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VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana Sangama, Belagavi-590018, Karnataka, India

‘REPORT ON INTERNSHIP TRAINING’


AT

HINDUSTAN AERONAUTICS LIMITED


(HELICOPTER MRO DIVISION, BENGALURU)
Submitted in partial fulfilment of requirement for the award of the degree of
Bachelor of Engineering In Mechanical Engineering
Submitted by
ABHISHEK.K.M 1SG17ME400
V.M.RAKESH 1SG17ME432
VENU A.V. 1SG17ME433
YASHWANTH.R 1SG17ME434

SAPTHAGIRI COLLEGE OF ENGINEERING


Department of Mechanical Engineering,
#14/5, Chikkasandra,Hesaraghatta Main Road, Bangalore-560057
DECLARATION

I hereby declare that this report entitled “ Internship Training At Hindustan


Aeronautics Limited (MRO Division Bangalore)” submitted by me in the partial
fulfilment for the degree of Bachelor of Engineering in the Department of
Mechanical Engineering , Visvesvaraya Technological University, is an
outcome of my own efforts and is an original one.

Date: 05-02-2019
Place: Bangalore

6TH Semester
Department of Mechanical Engineering
Sapthagiri College of Engineering
ACKNOWLEDGEMENT

It is indeed a great pleasure for me to present this internship training report on


Helicopter MRO Division carried out at HAL Bangalore, as a part of
curriculum of Bachelor of Engineering (Mechanical Engineering) degree.

I take this golden opportunity to thank all my mentors at HAL who with their
support and venerated guidance made this training a real success.
I express my sincere thanks to officers of HAL who in spite of their busy
schedules have lent their precious time for helping out me to understand various
systems used in HAL.

My heartfelt gratitude to Mr. K K BASAVARAJU Deputy manager


MRO,Final Assy, Mr. HARISH and Mr. MUTHURAMAN of transmission
department, and most importantly Mr. BHEEMANNA KUBAKADDI and
SHANMUGAM who helped me in completing my internship training.
INTRODUCTION ABOUT HAL
Hindustan Aeronautics Limited (HAL) is an Indian state-owned aerospace and defence
company headquartered in Bangalore, India. It is governed under the management of the
Indian Ministry of Defence.

The government-owned corporation is primarily involved in the operations of the aerospace


and is currently involved in the design, fabrication and assembly of aircraft, jet engines,
helicopters and their spare parts. It has several facilities spread across India including Nasik,
Korwa, Kanpur, Koraput, Lucknow, Bangalore, Hyderabad and Kasaragod. HAL HF-24
Marut fighter-bomber was the first fighter aircraft made in India.

HISTORY

HAL was established as Hindustan Aircraft Limited in Bangalore on the 23 December


1940 by Walchand Hirachand who became Chairman of the company. The companies office
was opened at a bungalow called "Eventide" on Domlur Road.

The organisation and equipment for the factory at Bangalore was set up by William D.
Pawley of the Intercontinental Aircraft Corporation of New York, who had already
established Central Aircraft Manufacturing Company (CAMCO) in partnership with Chinese
Nationalist government. Pawley obtained a large number of machine-tools and equipment
from the United States.

The Indian Government bought a one-third stake in the company and by April 1941 by
investing 25 lakhs as it believed this to be a strategic imperative. The decision by the
government was primarily motivated to boost British military hardware supplies in Asia to
counter the increasing threat posed by Imperial Japan during Second World War. The
Kingdom of Mysore supplied two directors, Air Marshal John Higgins was resident director.
The first aircraft built was a Harlow PC-5 On 2 April 1942, the government announced that
the company had been nationalised when it had bought out the stakes of Seth Walchand
Hirachand and other promoters so that it could act freely. The Mysore Kingdom refused to
sell its stake in the company but yielded the management control over to the Indian
Government.

