Engine Division Bangalore
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Brief History

Welcome to the Engine Division of Hindustan Aeronautics Limited.

The Engine Division, which is ISO-9002 certified, was set up in 1957 to manufacture Orpheus turbo jet engines under licence from Rolls Royce. In 1959, another licence agreement was signed with Rolls Royce to manufacture Dart engines to power HS-748 passenger aircraft and overhaul Avon engines fitted on Canberra & Hunter aircraft. Since then, the division has grown from strength to strength. It is now engaged in the manufacture of Artouste engines for Chetak/Cheetah helicopters, Adour engines for Jaguar aircraft and Garrett engines for Dornier aircraft. Engine division also undertakes repair and overhaul of various aero engines operated by Indian Airforce, Indian Navy, Indian Army, Coast Guard, Border Security Force, Corporate sector, State Government and other civil customers. The division has manufactured more than 2,100 aero engines and overhauled & repaired 11,000 engines.

The division, during four decades of its existence, has acquired state-of-art-technologies for manufacture, repair and overhaul of engines. It has a well equipped CNC shop comprising over 25 machine tools. Facilities also include Electron Beam Welding, vacuum Brazing, Electric Discharge / Chemical forming machines and others. The division has also set up shops for special coating processes to combat high temperature and atmospheric corrosion conditions, protection against surface erosions, such as Plasma Spray, Aluminium Silicon diffusion coating, Sermetal coating.

Engine and Test bed R & D centre, which is part of the Engine Division, has specialised in the development of small Gas Turbines & Engine Test Beds. The AERDC is equipped with necessary modern infrastructures. The R&D centre has developed a gas turbine engine for Pilotless Target Aircraft and jet Fuel Starter for starting the engine of Light Combat Aircraft. The R & D centre has also designed and installed engine test beds for Russian and western origin aero engines on turnkey basis.

NEW PROGRAMMES

Kaveri Engine

Kaveri, the designated engine for LCA, is being developed by GTRE, Bangalore. Various divisions of HAL are involved in the development and certification. The engine will be manufactured at engine division, HAL. The materials for engine components include high strength super alloy such as inconel on the hot end side and TI-64 on the cold end. The engine is twin spool, by pass type designed to provide dry thrust of 5291 kg reheat thrust of 8264 kg.

Engines for AJT, IJT and ALH

The engines for advanced Jet trainer project and intermediate Jet trainer project will also be manufactured by engine division in the near future. Further, the division will be participating in the co-design & co-production of engine for Advanced Light Helicopters.

Diversification

Manufacture of auxillaries such as 750 kw turbo alternator, forced draught turbo blowers and main circulating turbo pumps for leander class frigates form part of diversification.

Facilities

Engine Division has extensive manufacturing facilities consisting of conventional machines as well as CNC facilities. Some of he CNC facilities are

  • 7 Axis automatic NC NGV grinding centre with facilities like an auto loading & unloading by Robo and integrated CMM
  • 5 Axis machine centres both single spindle and twin spindle
  • 4 Axis and 3 Axis machines
  • Vertical turret lathes with live spindle
  • Disc lathe with touch probe facilities
  • Twin spindle vertical grinder
  • Jig boring
  • Turn mill centre
  • CNC Gear Grinder

Other facilities cover Fabrication and Coatings welding machineries, non-conventional machining facilities, few of these are

  • Electron Beam Welding
  • Robotic Plasma Spray Facility
  • CNC Electrical Discharge machines
  • Wire EDM
  • Electro chemical forming
  • Chemical size reduction
  • Sermetal and other coatings
  • All types of electro plating facilities
  • Vaccum brazing
  • Special welding features such as Fusion welding, Manual, Automatic Circumferential welding, Longitudinal welding, Orbital welding, Resistance welding (Spot welding, Stich welding, Seam welding)

The division can manufacture varieties of parts ranging from gears, casings, blades, impellers, stators.

For each type of engine produced a dedicated assembly line and test cell exists thus facilitating uninterrupted support to all customers.

Awating Contents.......................
 

