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)

souravtiwari14.07@gmail.com

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