In 1943 the Bangalore factory was handed over to the United States Army Air Forces but still
using Hindustan Aircraft management. The factory expanded rapidly and became the centre
for major overhaul and repair of American aircraft and was known as the 84th Air Depot. The
first aircraft to be overhauled was a Consolidated PBY Catalina followed by every type of
aircraft operated in India and Burma. When returned to Indian control two years later the
factory had become one of the largest overhaul and repair organisations in the East. In the
post war reorganisation the company built railway carriages as an interim activity.
After India gained independence in 1947, the management of the company was passed over
to the Government of India.

Hindustan Aeronautics Limited (HAL) was formed on 1 October 1964 when Hindustan
Aircraft Limited joined the consortium formed in June by the IAF Aircraft Manufacturing
Depot, Kanpur (at the time manufacturing HS748 under licence) and the group recently set
up to manufacture MiG-21 under licence, with its new factories planned in Koraput, Nasik
and Hyderabad. Though HAL was not used actively for developing newer models of fighter
jets, except for the HF-24 Marut, the company has played a crucial role in modernisation of
the Indian Air Force. In 1957 company started manufacturing Bristol Siddeley Orpheus jet
engines under licence at new factory located in Bangalore.

During the 1980s, HAL's operations saw a rapid increase which resulted in the development
of new indigenous aircraft such as the HAL Tejas and HAL Dhruv. HAL also developed an
advanced version of the Mikoyan-Gurevich MiG-21, known as MiG-21 Bison, which
increased its life-span by more than 20 years. HAL has also obtained several multimillion-
dollar contracts from leading international aerospace firms such as Airbus, Boeing and
Honeywell to manufacture aircraft spare parts and engines.

By 2012, HAL was reportedly bogged down in the details of production and has been
slipping on its schedules. On 1 April 2015, HAL reconstituted its Board with Mr. TS Raju as
CMD, Mr. S Subrahmanyan as Director (Operations), Mr. VM Chamola as Director (HR),
CA Ramana Rao as Director (Finance) and Mr. D K Venkatesh as Director (Engineering &
R&D). There are two Govt. nominees in the Board and six independent Directors.

In March 2017, HAL Chairman and Managing Director T Suvarna Raju announced that the
company had finalised plans for an indigenisation drive. The company plans to produce
nearly 1,000 military helicopters, including Kamov 226, LCH (Light Combat Helicopter)
ALH (Advanced Light Helicopter), and over 100 planes over the next 10 years. HAL will
manufacture the Kamov 226T helicopter under a joint venture agreement with Russian
defence manufacturers. The Kamov 226T will replace the country's fleet of Cheetah and
Chetak helicopters. Over the next 5 years, HAL will carry out major upgrade of almost the
entire fighter fleet of Indian Air Force including Su-30MKI, Jaguars, Mirage and Hawk jets
to make them "more lethal". The company will also deliver 123 Tejas Light Combat Aircraft
to the IAF from 2018–19, at a rate of 16 jets per year.
DEPARTMENT ASSIGNED

Helicopter MRO division was the assigned department in HAL for our industrial internship
training.

A BRIEF OVERVIEW OF HELICOPTER MRO DIVISION


Helicopter Division was established in July 1970. The division manufactures single engine as
well as twin engine helicopters to cater the growing needs of the market.

Helicopter Division manufactures Rudra, Dhruv, Cheetah, Chetak, Cheetal & Lancer
helicopters.

The division is supported by the co-located R&D centre – Rotary Wing Research & Design
Centre (RWR&DC).
The MRO division caters to the Maintenance, Repair & Overhaul activities of
helicopters. The Rotory Wing Academy focuses on training of pilots.

HAL started manufacturing of helicopters in 1962, by entering an agreement with M/s SUD-
AVIATION (Presently M/s EUROCOPTER, France) for production of Aloutte III
helicopters. (Chetak). The first Chetak (Aloutte III) in ‘Fly Away’ condition delivered in
1965.

License agreement for production of Cheetah (LAMA SA 315-B) signed with M/s SNIAS
(presently M/s, Eurocopter) in 1970. First Cheetah manufactured from raw materials was
delivered in 1976-77.

