planes or canards and attached to the last frame of this section.

Wing Center Section: It is the main load carrying structure of the aircraft. It provides attachment points for landing gears, outer wings, fuselage nose section, and fuselage tail section and air intakes.

Fuselage Tall Section: It comprises of air ducts, air Intakes and two engine compartments interconnected by an intermediate compartment. Horizontal stabilizers and vertical fins are attached to the rear part of fuselage tail section.

Outer Wings: Outer wings are an integrated part of the fuselage, trapezoidal in shape and swept back by 420. The flappersare attached at the trailing edge, which operate as ailerons and flaps. The leading edge flaps are located all along outer wingspan to improve the aerodynamic characteristics.

Air intakes: The engine air intakes are under slung and providedwith ramp panels the air intakes are closed by protective screen toprevent the ingress of foreign objects.

Landing Gear: The aircraft has tricycle type landing gear operatedby first hydraulic system. Only the main wheels are provided withbrakes, and the brakes are operated by hydraulic pressure. The nose landing gear is provided with wheel steering system

Flight Controls: The aircraft longitudinal control is achieved by synchronous deflection of stabilizers, lateral control by differential deflection of stabilizers and flaperons and directional control by rudders. Fly by wire system operates all the control surfaces. Foreplane or canard is introduced for providing larger stability andManoeuvrability at higher angle of attack and subsonic speeds. Wing leading flaps also act as lift augmenting device at greater angle ofattack. The fly by wire system operates canards and leading edge flaps automatically. All control surfaces are operated by both the hydraulic systems.

Hydraulic system: The hydraulic system comprises of twoindependent systems i.e.: First or Left hydraulic system and Secondor Right hydraulic system.(a)Hydraulic oil used:AMG-10/OM-15(b)Hydraulic tank capacity:15.8liters (each system)(c)Left hydraulic system capacity:40liters(d) Right hydraulic system capacity:40liters(e)System operating pressure:280+15kgf/cm2

Fuel System: The ac carries fuel in five metallic fuel tanks, which can be refuelled in air also. On ground the ac can be refuelled in two modes i.e. basic and full: in case of emergency the fuel can be dumped in air. The capacity of fuel tanks is as follows. Tank No. 1: 3260 kg Tank No. 2: 4160 kg Tank No. 3: 1060 kg Tank No. 4: 350 kg Tank No. 5: 650 kg Total : 9480 kg

Pneumatic System: There are three independent pneumatic systems. All the system bottles are charged with nitrogen to apressure of 200-15 kgf/cm2

a) Canopy Pneumatic Control System: It ensures opening, closing and sealingoperation of canopy, jettisoning of canopy in case of emergency andpressurization of alcohol tank used for canopy anti-icing. The bottle capacity is 8 litters.

b) Emergency Extension of Landing Gears: It extends the landing gears incase the first hydraulic system fails. The bottle capacity is 9 litres.

c) Emergency Extension of Refuelling probe: It extends the air-to-airrefuelling probe in case the second hydraulic system fails. The bottle capacity is 3 litres.

Marketing StrategiesMarketing is the relation between costumer and organization. When the customer contacts the organization then it is seen that the request is of our capability or not. If not then regret order is send. Else request is judged under various points of cost, terms and conditions, time duration etc. and the decided conditions are send to the customer now if the customer agree then order is placed for further process.Firstly HAL had only defences sector as the only customer, but now it has decided to expand it capabilities to earn more and more profit. Marketing mainly includes two units of marketing. They are civil and Export. It mainly deals with the defence requirements, but besides this there are many other costumers in India and outside India.

Marketing

Civil export(ISRO, Sahara Airlines, kingfisher, (Oman, UA, England,JET airways, etc.) Romania, Zimbabwe,Srilanka etc.)

CIVIL- In civil unit it mainly deals with the costumers of India only. They are different airlines and research organizations, army, navy, coast guard, air force, etc. They may contact for repairing of parts and for requirements of parts.

EXPORT- In this unit there are mainly customers of foreign they are airways of England, Oman, UA, etc. There are very strict rules for the trade between these organizations. These foreign organization look to HAL as a faithful organization. When customer contacts HAL then there are predefined steps to be followed by the organization.

These can be described in chart as

FLOW CHART FOR MARKETING PROCESS

DIVERSIFICATION

Hindustan Aeronautics Limited (HAL) has cruised past the Rs.7,500-croremark for the first time with a sales turnover of Rs.7,783.61 crores ($1.82 billion) during the Financial Year 2006-07, The Value of Production has also gone up by 55.54% to Rs. 9,201.88 crores, while the Profit of theCompany (Profit Before Tax) soared to Rs.1,743.60 crores, which is an increase of 54.88% over the previous year's performance.

The highlights are given below: Rupees in CroresParticulars2005-062006-07Growth overPrevious YearSales5342778345.69%VOP5916920255.54%Profit beforetax1126174454.88%Profit after tax771114949.03%Gross Block1694208122.85%

SUGGESTIONS

It is matter of great prestige to be a part of well&highly organizedNavaratna organization, HINDUSTANAERONAUTICS LIMITED. After being a part of such organization one has the chance to learn a lot about a successful organization. Besides this it also imparts the opportunities to strengthen the particulars professional skills. Atmosphere of organization teaches one the characters of Focusing, Planning, Decision making, Co-ordination etc. These golden experiences help the student to sharpen his/her professional as well personal skills. After being the training student of HAL a particular department is assigned to study. This department helps in all possible ways to guide the functions, working process, units prepared of the organization. One can learn a lot if he takes the proper interest.

CONCLUSION

The joy of flying has fascinated the human race for centuries. Defence avionics major &Navratana PSU Hindustan Aeronautics Limited (HAL) is in the business of building a whole range ofaircraft helicopters and jet trainers. Besides, the company manufactures aircraft components, overhauls fighter planes and trains future pilots .its success in the design and development oflight combat aircraft Tejas and advanced light helicopter Dhruvhas won admiration. HAL is the backbone of Indias air defence and continues to occupy the strategic importance reflecting a newpace of growth.Today the faster growing sector is the aviation sector & is likely to be a boon for the entire job market. It deals with the manufacture, design & development of aircrafts. The project is based on the instruments that are used in the manufacture of the various aircrafts. A deep knowledge of these instruments is crucial in the perfect design & manufacture of the aircrafts. The project will benefit those who have interest in the instrument & will provide the reader with the deeper knowledge ofthe topic.

Reference

Magazines of HAL

Manuals of departments

http://en.wikipedia.org/wiki/Wiki

Page-40 Mo Meraj