Sri Lanka Air Force Base- Katunayaka

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<ul><li><p>ACKNOWLEDGEMENTS </p><p> It was a great opportunity to me for completing my industrial training in one of Sri Lankas </p><p>most important establishments such as Sri Lanka Air Force which is South Asias one and only </p><p>establishment overhauling helicopters. It was even more enthusiastic to work with a group of very </p><p>highly skilled professionals, who were very friendly from the commencement of my training session. </p><p>First of all I must thank Industrial Training and Career Guidance Unit (ITCGU) of faculty of </p><p>Engineering, University of Peradeniya and National Apprentice and Industrial Training Authority </p><p>(NAITA) for conducting the training program and allowing us to get the required industrial exposure </p><p>for achieving challenges which should overcome by engineers in the industrial environment. </p><p> Then I offer my sincere thanks to the Commanding Officer of Mechanical Transport Repair and </p><p>Overhaul Wing (MTR&amp;OW) Group Captain Eng. Senarathna who was in-charge of us during the </p><p>training session and to Squadron Leader Eng N.S. Dikkumburage, Flight Lieutenant Eng. Chamila </p><p>Mallawarachchi, Squadran Leader Eng. Chamila Kahadakoralage who were in-charge of the training </p><p>session and also to Squadron Leader Eng. G.G.I.D. Viraj who was in-charge of workshop Engineer. </p><p>I must further thank, all workers who were at Air Craft Engineering wing, General Engineering </p><p>Wing, Mechanical Transport Repair &amp; Overhaul Wing for helping me without any hostility to improve </p><p>my knowledge. Actually it was a strange experience for me at the beginning of the training period and </p><p>I could spend valuable and pleasurably 11 weeks with aid of all the personnel who has given the </p><p>support and the assistance in completing my industrial training session. </p><p>E.M.K.S. Edirisooriya </p><p>Faculty of Engineering </p><p>University of Peradeniya </p></li><li><p>iii </p><p>CONTENTS </p><p>Acknowledgements i </p><p>Contents iii </p><p>List of Figures v </p><p>List of Abbreviations vi </p><p>Chapter 1 INTRODUCTION </p><p> 1.1 Introduction to Sri Lanka Air Force 1 </p><p> 1.2 SLAFs vision &amp; mission 1 </p><p> 1.3 Rank Structure 3 </p><p> 1.4 Decorations &amp; medals 3 </p><p> 1.5 Sri Lanka Air force base, Katunayaka 4 </p><p>Chapter 2 DISASSEMBLY OF A DEFFENDER TDI ENGINE </p><p> 2.1 Disassembling process 8 </p><p> 2.2 Important points to be considered 8 </p><p>Chapter 3 ASSEMBLY OF DEFENDER TDI ENGINE </p><p> 3.1 Assembling process 10 </p><p> 3.2 Settling tappet clearance 11 </p><p> 3.3 Important points to be considered 12 </p><p>Chapter 4 DISASSEMBLY OF DEFENDER TDI GEAR BOX </p><p> 4.1 Disassembling process 14 </p><p> 4.2 Important points to be considered 15 </p><p>Chapter 5 ASSEMBLY OF DEFENDER TDI GEAR BOX </p><p> 5.1 Assembling process 16 </p><p> 5.2 Important points to be considered 17 </p><p>Chapter 6 THE TRANSFER BOX </p><p> 6.1 Function of a transfer box 18 </p></li><li><p>iv </p><p>Chapter 7 LATHE MACHINES </p><p> 7.1 Main parts of lathe machine 19 </p><p> 7.2 General operation of lathe machine 20 </p><p> 7.3 External Threads cutting operation 21 </p><p> 7.4 Important points to be consider 21 </p><p>Chapter 8 WELDING </p><p> 8.1 Metal inert gas welding (MIG) 23 </p><p> 8.2 Gas welding 23 </p><p> 8.3 Tungsten Inert gas welding (TIG) 24 </p><p>Chapter 9 NON DESTRUCTIVE TESTING </p><p> 9.1 Radiographic testing 26 </p><p> 9.2 Magnetic