In 1990s, HAL has developed a light attack helicopter “Lancer”. The basic structure of the
lancer is derived from reliable and proven Cheetah helicopter. The helicopter has bullet proof
front panels. Gun cum Rocket pod one each (70 mm Rocket+12.5 mm Gun) fitted on either
side. An optical sight has been fitted for accurate firing.

The Cheetal helicopter is a re-engined variant of Cheetah helicopter. The Cheetal helicopter
set the world record of world’s highest landing at ‘Saser Kangri’ of Himalayas in 2006.
HAL Helicopter division has successfully manufactured 600 Single Engine helicopters. HAL
achieved self-reliance in design, developing & manufacturing of twin engine Advanced Light
Helicopter “Dhruv”. Dhruv is a multi role, multi mission all weather helicopter in the 5.5 ton
category. The indigenously designed twin engine helicopter started series production during
2001-2002.

The division is accredited with AS 9100 C & ISO 14001:2004 certifications. The division is
also approved by Directorate General of Civil Aviation (DGCA) for CAR 21, CAR 145 &
CAR M certifications.

HAL with the proven track record of manufacturing more than 700 helicopters, the helicopter
division has expand its design, developing & production range by manufacturing new
helicopters like Weapon System Integrated (WSI) version of Dhruv (Christened as “Rudra”),
Light Combat Helicopter (LCH) and Light Utility Helicopters (LUH).
TASKS PERFORMED

Acquiring the basic knowledge regarding the structure and operating principles of
helicopters.
Training started with the introduction to ALH (ADVANCED LIGHT HELICOPTER).
The body and the associated components of the helicopter are mostly made of composite and
other light materials which reduces the weight of the helicopter hence the name ALH.

Based on the structure on which the body is placed, helicopters are classified as
1. Wheel version.
2. Skid version.

1. Wheel version.

Wheel version is mostly preferred by Indian navy and coast guard, since the helicopter has to
be landed on the flat surface of moving ship.

Above figure shows the wheel version of helicopter used in Indian navy.
Wheel version is further classified as
 Fixed wheel
 Retractable wheel
If the wheels remain rigidly fixed to the body of the helicopter during all the time (flight or
landing) then such type of wheel version is known as fixed.

If wheel gets folded into the body of helicopter during flight and are opened during landing,
then such type of wheel version is known as retractable.

2. SKID VERSION

Skid version is preferred by Indian army and Indian air force, because irrespective of the land
conditions (flat/steep) the helicopter can be landed easily.
Figure above shows the skid version of helicopter used in Indian army.
Based on the display system of cockpit and the type of engines employed the helicopters are
classified as MARK 1, MARK 2, MARK 3 and MARK 4.

MARK 1
Display system –analogue.
Engine-TM333-2B2.
Power-800kw.
MARK 2
Display system-digital.
Engine –TM333-2B2.
Power-800kw.

MARK 3
Display system-digital.
Engine –shakti.
Power-900-1027kw.

MARK 4
Display system-digital.
Engine-shakti.
Power-900-1027kw.
Special characteristic- fully weaponized.

A brief information regarding the power generation and transmission of the same was also
learnt at HAL under the guidance of various officers in transmission and assembly division.
LEARNINGS AND TAKEAWAYS

1. Understanding of integration of working of various departments in the company to


achieve sound and errorless production of helicopters.

2. Enhancement of working and problem solving skills.

3. Knowledge regarding the working of helicopters i.e., aerodynamics, the structure of


helicopter, the engine, the control unit, power transmission etc.

4. Implementation of advanced technologies in manufacturing.

5. Effective time management skills.

NUMBER OF WEEKS COMPLETED IN INTERNSHIP TRAINING AT


HAL

Due to high demand for internships from various domains i.e., from various
fields of bachelors and masters programs, we were able to get only 15 days of
permission for internship training at HAL , in due course of time we were able
to acquire the maximum possible knowledge .

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