2011

HAL Hindustan Aeronautics Limited

TRAINING REPORT
SUBMITTED BY: RISHABH GUPTA 802141 MECHANICAL ENGG.

Prepared by

Rishbah Gupta Mechanical Engg. K.I.I.T University.

CERTIFICATE

Certified that Rishabh Gupta has done a training in Mechanical factory of HAL and has presented in this report for the award of Bachelor of Technology from K.I.I.T. University, Bhubaneswar. The training report embodies the original work and studies carried out by the student himself and the content do not form the basis for the award of any degree to the candidate or to anybody else.

Date:

S.P. Singh Manager Training.

With deep sense of gratitude, first and foremost express my profound thanks to Mr. S.P. Singh (Manager Training) for giving me this opportunity to do my summer training in Mechanical department of Hindustan Aeronautics Limited, Lucknow during the summer session 2011. Being renowned company of India & abroad, it gave me the opportunity to learn the work carried out here, got a glimpse of new environment & hard work of industrial unit. I also wish to acknowledge my indebtedness to the staff of HAL without whose cooperation; this training would not have been successful.

Rishabh Gupta.

Preface
Training has misinterpreted by most of us as a platform for project performation. Industrial training in true sense has been included in curriculum to make the student well versed with the technical procedure of various industries, the basic criteria for management of various resources in a company or industry.

The educational institution sole aim by industrial training is to improve the technical knowledge and to have a hand on experienced to make them realistic in thinking, to understand the procedure for manufacturing keeping mind the minute detail which will benefit the customer like no learning is proper without implementation.

Doctors, Lawyers, hotel management student surely hold a upper hand. Its because right from the second year of their graduation the are made to face the world and their problems with a tender mind. In due course of time slowly but steadily they, develop a competitive attitude and have a definite plan and aim as they complete their graduation.

Unlike the pitiable engineers like us who are completely isolated from industry. Therefore their should be industry institutions made compulsory for every engineering institutes.

 BRIEF HISTORY/INTRODUCTION OF INDUSTRY/ORGANIZATION ORGANISATIONAL CHART SYSTEMS/PLANT LAY OUT PRODUCTS &SPECIFICATIONS/ACTIVITES/SALIENT FEATURES PRODUCT FLOW CHART/PROCEDURES BASICS OF FLIGHT BASICS OF HYDRAULIC SYSTEM MARKETING STRATEGIES DIVERSIFICATIONS SUGGESTIONS CONCLUSIONS REFERENCES

(HAL FOUNDER)
Hindustan 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 of Hindustan Aircraft Limited at Bangalore in December 1940 in association with the erstwhile princely state of Mysore and late Shri Seth Walchand Hirachand, an industrialist of extraordinary vision. Govt. of India became one of its shareholders in March 1941 and took over the management in 1942. Hindustan Aircraft Limited was merged with Aeronautics India Limited and Aircraft Manufacturing Department Kanpur to form HAL on 1-october-1964. Today HAL has got 18 production divisions & 9 research & design centers 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 license production. HAL has so far produced about 3352 aircraft (which include 11 type of indigenous design), 3583 engines & overhauled over 8141aircraft & 27267 engines. HAL has engaged & succeeded in number of R & D programs for both 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
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& Cost Guards in March 2002, in its first year of 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 with primary objective of manufacturing systems and accessories for varies aircrafts and engines. At present it is turning out over 1100 different types of accessories. The division manufactures various systems viz. Hydraulics; engine Fuel systems, Airconditioning 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, Coast Guard & Border Security Force. Transport Aircraft & Helicopters have also been 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 the aerospace

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 Accessories 3.) 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 and brakes etc.

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Organizational chart

Chairman Managing Director General Manager AGM(Fuel) DGM Chief Manager Senior Manager Manager Deputy Manager Engineer AGM(Design) DGM Chief Manager Senior Manager Manager Deputy Manager Engineer AGM(Instrument) DGM Chief Manager Senior Manager Manager Deputy Manager Engineer AGM(Mechanical) DGM Chief Manager Senior Manager Manager Deputy Manager Engineer

Employees

Employees

Employees

Employees

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SYSTEM LAYOUT
Head 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-30

INSTRUMENT FACTORY This is further divided into two shops 1. Assembly shop 2. Manufacturing shop

Assembly shop is divided into: 1. SHOP 1 2. SHOP 2 3. SHOP 3 4. SHOP 4 5. ALH

Manufacturing shop is divided into: 1. 2. 3. 4. NGL Shop Smiths shop Gyro shop Press Shop

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Following systems or instruments are manufactured in Instrument factory. 1. 2. 3. 4. 5. Barometric instrument Gyroscopic instruments Electrical and Electronics equipments Fuel gauging systems 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 CONDITIONS TEMPERTURE: - 15 to 25 oC HUMIDITY: - 45 TO 55% DUST COUNT: - Less than 100,000 for class C shop(unmonitored) Less than 100,000 for class B shop Less than 10,000 for class A shop

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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 1970,s 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.

