HAL Summer Training Report

HINDUSTAN AERONAUTICS LIMITED
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S R INSTITUTE OF MANAGEMENT AND TECHNOLOGY
A
SUMMER TRAINING REPORT
OF

SUBMITTED BY:-
Mo Meraj
(B.Tech ME)
1148540052

Under the Guidance of
Mr. O P Tiwari Mr.AnuragSrivastav


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A
Summer Training Report
Of

Hindustan Aeronautics Limited
In partial fulfillment of requirements for the Degree of
Bachelor of Technology in Mechnical Engineering
SUBMITTED BY:
MO Meraj
1148540052
Under the Guidance of
Mr. O P Tiwari Mr.Anurag Srivastav

S.R INSTITUTE OF MANAGEMENT & TECHNOLOGY LUCKNOW

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ACKNOWLEDGMENT

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 Meraj
Roll No- 1148540052


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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/STRUC
TURALDETAILS.

MARKETING STRATEGIES.

DIVERSIFICATIONS..

SUGGESTIONS.....

CONCLUSIONS

REFERENCES

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HISTORY OF HAL
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 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 license production. HAL has so

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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 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 & 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, 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

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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 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


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DIVISIONS


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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) AGM(Design) AGM(Instrument) AGM(Mechanical)
DGM DGM DGM DGM

Chief Manager Chief Manager Chief Manager Chief Manager
Senior Manager Senior Manager Senior Manager Senior Manager
Manager Manager Manager Manager
Deputy Manager Deputy Manager Deputy Manager Deputy Manager
Engineer Engineer Engineer Engineer
Employee Employee Employee Employee


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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


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Assembly shopis divided into: -
1. SHOP1
2. SHOP 2
3. SHOP 3
4. SHOP 4
5. ALH

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

Following systems or instruments are manufactured in Instrument factory.
1. Barometric instrument
2. Gyroscopic instruments
3. Electrical and Electronics equipment
4. Fuel gauging systems
5. Ground level navigation systems

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


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STANDARD CLEAN ROOMS CONDITIONS
TEMPERTURE: -15 to 25oC
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 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.


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PRODUCT PROFILE OF HAL

1950s & 1960s


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1970s & 1980s


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1990s to till date


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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,
BootstrapReservoirs and various types.

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


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Ejection system
Ejection Seats, Release Units

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


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SERVICES-

MANUFACTURE & OVERHAUL OF AIRCRAFT
The 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 task such as manufacture of SU-30 MK 1 & Advanced Jet Trainer.

CUSTOMER SERICES

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
testRigs, custom- build Fuel/ Hydraulics Test rigs.


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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.

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 thefeedback received from Service Engineers, the division renders
adequate support for fully exploiting the products

.

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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


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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
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.


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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 HELICOPTER
Advanced Light Helicopter is a multi-role, multi-mission
helicopter designed & developed by HAL. The design of this 5.5 ton class,
twin-engine helicopter incorporates several state of the art technologies.
Extensive use of composites 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.

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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.


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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

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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


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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, guided bombs
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) of skills 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 is built up of three
sections; Nose sections, tall section and wing centre section.
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.


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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 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.

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Fly by wire system operates all the control surfaces. Fore plane 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 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 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


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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
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-
air refuelling probe in case the second hydraulic system fails. The bottle
capacity is 3 litres.


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MARKETING STRATEGIES
Marketing 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.


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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.


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These can be described in chart as

FLOW CHART FOR MARKETING PROCESS


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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 Crores
Particulars 2005-06 2006-07 Growth over
Previous Year
Sales 5342 7783 45.69%
VOP 5916 9202 55.54%
Profit beforetax1126 1744 54.88%
Profit after tax 7711 1494 9.03%
Gross Block 1694 2081 22.85%


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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.


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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 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
Dhruvhas won admiration. HAL is the backbone of Indias air defence 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

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

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