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Transcript of Summer Training Report HAL
GURUKUL KANGRI UNIVERSITY
HARIDWAR, UTTRAKHAND-249404
(Deemed to be university fully funded by UGC/Govt. of India)
Four Weeks Training Synopsis
Submitted to Submitted by
Kumar Sourav,
Rahul Mishra
7th SEM, M.E.
LUCKNOW UNIT
Profile of Student
Name: Kumar Sourav, Rahul Mishra
Enrolment No: 100268,
Branch: Mechanical (M.E. 2010-2014)
Ph. No. 9808009611, 8005178410
Address: Suras, Tiwari tola, Campierganj, Gorakhpur, Uttar
Pradesh- 273158
Details of Organization
Name of Company: HAL, Lucknow
Training In charge: Mr. S.P. Singh
Ph. No. 0522-2350995
Address: H.A.L. Colony, Indra nagar Colony, Lucknow, Uttar
Pradesh, 226016
ACKNOWLEDGEMENT
With deep sense of gratitude, first and foremost we
express our respect and thanks to Mr. S.P. Singh, Training In
charge, HAL, Lucknow, for giving us this very opportunity to
do summer training from 25th May to 25th July at HAL,
Lucknow.
We are also thankful to all the HAL staff, which took our
classes and helped us with the valuable guidance, inspiration
and encouragement.
Last but not the least, we express our respect and thanks
to the staff of HAL, without co-operation of whose this
training would not have been successful.
The training at HAL helps us to correlate the theoretical
knowledge with the practical application in industry. During
our training at HAL, we had the privilege of going through the
products used in aircrafts used by Indian Defence Services as
well as those having Commercial use.
CONTENT
Preface
About HAL
Organizational Growth of HAL
HAL’s Mission & Values
Products of HAL
Future Products
Units of HAL
Accessories Division, Lucknow
Products of Accessories Division, Lucknow
Airplane Basics
Introduction of Sukhoi-30 MKI
Specifications of Sukhoi-30 MKI
Fuel System
Types of Fuel System
Fuel System Components of SU-30MKI
Engine of SU-30MKI
Future Plans for SU-30MKI
Training Work
Conclusion
References
PREFACE
During the four weeks of training, we were introduced to various departments of Hindustan Aeronautics Limited. During that period, we came to know about their working, their motive behind work and in which way they are contributing towards the development. Here in the Lucknow unit, we had the privilege of going through products used by our Indian Defence Services, at the time of war and day-to-day activities and in commercial applications. Here are following examples: HYDRAULIC SYSTEM AND POWER CONTROL ENVIRONMENTAL CONTROL SYSTEM ENGINE FUEL CONTROL SYSTEM INSTRUMENTS ELECTRICAL POWER GENERATION AND CONTOL SYSTEM UNDERCARRIAGE, WHEELS AND BRAKES TEST RIGS
This training, we had at HAL, helped us to understand the linkage between theoretical knowledge and practical application at industry, further helping us to develop an awareness of industrial approach to problem solving, based on broad understanding of process and mode of operation of organization.
About HAL
Hindustan Aeronautics Limited (HAL) came into existence on 1st October 1964. The Company was formed by the merger of Hindustan Aircraft Limited with Aeronautics India Limited and Aircraft Manufacturing Depot, Kanpur. The Company traces its roots to the pioneering efforts of an industrialist with extraordinary vision, the late Seth Walchand Hirachand, who set up Hindustan Aircraft Limited at Bangalore in association with the erstwhile princely State of Mysore in December 1940. The Government of India became a shareholder in March 1941 and took over the Management in 1942. Today, HAL has 19 Production Units and 9 Research and Design Centres in 7 locations in India. The Company has an impressive product track record -12 types of aircraft manufactured with in-house R & D and14 types produced under license. HAL has manufactured over 3550 aircraft, 3600 engines and overhauled over 8150 aircraft and 27300 engines. HAL has been successful in numerous R & D programs developed for both Defence and Civil Aviation sectors. HAL has made substantial progress in its current projects: Dhruv, which is Advanced Light Helicopter (ALH) Tejas - Light Combat Aircraft (LCA) Intermediate Jet Trainer (IJT) Various military and civil upgrades.