particle testing 26 </p><p> 9.3 Ultrasonic testing 26 </p><p>9.4 Eddy current testing 27 </p><p> 9.5 Penetrate testing 27 </p><p>Chapter 10 CONCLUSIONS 28 </p></li><li><p>v </p><p>LIST OF FIGURES </p><p>Figure 2.1 Cross section of a diesel V engine 8 </p><p>Figure 2.2 Cross section of a Pushrod and overhead cam engine 9 </p><p>Figure 3.1 Measuring by using a dial gauge 10 </p><p>Figure 3.2 Measuring gap of a piston ring 10 </p><p>Figure 3.3 A piston ring compressor(Ring Clamp) 11 </p><p>Figure 3.4 Adjusting tappet clearance 11 </p><p>Figure 3.5 Setting tappet clearance 12 </p><p>Figure 3.6 The Engine head 13 </p><p>Figure 4.1 The components of a gearbox 13 </p><p>Figure 4.2 Separation of the gearbox 14 </p><p>Figure 4.3 Dog teeth in a gearbox 14 </p><p>Figure 5.1 Components of the Gearbox 15 </p><p>Figure 5.2 Components of the hub 15 </p><p>Figure 6.1 Components of a transfer box 16 </p><p>Figure 6.2 Components of a transfer box 17 </p><p>Figure 7.1 Main Components of a Lathe Machine 17 </p><p>Figure 7.2 A Lathe Machine 19 </p><p>Figure 8.1 The welding process 20 </p><p>Figure 8.2 Welding process 21 </p><p>Figure 8.3 The diagram of the MIG welding 21 </p><p>Figure 8.4 The diagram of the Gas welding 22 </p><p>Figure 8.5 The diagram of the TIG welding 22 </p><p>Figure 9.1 NDT testing 23 </p><p>Figure 9.2 Ultrasonic testing 24 </p><p>Figure 9.3 Eddy current testing 25 </p></li><li><p>vi </p><p>LIST OF ABBREVIATIONS </p><p>AEW AIRCRAFT ENGINEERING WING </p><p>GEW GENERAL ENGINEERING WING </p><p>LROW LAND ROVER OVERHAUL WING </p><p>MTR&amp;OW MECHANICAL TRANSPORT REPAIR &amp; OVERHAUL WING </p><p>SLAF SRI LANKA AIR FORCE </p><p>TDI TURBOCHAEGED DIRECT INJECTION </p></li><li><p> 1 </p><p>Chapter 1 INTRODUCTION </p><p>1.1 INTRODUCTION TO SRI LANKA AIR FORCE </p><p> Sri Lanka Air Force has been reputed to occupy the most advanced technology and machinery </p><p>in the country out of the three military forces operating in Sri Lanka at present. It has 16 base stations </p><p>covering the entire island, and 3 training bases. There are 5 stations which carry out Flying Formation </p><p>- Katunayake, Rathmalana, Higuraggoda, Anuradhapura and Vauniya. The 12 squadrons are situated at </p><p>these 5 bases. Housing flying formations are where they carry out day to day flying activities. </p><p>SLAF is a child of Royal Air Force in United Kingdom. Before the independence Royal Air </p><p>Force was carrying operation in Sri Lanka. SLAF was established by an act of parliament in 1949, act </p><p>number 41 of 1949. The exact date of the formation of the Air Force is however, taken as 3rd</p><p> March </p><p>1951. The first commander of the Air Force, Air Commodore G. C. Blaydon and Royal Air Force was </p><p>appointed to command the Royal Ceylon Air Force. On 22nd</p><p> may 1972, when Sri Lanka was declared </p><p>a republic, the name of the Royal Ceylon Air Force was changed to the Sri Lanka Air Force. </p><p>In our training period, the commander of the Sri Lanka Air Force is Air Chief Marshal Roshan </p><p>Gunathilake who is a son of the former Air Commander Air Vice Marshal W.D.H.S.W Gunathilake. </p><p>As well as Sri Lanka Air Force is dedicating for welfare activities. The objectives of those </p><p>activities are offering support to service personnel and their families to improve their living conditions </p><p>and morale. </p><p>1.2 SLAFS VISION &amp; MISSION </p><p> 1.2.1 Vision </p><p>TO ESTABLISH AN AIR FORCE OF HIGH OPERATIONAL EFFICIENCY </p><p>TO PRESERVE THE SOVEREIGNTY </p><p>OF SRI LANKA </p></li><li><p> 2 </p><p>1.2.2 Mission </p><p>TO PROVIDE HEAVY MAINTENANCE FACILITIES FOR </p><p>THE AIRCRAFT OPERATIONAL FORMATIONS. FURTHER, THE RESOURCES </p><p>AVAILABLE MAY ALSO BE USED TO UNDERTAKE COMMERCIAL PROJECTS WITH </p><p>PRIOR </p><p>1.2.3 Vision of DAE </p><p>To achieve flight safety and aircraft serviceability to its </p><p>highest standard, through improved competency and </p><p>work perfection. </p></li><li><p> 3 </p><p>1.3 RANK STRUCTURE </p><p>1.3.1 Commissioned Officers </p><p>Air Chief </p><p>Marshal Air </p><p>Marshal Air Vice </p><p>Marshal Air </p><p>Commodore Group </p><p>Captain Wing </p><p>Commander Squadron </p><p>Leader Flight </p><p>Lieutenant Flying </p><p>Officer Pilot </p><p>Officer </p><p>1.3.2 Other Ranks </p><p>Warrant Officer Flight Sergeant Sergeant Corporal Leading Aircraftman </p><p> 1.4 DECORATIONS &amp; MEDALS </p><p>Parama Weera </p><p>Vibushanaya </p><p> Weerodhara Vibhushanaya </p><p> Weera Wickrama </p><p>Vibhushanaya </p><p> Rana Wickrama Padakkama </p><p> Rana Sura </p><p>Padakkama </p><p> Vishishta Seva Vibhushanaya </p><p> Utthama Seva </p><p>Padakkama </p><p> Videsha Seva Padakkama </p><p> Republic Of Sri </p><p>Lanka Armed </p><p>Services Medal - </p><p>1972 </p><p> Sri Lanka Air Force 25th </p><p>Anniversary medal - 1976 </p><p> Queen Elizabeth II </p><p>Coronation </p><p>Medal - 1953 </p><p> Ceylon Armed Services Long </p><p>Service Medal - 1968 </p><p> Sri Lanka Armed </p><p>Services </p><p>Long Service </p><p>Medal-1979 </p><p> President's Inauguration </p><p>Medal - 1978 </p><p> 50th Independence </p><p>Anniversary </p><p>Commemoration </p><p> Desha Putra Sammanaya </p><p> North &amp; East </p><p>Operations Medal </p><p> Purna Bhumi Padakkama </p><p> Vadamarachchi </p><p>Operation Medal </p><p> Sri Lanka Air Force 50th </p><p>Anniversay Medal </p><p> Riviresa Campaign </p><p>Service Medal </p><p> Ceylon Armed Services </p><p>Inauduration Medal -1956 </p><p> United Nations' Service </p><p>Medal (CONGO) </p><p></p></li><li><p> 4 </p><p>1.5 SRI LANKA AIR FORCE BASE, KATUNAYAKE </p><p> The Sri Lanka Air Force Base Katunayake, </p><p>the largest Air Force Base in Sri Lanka , is situated in </p><p>close proximity to the Bandaranayke International </p><p>Airport. The Base provides administrative, logistical, </p><p>general and civil engineering services to all lodger </p><p>formations located within the Base. The following </p><p>flying Squadrons are among the major lodger </p><p>formations in the base </p><p> No. 04 Helicopter Squadron </p><p> No. 05 Jet Squadron </p><p> No. 10 Fighter Ground Attack Squadron </p><p> No. 14 Squadron </p><p>In addition to the above flying formations the following formations are also located within the Base. </p><p> Supply &amp; Maintenance Depot </p><p> Electronic &amp; Communication </p><p> Command Argo Unit </p><p> Runway Maintenance Wing </p><p> Aeronautical Engineering Wing </p><p> General Engineering Wing </p><p> Aircraft Spares Depot </p><p> Air Defence Cmd &amp; Control Center </p><p> Hospital </p><p> Radar Maintenance Wing </p><p> Motor Transport Repair Operating Wing </p><p> No 26 Regiment Wing </p><p> Air Field Construction Wing </p><p> No 43 Color Wing </p><p> No 62 Intelligence Wing </p><p> Parachute Training School </p><p> Mechanical &amp; Electrical Wing </p><p> Dental Unit </p><p> SLAF Band </p><p> No 01 Air Defence Radar Squadron </p><p> Special Project Unit </p><p> Equipment Provisioning and Accounting Unit </p></li><li><p> 5 </p><p>A fully equipped gymnasium, a swimming pool and a cinema are