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PRODUCT PROFILE 1950s & 1960s

BASANT

AJEET

JAGUAR *

HPT-32

MIG 21 M

HS 748

HTT-34

KIRAN Mk II

CHEETAH*

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1970s & 1980s

BASANT

AJEET

JAGUAR *

HPT-32

MIG 21 M

HS 748

HTT-34

KIRAN Mk II

CHEETAH*

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1990s to Date

MIG-27M

IJT *

HAWK - AJT *

DO 228 *

LANCER * SU-30MKI*

LCA *

ALH (DHRUV)*

* Current products

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Products of HAL Lucknow division

Instruments Sensors, Gyros Flight instruments, electrical indicators, Fuel Gauge probes, Gyros, sensors and Switches Electrical power generation and control AC/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 control Pumps, Accumulators, Actuators Electro-Selectors, Bootstrap Reservoirs and various types. Environmental control system Pneumatics and oxygen system, cold air unit, water Extractors, valves. Ejection system Ejection Seats, Release Units Engine fuel control system Booster pumps, main and Reheat Fuel systems, Nozzle Actuators.

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

The division has established full fledge infrastructure, facilities & system for ensuring optimum level for customers satisfaction on the products & services rendered. The major area includes Overhaul/ Repair of Rotable The 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 test Rigs, custom- build Fuel/ Hydraulics Test rigs. Site Repair The Division undertakes site repair of Aircraft at IAF bases by deputing site repair teams. Defect Investigation/Failure Analysis The 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.
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 Product Training The Division has positioned Service Engineers at various IAF bases to closely liaise and to access the requirement of the customer. Based on the feed back 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 shop is divided into: SHOP 1 SHOP 2 SHOP 3 SHOP 4 ALH Manufacturing shop is 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

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Process of product preparation follows certain steps. When the customer places the order and it approved by the authorities the planning of steps for preparations are to be layer by authorities now assembly of the material is done and stored in stored. Now these are collected as required and experts prepare unit. Now the important step comes of testing. Testing is done under specified 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

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Balance of aircraft
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Hydraulics: Introduction
1. Hydraulics is based on a very simple fact of nature - you cannot compress a liquid. 2. You can compress a gas (think about putting more and more air into a tire, the more you put in, the higher the pressure). 3. If you're really strong you can compress a solid mass as well. But no matter how much pressure you apply onto a liquid, it isn't possible to compress it.

4. Now if you put that liquid into a sealed system and push on
it at one end, that pressure is transmitted through the liquid to the other end of the system. The pressure is not

diminished.

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Hydraulics: Aircraft
1. Hydraulic systems controls a wide range of components by transmitting a force through a confined fluid. 2. Hydraulics can transmit high forces rapidly and accurately, they are the prime source of power in aircraft systems such as flying controls, flaps, retractable undercarriages and wheel brakes. 3. Modern aircrafts include different types of subsystems, closely interlinked to each other. 4. Hydraulic subsystem is used for actuating most of the mechanical subsystems like landing gear, flight control surfaces, weapons system etc. 5. Hydraulic system is a very essential part of the aircraft and its reliability and functionality are very essential to the flight worthiness of the whole aircraft.

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CONCEPT
1. Hydraulic systems take engine power and convert it to hydraulic power by means of a hydraulic pump. This power can be distributed throughout the airplane by means of tubing that runs through the aircraft. 2. Hydraulic power may be reconverted to mechanical power by means of an actuating cylinder, or turbine.

(i) A hydraulic pump converts mechanical power to hydraulic power

(ii) An actuating cylinder converts hydraulic power to mechanical power (iii) Landing Gear (iv) Engine power (mechanical HP)

3. If an electrical system were used instead of a hydraulic system, a generator would take the place of the pump and a motor would take the place of the actuating cylinder.

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Some Hydraulic Systems in Aircrafts

1. Primary control boosters 2. Retraction and extension of landing gear 3. Sweep back and forth of wings 4. Opening and closing doors and hatchways 5. Automatic pilot and gun turrets 6. Shock absorption systems and valve lifter systems 7. Dive, landing, speed and flap brakes 8. Pitch changing mechanism, spoilers on flaps 9. Bomb bay doors and bomb displacement gears

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Hydraulics: Principles of Operation

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Hydraulics System: Advantage

1. It is lighter in weight than alternate existing systems. 2. It is dead beat, that is, there is an absence of sloppiness in its response to demands placed on the system. 3. It is reliable; either it works or doesn't. 4. It can be easily maintained. 5. It is not a shock hazard; it is not much of a fire hazard. 6. It can develop practically unlimited force or torque. 7. Hydraulic systems can control motion without worrying about the effect of temperature.