HAL has played a significant role for India's space programs by participating in the manufacture of structures for Satellite Launch Vehicles like: PSLV (Polar Satellite Launch Vehicle) GSLV (Geo-synchronous Satellite Launch Vehicle) IRS (Indian Remote Satellite) INSAT (Indian National Satellite)
Apart from these, other major diversification projects are manufacture and overhaul of Industrial Marine Gas Turbine and Airport Services. HAL has formed the following Joint Ventures (JVs): BAeHAL Software Limited Indo-Russian Aviation Limited (IRAL) Snecma HAL Aerospace Pvt Ltd SAMTEL HAL Display System Limited HALBIT Avionics Pvt Ltd HAL-Edgewood Technologies Pvt Ltd INFOTECH HAL Ltd
HAL's supplies/services are mainly to Indian Defence Services, Coast Guards and Border Security Forces. Transport Aircraft and Helicopters have also been supplied to Airlines as well as State Governments of India. The Company has also achieved a foothold in export in more than 30 countries, having demonstrated its quality and price competitiveness. HAL has been awarded with numbers of appreciation awards for serving country this long.
ORGANIZATIONAL GROWTH OF HAL
OUR VISION
To become a significant global player in the aerospace
industry.
OUR MISSION
To achieve self-reliance in design, development,
manufacture, upgrade and maintenance of aerospace
equipment diversifying into related areas and managing the
business in a climate of growing professional competence to
achieve world class performance standards for global
competitiveness and growth in exports.
OUR VALUES
CUSTOMER SATISFACTION
We are dedicated to building a relationship with our
customers where we become partners in fulfilling their
mission. We strive to understand our customers' needs and
to deliver products and services that fulfil and exceed all their
requirements.
COMMITMENT TO TOTAL QUALITY
We are committed to continuous improvement of all our
activities. We will supply products and services that conform
to highest standards of design, manufacture, reliability,
maintainability and fitness for use as desired by our
customers.
COST AND TIME CONSCIOUSNESS
We believe that our success depends on our ability to
continually reduce the cost and shorten the delivery period
of our products and services. We will achieve this by
eliminating waste in all activities and continuously improving
all processes in every area of our work.
INNOVATION & CREATIVITY
We believe in striving for improvement in every activity
involved in our business by pursuing and encouraging risk-
taking, experimentation and learning at all levels within the
company with a view to achieving excellence and
competitiveness.
TRUST & TEAM SPIRIT
We believe in achieving harmony in work life through
mutual trust, transparency, co-operation and a sense of
belonging. We will strive for building empowered teams to
work towards achieving organisational goals.
RESPECT FOR THE INDIVIDUAL
We value our people. We will treat each other with
dignity and respect and strive for individual growth.
PRODUCTS OF HAL AIRCRAFT OF RUSSIAN ORIGIN
SU 30MKI: Twin-seater, Multi-role, Long range Fighter
/ Bomber /Air Superiority Aircraft.
MiG-27 M: Single-seater Tactical Fighter / Bomber
with variable sweep wings.
MiG-21 VARIANT: Single-seater Front line
Tactical Interceptor / Fighter Aircraft.
SOME PARTS OF RUSSIAN ORIGIN AIRCRAFTS
Metallic Drop Tanks Undercarriage Ejection Seat Canopy Flexible Rubber Fuel Tanks Aerospace Fasteners
SOME AIRCRAFT OF WESTERN ORIGIN
Jaguar Hawk Rafael
HELICOPTERS
DHRUV (ADVANCED LIGHT HELICOPTER)
Production started on 2000-2001. Multi-roll, Multi-mission helicopter, fully designed by
HAL. Twin engine configuration and designed to perform both
attack and utility purpose.
DHRUV (ADVANCED UTILITY HELICOPTERS)
Seating capacity 2 Pilots + 14 seats.
Dual flight controls.
CHETAK
Multi-roll seven seater helicopter.
Highly maneuverable and suited to fly over sea, tropical
and desert condition and can be used for
communication, rescue, aerial survey, cargo and
passenger transport.
Armed with missiles and torpedoes.
CHEETAH
HAL version of Aerospatiale Lama SA 315.
Operate with wide range of weights, centers of gravity
and altitude conditions.
Powered by Artouste-lllB engine, manufactured by HAL
under license from Turbomeca of France.
SOME MORE PRODUCTS OF HAL
COMMUNICATION/NAVIGATION EQUIPMENTS
ADVANCED COMMUNICATION EQUIPMENTS
ACCESSORIES FOR AIRCRAFTS, HELOCOPTERS AND AERO
ENGINES
AERO ENGINES OF RUSSIAN ORIGIN
AERO ENGINES OF WESTERN ORIGIN
FUTURE PRODUCTS
FIFTH GENERATION FIGHTER AIRCRAFT
INTERMEDIATE JET TRAINER
MULTI-ROLE TRANSPORT AIRCRAFT
HEAVY-LIFT HELICOPTER
HINDUSTAN TURBO TRAINER-40
INDIAN MULTI-ROLE HELICOPTER
UNITS OF HAL
19 Production Units & 9 R&D in 7 Locations
across India
Banglore Division
Kanpur Division
Koraput Division
Hydrabad Division
Nasik Division
Lucknow Division
Korwa Division
ACCESSORIES DIVISION, LUCKNOW
The Division was established in 1970 with the primary
objective of manufacturing systems and accessories for
various aircraft, helicopters and engines with a view to
attain self-sufficiency in this field in the country. The
Division started with the manufacture of hydro-mechanical
accessories and instruments under license for Marut and
Kiran aircraft. This was followed by license manufacture of
accessories for MiG-21 aircraft, Cheetah/Chetak
helicopters, Dornier and other defense applications.