  • The Engine Division has been credited with ISO 9002 Certificate from December 1995 onwards
  • Laboratory is approved by Honeywell, USA as authorised 'SOAP' (Spectrometric Oil analysis Programme) facility for Garett Engine.
  • Laboratory and Quality organisation are approved by civil and Military Air-Worthiness Authorities, DGCA and DGAQA.
  • The Division is also approved by Honeywell, Rolls Royce, and Turbomeca.
  • Honeywell Authorised Service Centre for repair / overhaul of Garrett TPE 331 series Engines.
  • Approved by Directorate of Warship equipment for manufacture of Frigate components.
DART 533 - 2 AND 536 - 2T
The Dart series of Engines were manufactured since 1966 under licence from Rolls Royce, UK. At present, these Engines are being repaired and overhauled. Two Dart Engines power HS-748 aircraft.

This engine has two-stage Centrifugal Compressors, three- stage Turbine and utilises water methanol injection to increase the shaft Horse Power.
Main Characteristics
Maximum Diameter (m)0.960
Length (m)2.490
Weight (kg)628.6
Power (shp) 533-2 1835 (dry)
1990 (wet)
536-2T1835
2040 (wet)
Specific Fuel Consumption (kg / kg-hr) 0.348
ORPHEUS 70105
Orpheus 70105, indigenously modified by HAL, is a derivative of Orpheus 701 at lower rating and is the Power Plant for Kiran MK II Aircraft indigenously designed by HAL.
Main Characteristics
Maximum Diameter (m)0.822
Length (m)2.290
Weight (kg)420
Thrust (kg) 1875
Specific Fuel Consumption (kg / shp-hr)0.348
AVON
Avon is a Turbo Jet Engine designed and developed by Rolls Royce and is being overhauled / repaired under licence at HAL from 1959. Avon MK 1 is used in Canberra Trainer Aircraft. Avon MK 109 is used in Canberra Bomber and Avon MK 203 / 207 power the Hunter Fighter.
Main Characteristics
  AvonMK 1 AvonMK 109 AvonMK 203/207
Maximum Diameter (m) 1.07 1.09 1.05
Length (m) 2.58 3.53 3.12
Thrust (kg) 2955 3363 4613
Specific Fuel Consumption(kg / kg-hr) 0.94 0.95 0.88
ADOUR MK 804 E
The Adour MK 804 Engine is being repaired and overhauled under licence from Rolls Royce, UK. This is similar in construction to the MK 811 engine.
Main Characteristics
Maximum Diameter (m)1.278
Length (m) 2.990
Weight (kg) 733
Thrust (kg) 2343 (dry)
3347 (wet)
Specific Fuel Consumption (kg / kg-hr) 0.79
Gnome 1400 - IT
The Gnome 1400 - IT engines being repaired and overhauled under licence from Rolls Royce, UK and is the Power Plant for Seaking Helicopter.

It is a Turbo shaft single spool with 10-stage Axial Compressor, two-stage Turbine and free Power Turbine.
Main Characteristics
Maximum Diameter (m)0.574
Length (m)1.376
Weight (kg) 168
Power (shp) 1535
Specific Fuel Consumption (kg / kg-hr) 0.276
Service facilities in HAL Engine Division

  • Repair and Overhaul of Engines
  • Spectro Photo-metric Oil Analysis (SOAP test) 
  • Electron Beam Welding
  • Robotic Plasma Spray Facility 
  • Sermetal Coating (High Temperature Corrosion Resistance Painting)
  • Chemical Milling
  • Turn Key Basis - Design and Construction of Engine Test Beds.
Deputy General Manager
Customer Service
Engine Division
Hindustan Aeronautics Limited
Bangalore Complex
Post Box No. 9310
C V Raman Nagar
Bangalore - 560 093

Telephone : 91 - 80 - 22313628
Fax : 91 - 80 - 22314686
e-mail: customer_support.engines@hal-india.com


Executive Director
Engine Division
Hindustan Aeronautics Limited
Bangalore Complex
Post Box No. 9310
C V Raman Nagar
Bangalore - 560 093

Telephone : 91 - 80 - 22312753
Fax : 91 - 80 - 22311180
GEN FAX : 91 - 80 - 22311397
e-mail: ed.engines@hal-india.com