Engine Division Koraput
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Brief History

Engine Division, koraput was established in the year 1964 to manufacture R11F2-300 Sr III engines for fitment in MiG-21FL Aircraft under licence from erstwhile USSR. In 1976 facilities were established to manufacture R25 engines for fitment in MiG-21BIS aircraft. Subsequently Division also manufactured R29b and RD33 Engines under licence from Russia.

Since the early 1970, overhauling facilities were established in the Division and Division has been overhauling Aero Engines of Various types i.e. R11, R25, R29 and RD33 which power MiG-21FL, MiG-21BIS, MiG-27 and MiG-29 respectively. 

Over last five decades Division has manufactured more than 1300 engines and overhauled more than 7000 Aero Engines of various types with an aim to ensure maximum aircrafts flying.

R25/R29/RD33 Overhaul Projects

The Division follows the 'Group Technology' with the Engine parts being dismantled, viewed and loaded to different work centers for ROH activities. Regular review of progress through latest IT enabled systems ensures timely completion of assemblies and sub-assemblies of the engines. The stripped components are subject to stringent quality checks using modern technology like CMM, NDT and other non-contact measurements. Repair and refurbishing of worn-out parts and sub-assemblies are undertaken by skilled workmen. Division is also manufacturing most of the components in-house, which are required during overhaul. Repairs and Refurbishing Processes include welding, hard alloy coatings, vibro-tumbling, micro-shot peening, ultrasonic strain hardening, nickel alloy powder coating and a large number of protective coatings. Assemblies, sub-assemblies and Engine accessories undergo rigorous functional tests on various Hydraulic, Fuel and Electrical Rigs. Quality control checks are carried out using various NDT methods, like X-ray, Magna-flux, Dye-penetrant check and ultrasonic inspection besides other conventional techniques. Overhaul of accessories is carried out in environmentally controlled rooms. Every manufactured / overhauled Engine undergoes rigorous tests on Engine test beds that simulate all flight conditions. The preliminary and final acceptance test, hot test, endurance test and gas dynamic stability tests are conducted through computerized controls. Electronically assisted throttle, digital and analog read-outs help get real-time simultaneous data and engine parameters during Engine testing.

TBO & TTL of different Engines are given below:                                                                                                                     
Project TBO TTL
R25 400 Hrs 1200 Hrs
R29 550 Hrs 1500 Hrs
RD33 300 Hrs 1000 Hrs

Rotables
In  addition to Engine IAF gives us additional task to overhaul Rotables. There are  more than 40 types of Rotables which are being overhauled in-house. All these  Rotables undergo vigorous Quality checks and testing procedure before being  released to bases for exploitation.

Supply of Spares and other major  units 
The Division manufactures and supplies the entire range of  spares required for first and second-line servicing of engines at the IAF bases  and base repair depots.

Site Repair 
The Division undertakes site repair of Engines at the IAF bases  by deputing site repair teams regularly.

Defect Investigation/Failure Analysis 
The Engines / Aggregates which are received due to premature  withdrawal from the units are studied and the causes for defects/failures are  investigated. After proper analysis and deliberation, corrective action is  taken to minimize the recurrence of defects in future.

Workshops 
The Division conducts workshops regularly to the customers at  Koraput in specialized areas for better understanding and utilization of the  products.

Positioning of Service Engineers 
The Division has posted Service Engineers at various IAF bases  to closely liaise and assess the requirement of the customers. Based on  the feed-back received from these Service Engineers, the Division renders  adequate support for fully utilizing the products.

 

Certificates

  1. Quality Systems Certificate 9100C received
  2. Environment System Certificate 14001:2004
  3. NADCAP certificate for Central laboratory
Engine Division - Koraput has the following high tech facilities
  • Large capacity lathes for tip tuning and tip grinding of rotor assemblies.
  • Ultrasonic strain hardening and micro shot peening equipment for disc slots and blade roots.
  • Submerged and argon arc welding of stator casings.
  • Honeycomb forming through progressive die.
  • Radiographic quality weldments on heat resistant steels, aluminum, magnesium, nickel and titanium alloys.
  • Manufacture of annual and can-annular flame tubes, combustion chambers, bearing housings, diffuser and adjustable nozzle castings.
  • Machining of a wide range of flanges and bushes.
  • Facility for production of a wheel range of gears, splines, gear box casings, rings, ring holders, bushes and brackets.
  • Facility for normalising, carburising, Cyaniding, Nitriding, Alitising, Solutionising, Aging, Diffusion Annealing, Sub-zero treatment and Vacuum & inner gas heat treatment to achieve the desired mechanical and metallurgical properties of materials.
  • Facility for high temperature resistant enameling of flame tubes, adjustable nozzles and other hot zone components.
  • Carrying out defect investigation and fractography study along with metallurgical analysis using SCANNING ELECTRON MICROSCOPE.
  • Hot Iso-static Pressing of Titanium, Nickle based and Aluminum based parts to reduce micro defects in casting results in increase of acceptance level of casting.
  • ROBOTIC PLASMA COATING of Engine parts to reduce cycle time by less than 50%.
  • Sand Rapid Prototyping Technology (RPT) for manufacturing of Sand moulds & cores directly from the CAD model using 3D Sand Printing Technology
  • Isothermal forging
  • Vacuum Investment casting

Category of Aero Engine Parts Outsourced are:

            

Sheet Metal Parts

  • Types: Brackets, Plain Washers, Lock Washers, Turbine Locks, Sealing Rings, Braids, Gasket, Screen, Shield, Liner, Circlip
  • Operations: Routing, Bending, Forming, Blanking, Piercing, Drilling etc.