Additionally repair and overhaul of Lucknow manufactured
accessories as well as those fitted on directly purchased
aircraft, such as Mirage and Sea Harrier was undertaken.
At present, it is manufacturing, repairing and overhauling
more than 800 different types of systems and accessories
under license. The range of items cover unit for hydraulics,
engine fuel system, environment control system,
pressurization system, gyroscopic instruments, barometric
instruments, electrical system items, under carriage, and
electronic items. The number of licensors exceeds twenty.
From inception, the Division has laid emphasis on
developing indigenous capability through design and
development of various systems and accessories. This
capability has culminated in indigenous design and
development of a variety of systems and accessories for
the Light Combat Aircraft (LCA), Advanced Light Helicopter
(all versions i.e. Army, Air force, Navy & Civil) and
Intermediate Jet Trainer (IJT-36). The Division has also
developed and has made successful strides into the area of
Microprocessor based control systems. Design and
Development capabilities include Environmental Control
Systems & Pneumatics, Fuel Management, Engine Fuel
Control & aircraft fuel systems, Microprocessor based
Controllers, Hydraulic System & Power Controls, Wheels
and Brakes, Cockpit instruments and sensors, Gyroscopes,
Electrical Power Control Protection, Navigation and
Display, Land Navigation, Ground support equipment,
Dedicated Test rigs, and Computerized test equipment.
The Division has diversified in other defence applications
like tanks and armoured vehicles for Army, and
took commercial applications of Hydraulic items,
Gyroscopic Equipment, Special Purpose Test Equipment &
Ground Support Equipment. The Division has also made
steady progress in the area of Exports. The range of
products and services available for exports include:
Rotables and spares of Jaguar International and Cheetah (Lama), Chetak (Alouette) Helicopters
Ground Support Equipment for MiG 23, 27, 29 Mirage-2000, Jaguar, LCA, Su-30, Sea-Harrier, Dornier DO-228, Avro HS-748, Cheetah, Chetak, MI-17, and ALH.
Repair and Overhaul of aircraft accessories of MiG series, Jaguar International, Cheetah (Lama), Chetak (Alouette) and Dornier.
The Division today has a prime name in the aviation world and a number of international companies are interested to join hands with it for future projects. Accessory division, Luknow is divided into three main factories namely: Mechanical Factory Instrument Factory Fuel Factory
PRODUCTS OF ACCESSORIES DIVISION, LUCKNOW
Undercarriage systems Wheels and Brake systems Hydraulic Systems Aircraft and Engine Fuel Systems Panel Instruments (Barometric and gyroscopic) Electric Power Generation and Control systems Environmental control systems. Flight Control Actuators Ground Support Equipment and test Rigs
AIRPLANE BASICS
This page shows the parts of an airplane and their functions. Airplanes are transportation devices which are designed to move people and cargo from one place to another. Airplanes come in many different shapes and sizes
depending on the mission of the aircraft. The airplane shown
on this slide is a turbine-powered airliner which has been
chosen as a representative aircraft. For any airplane to fly,
you must lift the weight of the airplane itself, the fuel, the
passengers, and the cargo. The wings generate most of the
lift to hold the plane in the air. To generate lift, the airplane
must be pushed through the air. The jet engines, which are
located beneath the wings, provide the thrust to push the
airplane forward through the air. The air resists the motion in
the form of aerodynamic drag. Some airplanes use propellers
for the propulsion system instead of jets.
To control and manoeuvre the aircraft, smaller wings are
located at the tail of the plane. The tail usually has a fixed
horizontal piece (called the horizontal stabilizer) and a fixed
vertical piece (called the vertical stabilizer). The
stabilizers' job is to provide stability for the aircraft, to keep it
flying straight. The vertical stabilizer keeps the nose of the
plane from swinging from side to side, while the horizontal
stabilizer prevents an up-and-down motion of the nose. (On
the Wright brother's first aircraft, the horizontal stabilizer
was placed in front of the wings. Such a configuration is
called a canard after the French word for "duck").
