Sukhoi Engine Division Koraput
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Brief History

Engine Division, Koraput was established in the year 2004 to manufacture AL31FP Engines engines for fitment in Su-30MKI Aircraft under Licence from Russia. In 2007-08 facilities were established for overhauling of AL31FP Engines under licence from Russia.
 
Over last five decades, Division has manufactured more than 350 engines and overhauled more than 300 Aero Engines with an aim to ensure maximum aircrafts flying.

AL31FP Manufacturing & Overhaul Project

Progress of manufacturing and overhaul works is reviewed 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. Manufacturing, 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. Manufacturing, Repairs and Refurbishing Processes include machining, 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 and TTL of AL31FP Engine is :

Project

TBO

TTL

AL31FP

1000 Hrs

2000 Hrs


Rotables
In  addition to Engine IAF gives us additional task to overhaul Rotables. There are more than30 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 ISO 9001:2008 & AS 9100C valid upto 15.09.2018
  2. Energy management system certificate 50001:2011 valid upto 03.08.2019
  3. Environment System Certificate 14001:2004 valid upto 10.09.2018
  4. NABL certificate ISO/IEC 17025:2005 for Testing and Calibration laboratory valid upto 28.10.2017
Sukhoi Engine Division - Koraput has the following high tech facilities
  • Creep feed grinding machine for machining of blades
  • 5-axes CNC blade milling machine for machining of blades
  • Fatigue testing machine for blades
  • Powder metallurgy equipment for metallic inserts.
  • Single Crystal furnace for high pressure Turbine blade 
  • Manned chamber welding equipment for welding of Ti components
  • Vacuum Heat Treatment furnace for Ion Nitriding and Alphatising 
  • Special furnaces for coating the engine parts
  • Pneumo-thermo Press for achieving intricate contours on Titanium alloys
  • Isothermal forming 
  • Electron Beam Welding
  • Robotic plasma coating equipment 
  • MAP Coating equipment for coating of blades
Category of Aero Engine Parts Outsourced are:

 
Sheet Metal Parts
Types: Branch pipes, Brackets, Damper, Plain Washers, Filter mesh, Filter disc, Screen, Deflector, Lock Washers, Turbine Locks, Sealing Rings, Braids, Gasket, Shield, Liner, Circlip

Operations: Wire cut EDM, Routing, Bending, Forming, Blanking, Piercing, Drilling etc.
Machined Parts
Types: Turbine & Compressor Blades, Hollow guide vanes, Brazed guide vanes, Bi-hexagonal bolts, Sphere, Graphite seals, Bush, Ring, Bolts, Brackets, Discs, Shafts, Tie Rod, Flange, Swirler, Deflector, Valve, Piston, Cylinders, Elbow, Axle, Ring Holders 

Operations: 
  • Conventional Machining, CNC Machining, EDM 
  • Blades Machining, Blade Polishing, Creep geed grinding 
  • Internal, External, face & groove, Grinding, Gear profile Grinding
  • Thread Rolling, Graphite machining
  • Machining after Nitriding / Ion- Nitriding
  • 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
  1. Best Performing Division Award 2015-16 for the category Improvement in Value addition per Employee over previous year
  2. National Safety Award – 2011 from Ministry of Labour.
  3. Excellence in Suggestion Scheme Context – 2013 dtd.12-02-2014
  4. Rajbhasa Karyayanwayan Puruskar – 1st, Corporate Office, Bangalore - 2016
  5. Rashtrya Bhasa Gaurav Award – 2016, Rashtrya Bhasha swabhiwan Nyas, New Delhi.
  6. Karalay Deep Puruskar – 2016, Raj Bhasa Sansthan , New Delhi.
  7. Best performing Division- Category Outsourcing to sales ratio – 2012-13
The Sukhoi 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 Su-30MKi aircraft and supply of spares required during service
AL31FP Engine
Engine AL31FP is a Double contoured, turbojet with two spool compressor with heat exchanger system for cooling of turbine, with mixing of streams of outer and inner contours after turbine, with after burner reheat and supersonic all-ratings adjustable jet nozzle with rotating nozzle and controlled vectors of thrust.

The engine is of a modular construction ensuring higher technological characteristics of assembly, operation know-how and flexibility during overhaul (worn-out or damaged module can be replaced with new ones) in the operational bases.

 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, Vector Jet Nozzle parts,
 
Feature AL31FP Engine

Max. Diameter, mm

1148

Length, mm

4945

Dry Weight, kg

2005

Specific Fuel Consumption, Dry mode, kg /kg thrust / hr

0.69

Fuel Reheat Mode

1.93

Manufacturing of New AL31FP Engines and Overhaul of AL31FP Engine & its aggregates, Supply of Spares.

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.
Manufacturing, Repairs and Refurbishing Processes include machining, 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 AL31FP Engine testing. 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 centres.

Regular follow-up through PC 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: gmed.koraput@hal-india.com


General Manager(SED)
Hindustan Aeronautics Limited
Sukhoi Engine Division -Koraput
P.O. Sunabeda - 763 002,
District Koraput (Orissa) 
India.
Telephone: +91 06853 - 221200
Fax:           +91 6853 - 222292
Email: jitendra.sahu@hal-india.com