Machined Parts

  • Types : Bush, Ring, Bolts, Brackets, Blades, Discs, Shafts, Tie Rod, Flange, Swirler, Deflector, Valve, Piston, Cylinders, Elbow, Axle , Ring Holders 
  • Operations: 
  1. Conventional Machining, CNC Machining 
  2. Blades Machining, Blade Polishing 
  3. Internal, External, face & groove, Grinding, Gear profile Grinding
  4. Thread Rolling
  5. Machining after Nitriding / Ion- Nitriding
  6. Gear Shapping, Hobbing, Spline Milling Worm, Worm Wheel

Non Metallic Component

  • PTFE Rings, Bush, Shaft, Gasket
  • Fibre Gasket

Aero Engine Sub Assembly

Pump Casing

Tooling Items

  • Ground Handling Equipment- Trolleys, Working Stand
  • Measuring Tools – Rain plug Gauge, Thread Plug, Ring Gauge, Co-axiality  Gauge
  • Cutting Tools – Drills, Taps, Reamer, Threading dies, Broaches, Gear Hubs
  • Hand Tools
  • Press Tools – Blanking and Piercing dies, Moulds
  • Best Performing Division Award 2015-16 for the category Improvement in Value addition per Employee over previous year
  • National Safety Award – 2011 from Ministry of Labour.
  • Excellence in Suggestion Scheme Context – 2013 dtd.12-02-2014
  • Rajbhasa Karyayanwayan Puruskar – 1st, Corporate Office, Bangalore - 2016
  • Rashtrya Bhasa Gaurav Award – 2016, Rashtrya Bhasha swabhiwan Nyas, New Delhi.
  • Karalay Deep  Puruskar – 2016, Raj Bhasa Sansthan , New Delhi.
  • Best performing Division- Category  Outsourcing to sales ratio – 2012-13
The Engine Division at Koraput, a unit of HAL's vast network, has the unique distinction of being one amongst the few Aero Engine manufacturers in the world.

The spectrum of manufacturing facilities extends literally from the production of nuts and bolts to discs, shafts, blades, forgings and castings - all that are required to make an Aero Engine right from the Raw materials.

This spectrum is further enlarged to include overhaul of Aero Engines for the MiG family and supply of spares required during service
 
R25 engine
This is a Twin Spool, Axial Flow, Turbojet Engine fitted with After burner and a variable area Jet nozzle. It powers the MiG-21 BiS multi-role Fighter Aircraft. The Engine has provision for an emergency After-burner thrust boost, which can be selected below 4.5 KM altitude.
R-29B engine
This Engine is a Twin spool, Axial flow Turbojet Engine incorporating After-burner system and variable area Jet nozzle of convergent-divergent type. The Engine is equipped with automatic Fuel regulation system, Turbo-starter, Anti-surge system, Temperature controller, Constant speed drive for AC Generator and Two speed drive for Hydraulic Pump. R-29B Engine powers MiG-27 M, a Multi-role Ground attack / Air combat Aircraft.
Precision Components
The Division also produces precision components like: total gamut of Blades ranging from Compressor Rotors and Stators to Turbine Blades and Nozzle Guide Vanes, intricate Cored Magnesium Alloy Gear Casings, Compressor and Turbine Discs and Shafts, JIS class-l/DlN 5 Spur, Helical Gears and DIN 6 straight and Hypoid / Spiral Bevel Gears ranging from module 1 to 6.

Salient Features
FeatureR11 Mfg & O/HR25 Mfg & O/HR29B MfgRD 33 O/H
Max. Diameter, mm906907986990
Length, mm4600461549924260
Dry Weight, kg1126121017721050
Specific Fuel Consumption, Dry mode, kg /kg thrust / hr0.990.960.940.77
Fuel Reheat Mode2.372.251.802.05
Repairs, Major Servicing, Supply of Spares
Since the early 1970's, the Division has been overhauling Aero Engines to make fighter Aircraft flight-worthy again for the Indian Air Force.

The Division follows the 'Flow Line Group Technology' with the Engine parts being dismantled, viewed and loaded to different work centers.

Regular follow-up through On-line system ensures timely completion of sub-assemblies.

The stripped components are subject to detailed micrometric and Non Destructive Testing (NDT) checks. Repair and refurbishing of worn-out parts and sub-assemblies are undertaken by  skilled workmen.

Repairs and Refurbishing Processes include welding, hard alloy coatings, vibro-tumbling, micro-shot peening, ultrasonic strain hardening, nickel alloy powder coating and a large number of protective coatings. Assemblies and sub-assemblies undergo rigorous functional tests on various Hydraulic, Fuel and Electrical Rigs.

Quality control checks are carried out using various NDT methods, like X-ray, Magna-flux, Dye-penetrant check and ultrasonic inspection besides other conventional techniques. Overhaul of accessories is carried out in environmentally controlled rooms. All the accessories after overhaul are subjected to stringent tests on test rigs.

Every manufactured / overhauled Engine undergoes rigorous tests on Engine test beds that simulate all flight conditions.

The preliminary and final acceptance test, hot test, endurance test and gas dynamic stability tests are conducted through computerised controls.

Electronically assisted throttle, digital and analog read-outs help get real-time simultaneous data and engine parameters during R-29B and RD-33 Engine testing. 
 
Executive Director (ED & SED)
Hindustan Aeronautics Limited

Engine Division - koraput
P.O. sunabeda - 763 002,
District Koraput (Orissa) 
India.

Telephone: +91 06853 - 220200
Fax:           +91 6853 - 220004 / 220217
Email: ed.koraput@hal-india.com


General Manager(ED)
Hindustan Aeronautics Limited

Engine Division - koraput
P.O. sunabeda - 763 002,
District Koraput (Orissa) 
India.

Telephone: +91 06853 - 220363
Fax:           +91 6853 - 220004 / 220217
Email: gmed.koraput@hal-india.com