At the rear of the wings and stabilizers are small moving
sections that are attached to the fixed sections by hinges. In
the figure, these moving sections are coloured brown.
Changing the rear portion of a wing will change the amount
of force that the wing produces. The ability to change forces
gives us a means of controlling and manoeuvring the
airplane. The hinged part of the vertical stabilizer is called the
rudder; it is used to deflect the tail to the left and right as
viewed from the front of the fuselage. The hinged part of the
horizontal stabilizer is called the elevator; it is used to deflect
the tail up and down. The outboard hinged part of the wing is
called the aileron; it is used to roll the wings from side to side. Most
airliners can also be rolled from side to side by using the
spoilers. Spoilers are small plates that are used to disrupt the
flow over the wing and to change the amount of force by
decreasing the lift when the spoiler is deployed.
The wings have additional hinged, rear sections near the
body that are called flaps. Flaps are deployed downward on
take-off and landing to increase the amount of force
produced by the wing. On some aircraft, the front part of the
wing will also deflect. Slats are used at take-off and landing
to produce additional force. The spoilers are also used during
landing to slow the plane down and to counteract the flaps
when the aircraft is on the ground. The next time you fly on
an airplane, notice how the wing shape changes during take-
off and landing.
The fuselage or body of the airplane holds all the
pieces together. The pilots sit in the cockpit at the front of
the fuselage. Passengers and cargo are carried in the rear of
the fuselage. Some aircraft carry fuel in the fuselage; others
carry the fuel in the wings.
As mentioned above, the aircraft configuration in the
figure was chosen only as an example. Individual aircraft may
be configured quite differently from this airliner. The Wright
Brothers 1903 Flyer had pusher propellers and the elevators
at the front of the aircraft. Fighter aircraft often have the jet
engines buried inside the fuselage instead of in pods hung
beneath the wings. Many fighter aircraft also combine the
horizontal stabilizer and elevator into a single stipulator
surface. There are many possible aircraft configurations, but
any configuration must provide for the four forces needed for
flight.
INTRODUCTION OF SUKHOI-30 MKI
The Sukhoi 30MKI is an air superiority fighter developed by Russia's Sukhoi and assembled under licence by India's Hindustan Aeronautics Limited (HAL) for the Indian Air Force (IAF). The Sukhoi Su-30 is a twin-seater, multi-role, long range heavy, all-weather, long-range fighter.
Development of the SU-30 started after India signed a deal with Russia in 2000 to manufacture 140 Su-30 fighter jets. The first Russian-made Su-30MKI variant was accepted into the Indian Air Force in 2002, while the first indigenously assembled Su-30MKI entered service with the IAF in 2004. In 2007, the IAF ordered 40 additional MKIs. The IAF had 157 Su-30MKIs in service as of January 2013, it plans to have a fleet of 272. The Su-30MKI is expected to form the backbone of the Indian Air Force's fighter fleet to 2020 and beyond.
The aircraft is tailor-made for Indian specifications and integrates Indian systems and avionics as well as French and Israeli subsystems. It has abilities similar to the Sukhoi Su-35 with which it shares many features and components.
DESIGN OF SU-30MKI
The IAF currently operates four squadrons of Su-30MKI
aircraft. The Su-30MKI airframes are usually painted in a sky
blue pattern, sometimes with the serial number marked
under the cockpit.
The Su-30MKI is a two seat aircraft that can be flown from
either seat. This allows tasks to be shared between the crew,
with one crew member flying and the other fighting in a
combat situation. Having two pilots also means that the Su-
30MKI can stay in the air longer by enabling the pilots to take
turns flying and resting, so the aircraft can take full
advantage of the in-flight refueling. A selection of special in-
flight meals has been designed for the pilots.
The fuel system provides a range of 300 kilometres or a
2.75 hour long combat mission. In-flight refueling is made
possible by a retractable probe, in order to increase the flight
time up to ten hours for a range of 8000 kilometres. Mk 32.B
buddy-buddy refueling pods and Cobham 754 buddy
refueling pods can also be used.
The Su-30MKI has an FBW which has quadruple
redundancy. The pilot uses a standard control stick, but there
is a switch that can be used to switch on automatic
computation for the use of swivelling nozzles and
aerodynamic surfaces during difficult manoeuvres.
The Su-30MKI is a twin-finned plan that has an airframe
made of titanium and of high strength aluminium alloys. The
airframe contains a relatively high proportion of composites.