among the many recreational and </p><p>sports facilities offered by the Base for its personnel. The housing complex located within the Base </p><p>provides accommodation to several hundred families of the AF personnel serving at the SLAF Base </p><p>Katunayake. </p></li><li><p> 6 </p><p>ORGANIZATION OF SLAF </p><p> 3 O</p><p>F 7</p><p>CO AP &amp; </p><p>SU </p><p>BASE </p><p>COMMANDERS </p><p>COS OF </p><p>SQUADRONS </p><p>CO </p><p>AEW </p><p>OCM </p><p>NO 2 (HTS) </p><p>SQUADRON </p><p>OCM </p><p>NO 1 (FTW) </p><p>SQUADRON </p><p>OCM </p><p>NO 3 (MARI) </p><p>SQUADRON </p><p>OCM </p><p>NO 14 (JET) </p><p>SQUADRON </p><p>OCM </p><p>NO 11 </p><p>(UAV) </p><p>SQUADRON </p><p>OCM </p><p>NO 7 (HELI) </p><p>SQUADRON </p><p>OCM </p><p>NO 4 (HELI) </p><p>SQUADRON </p><p>OCM </p><p>NO 9 (AHS) </p><p>SQUADRON </p><p>OCM </p><p>NO 10 (KFIR) </p><p>SQUADRON </p><p>OCM </p><p>NO 5 (JET) </p><p>SQUADRON </p><p>OCM </p><p>NO 6 (HELI) </p><p>SQUADRON </p><p>OCM </p><p>NO 8 (LTS) </p><p>SQUADRON PILOTS </p><p>COMMANDER OF SRI LANKA AIR FORCE </p><p>DAE DIRECTOR OF </p><p>AERONAUTICAL </p><p>ENGINEERING </p><p>CHIEF OF STAFF </p><p>DGE DIRECTOR OF </p><p>GENERAL </p><p>ENGINEERING </p><p>DOPPS DIRECTOR OF </p><p>AIRCRAFT </p><p>OPERATIONS </p><p>DHS DIRECTOR </p><p>OF HEALTH </p><p>SERVICES </p><p>DW DIRECTOR </p><p>OF </p><p>WELFARE </p><p>DP </p><p>DIRECTOR OF </p><p>PLANNING </p><p>DETE DIRECTOR OF </p><p>ELECTRICAL &amp; </p><p>TELECOMMUNICATION </p><p>ENGINEERING </p><p>DA DIRECTOR OF </p><p>ADMINISTRATION </p><p>DT DIRECTOR </p><p>OF </p><p>TRAINING </p><p>DCE DIRECTOR OF </p><p>CIVIL </p><p>ENGINEERING </p><p>DL DIRECTOR </p><p>OF </p><p>LOGISTICS </p><p>MINISTER OF DEFENSE </p><p>PRESIDENT OF SRI LANKA </p></li><li><p> 7 </p><p>ORGANIZATION OF AEW </p><p>SNCO I/C </p><p>CIVIL </p><p>CONTROL </p><p>SNCO I/C </p><p>DISCIPLIN</p><p>ARY </p><p>SNCO I/C </p><p>ORDERL</p><p>Y ROOM </p><p>OC </p><p>SPECIAL </p><p>PROJECT </p><p>WIN</p><p>G </p><p>WAR</p><p>RAN</p><p>COMMANDING OFFICER </p><p>OC TECH </p><p>PLANNING </p><p>&amp; </p><p>CONTROL </p><p>OC </p><p>ADMINISTRATION </p><p>OC </p><p>AR &amp; </p><p>SS </p><p>OC </p><p>PSES </p><p>OC </p><p>AVIONICS </p><p>OC </p><p>LOGIST</p><p>IC </p><p>WO I/C </p><p>SAFETY BAY </p><p>WO I/C </p><p>COMPO</p><p>NENT </p><p>BAY </p><p>WO I/C </p><p>NDT LAB </p><p>WO I/C </p><p>ROTOR </p><p>BAY </p><p>WO I/C </p><p>AR &amp; </p><p>SS </p><p>WO I/C </p><p>SPECIAL </p><p>PROJECT </p><p>WO I/C </p><p>ENGINE </p><p>BAY </p><p>WO I/C </p><p>ELECTRICAL </p><p>BAY </p><p>WO I/C </p><p>INSTRUMENT </p><p>BAY </p><p>SNCO </p><p>I/C </p><p>FORWA</p><p>RD </p><p>SNCO I/C </p><p>ORDERLY </p><p>ROOM </p><p>WING </p><p>WARRAN</p><p>T </p><p>OFFICER </p><p>WO I/C </p><p>COMPONEN</p><p>T BAY </p><p>WO I/C </p><p>ROTOR </p><p>BAY </p><p>WO I/C </p><p>AR &amp; SS </p><p>WO I/C </p><p>TECH </p><p>PLANNING </p><p>&amp; CONTROL </p><p>WO I/C </p><p>SPECIAL </p><p>PROJECT </p><p>WO I/C </p><p>ENGINE BAY </p><p>SNCO I/C </p><p>FORWAR</p><p>D SUPPLY </p><p>UNIT </p></li><li><p> 8 </p><p>Chapter 2 : DISASSEMBLY OF A DEFENDER TDI ENGINE </p><p> Figure 2.1: Cross section of a diesel V engine </p><p>2.1 Disassembling process </p><p>The procedure is initiated by removing the oil sump by removing purge nut sump. Next attempted the </p><p>drain water in the cooling system, but since the drain nut system is corroded cooling becomes difficult </p><p>and there the water in the system that was in the system without removing. Then...</p></li></ul>


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