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Hydraulics Fluids

1.

Water-based hydraulic fluid: Used in naval aircraft because it is not flammable. However, it is still corrosive. It is a water based lubricant which is chemically treated. Its commercial name is HYDROLUBE 2. Mineral-based petroleum oil: Used by NATO. It has a cherry red dye added to it. 3. Synthetic Oils: Have much appeal. They are non-flammable and work over a wide temperature range. One such synthetic oil has a purple or green color and is made from a phosphate-ester base.

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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. To destroy aerial targets, a provision is made for employment of all angle 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. To destroy ground targets, use is made of unguided bombs, guided bombs and missiles. The aircraft is also equipped with a rapid-fire gun mount with caliber of 30mm. The aircraft is also intended for training, acquisition (perfection) of skills in flying techniques, air navigation and combat employment including participation in group combat actions.

2.

3.

4.

Main Features Fuselage: The fuselage of SU-30MKI aircraft is an integrated aerofoil body that provides 40% of aircrafts total lift. The fuselage is built up of three sections; Nose sections, tall section and wing center section. Fuselage Nose Section: It is an all-metal semi monologue construction. It includes nose cone, two cabins, 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
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 Outer Wings: Outer wings are an integrated part of the fuselage, trapezoidal in shape and swept back by 42 0. The flaperons are 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 provided with ramp panels the air intakes are closed by protective screen to prevent the ingress of foreign objects. Landing Gear: The aircraft has tricycle type landing gear operated by first hydraulic system. Only the main wheels are provided with brakes, 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. Fore plane or canard is introduced for providing larger stability and Maneuverability at higher angle of attack and subsonic speeds. Wing leading flaps also act as lift augmenting device at greater angle of attack. 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 two independent systems i.e.: First or Left hydraulic system and Second or Right hydraulic system. (a) (b) (c) (d) (e) Hydraulic oil used: AMG-10/OM-15 Hydraulic tank capacity: 15.8 liters (each system) Left hydraulic system capacity: 40 liters Right hydraulic system capacity:40 liters System operating pressure: 280+15 kgf/cm2

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 Fuel System: The ac carries fuel in five metallic fuel tanks, which can be refueled in air also. On ground the ac can be refueled 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 a pressure of 200-15 kgf/cm2 a) Canopy Pneumatic Control System: It ensures opening, closing and sealing operation of canopy, jettisoning of canopy in case of emergency and pressurization of alcohol tank used for canopy anti-icing. The bottle capacity is 8 liters. b) Emergency Extension of Landing Gears: It extends the landing gears in case the first hydraulic system fails. The bottle capacity is 9 liters. c) Emergency Extension of Refueling probe: It extends the air-to-air refueling probe in case the second hydraulic system fails. The bottle capacity is 3 liters.

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Marketing is the relation between costumer and organization. When the costumer 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 defense 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 defense requirements, but besides this there are many other costumers in India and outside India.

Marketing

Civil (ISRO, Sahara Airlines, kingfisher airways, etc.)

export (Oman, UA, England, kingfisher, JET 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.
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These can be described in chart as

CUSTOMER
Approved proposal

RFQ/RFP MARKETING

ENQUIRY REVIEW
Techno/commerci al proposal

Preparation (export evolution, pricing committee, etc.)

Vetting (finance) Approval (competent authority)

FLOW CHART FOR MARKETING PROCESS

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Hindustan Aeronautics Limited (HAL) has cruised past the Rs.7,500-crore mark 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 the Company (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 Crores Particulars Sales VOP Profit tax before 2005-06 2006-07 5342 5916 1126 771 1694 7783 9202 1744 1149 2081 Growth over Previous Year 45.69% 55.54% 54.88% 49.03% 22.85%

Profit after tax Gross Block

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SUGGESTIONS

It is matter of great prestige to be a part of well& highly organized Navaratna organization, HINDUSTAN AERONAUTICS 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.

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Conclusion
The joy of flying has fascinated the human race for centuries. Defense avionics major & Navratana PSU Hindustan Aeronautics Limited (HAL) is in the business of building a whole range of aircraft helicopters and jet trainers. Besides, the company manufactures aircraft components, overhauls fighter planes and trains future pilots .its success in the design and development of light combat aircraft Tejas and advanced light helicopter Dhruv has won admiration. HAL is the backbone of Indias air defense and continues to occupy the strategic importance reflecting a new pace 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 of the topic.

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Reference
Magazines of HAL

Manuals of departments
Wikipedia Official H.A.L website Internet

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