The configuration of the Su-30MKI is an unstable longitudinal
tri-plane. A streamlined profile is maintained between the
engine nacelles and tail beams by the use of trouser fairings
to fit the nacelles. The fuel tank, brake parachute container
and equipment container is fitted into the section of the
central beam between the engine nacelles. The avionics bay,
cockpit and radar compartments are fitted into the semi-
monologue fuselage head. The Su-30MKI has a wing that has
greater relative thickness. This enables more fuel to be
carried. The wing has high lift devices with deflecting leading
edges. The wing curvature can be changed using remote
controls for subsonic flights.
The Su-30MKI has two Al 31FP Turbofan engines, each of
which has 29400 pounds of full afterburner thrust. These
engines have thrust vectoring nozzles that can deflect 32
degrees horizontally and 15 degrees vertically, which can
produce a corkscrew effect that enhances manoeuvrability.
The engines have a MTBO of about 1000 hours. The TV
nozzles have MTBO of about 250 hours.
A digital FBW ensures excellent control and stability. The
canard increasing the lifting effectiveness and it is particularly
important for control at high angles of attack. The Su-30MKI
has no limits on AoA. The aerodynamic configuration of the
Su-30MKI combined with thrust vectoring gives the aircraft
superb manoeuvrability.
In the cockpit, the crew has ejection seats (zero-zero KD-
36DM) that are inclined to 30 degrees, and have modified
communication/oxygen interface blocks. The seat to the rear
is raised up to provide improved visibility. There are
containers for supplies of water and food in the cockpit, as
well as a system for waste disposal and the provision of
larger amounts of oxygen than in older aircrafts.
An A-737 GPS compatible satellite navigation system with
an integrated SAGEM Sigma-95 GPS and an inertial ring laser
gyroscope navigation system are used to enable navigation in
all conditions of weather and in both daytime and night time.
The Su-30MKI has N011M Phased Array radar, which is
multimode dual frequency radar that uses non cooperative
targeting methods. This radar system is designed to detect
fighters at ranges of between 150 and 160 kilometres and it
is capable of engaging eight targets and tracking 20. In the air
to ground mode, the system can detect large targets at 400
kilometres and small ground targets of about the size of a
tank at 40 to 50 kilometres. The NIIP N011M Bars or Panther
radar’s display processors, radar computer, and mission
computer were all developed in India as part of Project
Vetrivale. The aircraft’s radar can also be used as a command
post to coordinate with other aircraft.
The SU-30MKI uses an opto-electronic system for
targeting and surveillance. This system includes an IR
direction finder, a laser rangefinder and a helmet mounted
sight system. Communications equipment includes HF and
VHF radio sets, an antenna feeder assembly and a digital,
secure telecommunications system. There is an automatic
and noise proof system for target data exchange that can be
used to coordinate multiple aircraft.
The locator system can be used in both day time and
night time, together with the sighting system mounted on
the helmet. The Rafael Listening pod is used for Laser Guided
Munitions and there is an APK-9 data link pod for the Kh-
59ME. The Su-30MKI uses the OLS-30, which is an improved
version of the OLS-27 used in the Su-27. The OLS-30 provides
improved software and service life, a micro-cryogenic screen
and a receiver that is vibration proof. It has a range of 40
kilometres head on and 90 kilometres in pursuit.
The combat load can be mounted in 12 different stations.
More than 70 different types of weapons, both guided and
unguided, can be used with the SU-30MKI. This enables the
aircraft to be used in diverse types of missions. The
maximum combat load is 8000kg. The IAF can use all of the
compatible Russian AGMs and AAMs, and they also have
access to the RVV-AE, which is not being used by the Russian
Air Force. The Su-30MKI has an inbuilt single barrel 30mm
GSh-301 gun (150 rounds). The Astra BVRAAM and AAM KS-
172 are to be integrated into the aircraft. The self-defense
system of the Su-30MKI includes the Tarang Mk II Radar
Warning Receiver, as well as a number of flares/chaff
dispensers and active jammers.
SPECIFICATIONS OF SUKHOI-30 MKI
GENERAL CHARACTERISTICS Crew: 2 Length: 21.935 m (72.97ft) Wingspan: 14.7m (48.2ft) Height: 6.36 m (20.85ft) Wing area: 62.0 m2 (667ft2) Empty weight: 18,400 kg (40,565lb) Loaded weight: 24,900 kg (54,895lb) Max. take-off weight: 38,800 kg (85,600lb) Power plant: 2 * AL-31FP turbofans with thrust
vectoring, 123 KN with afterburner.
PERFORMANCE Max. Speed: Mach 2.35(2,500 km/h) at 11,000m Range: 5,000 km (2,700 nmi) with internal fuel tank Endurance: 3.75 hrs (up to 10 hrs within flight refuelling) Service ceiling: 17,300 m (56,800ft) Rate of climb: >300 m/s (45,275ft/min) Wing loading: 401 kg/m2 (82.3lb/ft2) Thrust/Weight: 1.1
FUEL SYSTEMS
An aircraft's fuel system has a more profound effect on
aircraft performance than any other airframe system.
Without fuel, the mission inevitably comes to an abrupt stop
and, unless the flight crew is very, very lucky, the ensuing
forced landing will cause severe or catastrophic aircraft
damage.
The purpose of an aircraft fuel system is to store and
deliver the proper amount of clean fuel at the correct
pressure to the engine. Fuel systems differ greatly due to
different performance of the aircraft in which they are
installed.
Fuel systems should provide positive and reliable fuel flow
through all phases of flight including:
Changes in altitude
Violent maneuvers
Sudden acceleration and deceleration
Fuel systems should also continuously monitor system
operation such as:
Fuel pressure
Fuel flow
Warning signals
Tank quantity
TYPES OF FUEL SYSTEM
GRAVITY FEED SYSTEM
PRESSURE FEED SYSTEM
GRAVITY FEED SYSTEM
Gravity-Feed Systems use only the force of gravity to
push fuel to the engine fuel-control mechanism.
The bottom of the fuel tank must be high enough to
provide adequate pressure to the fuel-control
component.
This type of system is often used in high-wing light
aircraft.
PRESSURE FEED SYSTEM
Pressure-Feed Systems require the use of a fuel pump to
provide fuel-pressure to the engine’s fuel-control
component.
There are two main reasons these systems are
necessary:
The fuel tanks are too low to provide enough pressure
from gravity.
The fuel tanks are a great distance from the engine.
Also, most large aircraft with higher powered engines
require a pressure system regardless of the fuel tank
location because of the large volume of fuel used by the
engines.
FUEL SYSTEM COMPONENTS OF SU-30MKI
FUEL TANK
CENTRIFUGAL PUMP
MAIN FUEL PUMP AND REGULATOR
AFTERBURNER FUEL PUMP
PLUNGER FUEL PUMP
FUEL METERING DEVICE
NOZZLE & AFTERBURNER REGULATOR
MAIN FUEL DISTRIBUTER
AFTERBURNER FUEL DISTRIBUTER
CONTROL UNIT
FUEL FLOW AND METERING SYSTEM
FUEL QUANTITY TRANSMITTERS
FUEL FLOW TRANSMITTERS
FUEL QUANTITY UNIT
FUELING CONTROL PANNEL
ELECTRONICS TRANSDUCER UNIT
SEMICONDUCTOR RELAY CONTROL UNIT
VALVES
FILTERS & STRAINERS
FUEL TANK
Number of fuel tanks: 6
Name of fuel tanks: 1, 2, 3RT, 3LT, 4, 5
Fuel Capacity: 1200 kg
Special detail: Tank no. 2 is the main tank & also known
as service tank having fuel capacity of 600 kg
CENTRIFUGAL PUMP
Centrifugal pump boost fuel pressure from aircraft tank to
the range if 5 to 8 Kgf/cm2 and supplies to the inlet of high
pressure fuel pump (Main Fuel Pump, Afterburner Fuel
Pump, Plunger Pump).
Basic Parameters:
Pump Drive Engine Gear Box Rotation of Shaft 8,000 RPM
Max. Fuel Flow 81,000ltrs/hrs Temperature of Fuel at Inlet -60 to 100 degrees
MAIN FUEL PUMP & REGULTOR
It is gear type pump & regulator and, supplies metered
fuel to main combustion chamber during starting
acceleration and deceleration through Main Fuel Distributer
as per control provided by Digital Engine Control Unit.
Basic Parameters:
Pump Drive Engine Gear Box
Rotation of Shaft 61,000 RPM Inlet Fuel Pressure 4 to 12 Kgf/cm2
Outlet Fuel Pressure 90 Kgf/cm2 max. Fuel Flow 10,000 Kg/ltr
AFTERBURNER FUEL PUMP
It supplies fuel to the Nozzle & Afterburner Regulator, in
reheat mode only, as command pressure received from Main
Fuel Pump & Regulator. During normal operation mode of
engine, inlet valve of Centrifugal type pump remains shut &
cooling flow only is circulated through Afterburner System.
Basic Parameters:
Pump Drive Engine Gear Box Rotation of Shaft 26,900 RPM Inlet Fuel Pressure 4.4 to 11 Kgf/cm2
Outlet Fuel Pressure 70 Kgf/cm2 Fuel Flow 36,000 Kg/hr
PLUNGER FUEL PUMP
It is a part of Jet Nozzle Controlling System to supply high
pressure fuel for operation to Jet Nozzle Throat Area and to
control the Jet Nozzle of Thrust Vector Control Unit (TVC).
Basic Parameters:
Pump Drive Engine Gear Box Rotation of Shaft 4,100 RPM Fuel Pressure 90 to 210 Kgf/cm2 Fuel Flow 18 to 80 ltrs/min
FUEL METERING DEVICE
It is meant for injection of additional fuel in limited
quantity for a short period as per the electrical signal
provided by the aggregate in conformity with the mode of
operation of unit in starting Jet Nozzles. On receiving of EI
signal by the aggregate, injection of metered fuel is
performed & injection stops on removal of EI signal.
Time between receiving of EI signal for injection and
appearance of pressure in outlet pipe union is max. 0.1
second.
Fuel injection is not permitted in absence of EI signal.
NOZZLE AND AFTERBURNER REGULATOR
It supplies regulated fuel to 16 cylinders for operations of
Jet Nozzle Throat Area & for controlling the Jet Nozzle of TVC.
It also supplies metered fuel to 5 manifolds of Afterburner
through Afterburner Fuel Distributer.
Basic Parameters:
Inlet Fuel Pressure(Nozzle) 220 Kgf/cm2
Inlet Fuel Pressure(Regulator) 100 Kgf/cm2
Outlet Fuel Pressure 62 Kgf/cm2 Fuel Flow 36,000 Kg/hr
MAIN FUEL DISTRIBUTER
It distributes metered fuel from Main Fuel Pump &
Regulator between Primary & Main Manifold along the
contour of main combustion chamber.
Basic Parameters:
Fuel Pressure at Inlet 90 Kgf/cm2 max. Drain Pressure 0.6 to 3.5 Kgf/cm2 Fuel Flow Primary Manifold 750 Kg/hr Fuel Flow Main Manifold 9,000 Kg/hr
AFTERBURNER FUEL DISTRIBUTER
It distributes metered fuel from Nozzle & Afterburner
Regulator between five manifolds of Afterburner and ensures
primary filling and dumping of manifold fuel. It works
together with Nozzle & Afterburner Regulator, Main Fuel
Pump & Regulator and Afterburner Fuel Pump.
Basic Parameters:
Fuel Pressure at Inlet 62 Kgf/cm2
Drain Pressure 2 Kgf/cm2 max. Fuel Flow Starting Manifold 3,600 Kg/hr Fuel Flow 1st & 4th Manifold 16,200 Kg/hr Fuel Flow 3rd & 5th Manifold 16,200 Kg/hr
CONTROL UNIT
It provides command pressure to Plunger Pump based on
fuel supply received from Main Fuel Pump & Regulator and
electrical signal received from Digital Engine Control Unit.
Basic Parameters:
Fuel Pressure at Inlet 20 to 90 Kgf/cm2 Command Pressure 10 to 45 Kgf/cm2
Drain Pressure 0.6 to 3.5 Kgf/cm2
FUEL CONTROL & METERING SYSTEM
This system measures fuel quantity available in aircraft.
This system performs following major function:
Fuel flow metering: - This part computes total quantity
of fuel available in aircraft & transmits to various
airborne systems for display & recording.
Fuel quantity gauging: - This part exclusively computes
quantity of fuel available in service tank & transmits to
various airborne systems for display & warning.
Automatic control: - This part manages sequence of fuel
flow to/from various tanks during refueling as well as
during consumption.
FUEL QUANTITY TRANSMITTERS
These sensors are used for computing fuel quantity in
service tank. Capacitance of the probes changes based on the
variation in fuel level in tank. Resultant capacitance of
following probes acts as an input for computing fuel in
service tank.
FUEL FLOW TRANSMITTERS
These are impeller types of sensors which produces signal
proportional to the rate of flow of fuel through it. Fuel
consumed by aircraft is computed based on the signals
provided by these sensors.
FUEL QUANTITY UNIT
This instrument computes quantity of fuel in service tank
based on signals from sensors which are fuel probes. It
delivers computed information to following instruments:
Digital light indicator
Refueling Control Panel
Stand by Equipment
Complex Information Signaling System
It gives warning signal to pilot for residual fuel of 150 kg in
main tank.
FUELING CONTROL PANNEL
This instrument is a display device & is used on ground
during refueling. It performs following functions:
To display total fuel quantity
To display fuel quantity of service tank
To display actual fuel density
ELECTRONICS TRANSDUCER UNIT
This unit is main processing part of automatic control
portion of Fuel Flow & Metering System. It manages fuel flow
based on signals from sensors, magnetic operated level
switches fitted in various tanks. It also senses total residual
fuel quantity & transmits the warning signal to pilot.
SEMICONDUCTOR RELAY CONTROL UNIT
This is a part of automatic control portion of Fuel Flow &
Metering System. This instrument works as an amplifier & a
switching device for the signals required for opening &
closing of valve of various tanks of aircraft.
VALVES
Fuel selector valves are used in aircraft fuel systems to:
Shut off fuel flow
Cross-feed
Transfer fuel
Selector valves may be operated manually or electrically
depending on the installation.
FILTERS & STRAINERS
Fuel is usually strained at three points in the system:
Through a finger or bootstrap strainer in the bottom of
the fuel tank
Through a master strainer which is usually located at the
lowest point in the system
Through a third strainer near the fuel control unit
ENGINE OF SU-30MKI
AL-31FP is a high temperature turbojet by-pass engine of
modular design. A specific feature of AL-31FP is an axi-
symmetric vectoring nozzle with a thrust vector angle of ±15°
in the vertical plane providing super manoeuvrability of the
aircraft. The vectoring nozzle control is integrated with the
engine control system. AL-31FP engines ensure stable
operation in all available evolutions of the aircraft in super
manoeuvrability modes. AL-31FP engines power advanced
multi-purpose Su-30 MKI fighters of the 4+ generation.
GENERAL CHARACTERISTICS
Type: Two-shaft afterburning turbofan
Compressor: 4 fan and 9 compressor stages
Turbine: 2 single-staged turbines
Length: 4,990 mm (196in)
Diameter: 905 mm (35.6in) inlet, 1,280 mm (50in) max.
external
Dry Weight: 1,570 Kg (3,500lb)
FUTURE PLANS
The Su-30MKI fighters, deployed by the Indian Air Force,
will be upgraded with certain fifth generation aircraft
characteristics to convert it into a Super Sukhoi. Bangalore-
based Hindustan Aeronautics Limited (HAL) holds a
production certificate for manufacturing the fighters and will
be in-charge of upgrading the SU-30MKIs to 5G Super Sukhoi
jets. Su-30MKI jets are a part of two major modernisation
programmes, one of which aims to adapt the Su-30MKI to
BrahMos supersonic missiles, while the other seeks ways to
achieve a dramatic improvement in the fighter’s
performance.
India will see its fighters modernised within the
framework of the so-called Super programme, which involves
introduction of an upgraded pilot cockpit, new radar and
several structural elements enhancing the jet’s stealth
features that make it less visible to the enemy. The upgrade
will cover all aircraft employed by IAF, increasing the Su-
30MKI’s weapons load and list.
The modernised Su-30MKI is reported to be able to carry
under its body one BrahMos missile, which is expected to
weigh less than its land-based and naval counterparts.
According to reports, the IAF plans to upgrade 44 Su-30MKI
fighters to equip them with BrahMos missiles.
TRAINING WORK
During this four week summer training program at HAL,
Lucknow, we were introduced to different departments of
HAL and we come to know their working, HAL relation with
IAF, different projects undergoing at HAL. We visited three
different factories at HAL, Lucknow. Those were:
Mechanical factory
Instrument factory
Fuel factory
We also visited the Design Section (ASERDC) and Central
Laboratory at Accessories Division, Lucknow.
During our visit to different factories at HAL, Lucknow, we
found that the major project undergoing here was related to
Fuel System of Su-30MKI, and this is what our training report
is concentrated at.
We are very much thankful to Mr Tariqh Khan, who
guided us throughout our training period and helped us to
come up with this report.
CONCLUSION
With continuous growth and development in avionics
technology worldwide, HAL has spread its wings across the
length and breadth of India and has made its presence felt in
nearly 30 countries in the world. We are proud of its
heritage, continuous growth and prosperity.
HAL has always proved itself in the field known for its
complex technology with zero tolerance for slightest of
quality aberration.
HAL is in the business of building a whole range of trainer,
transport and combat aircrafts and helicopters, aero engines,
communication and aerospace equipment. HAL is backbone
of IAF and continues to occupy the strategic importance
reflecting a new pace of growth.
Accessories Division, Lucknow, being very important
division of HAL, deals with manufacturing, repair and over
haul of accessories used in aircrafts and helicopters.
Accessories of Su-30MKI are latest program being held at
Accessories Division, Lucknow and this report is all about Fuel
System of Su-30MKI.
REFERENCES
http://hal-india.com/
https://en.wikipedia.org/wiki/Sukhoi_Su-30MKI
http://defenceforumindia.com/forum/indian-air-
force/48162-super-sukhoi-30-mki.html