AEROMAG HAL @ 80 Special Issue

a magazine dedicated to aerospace & defence industry www.aeromag.in | December 2020

R MADHAVAN Chairman & Managing Director

1940 - 2020

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Our salutations to Hindustan Aeronautics Limited on their 80th Anniversary!

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Content Editorial Advisory Board Dr. C.G. Krishnadas Nair Air Chief Marshal S. Krishnaswamy (Rtd)

PVSM, AVSM, VM & Bar Air Marshal P. Rajkumar (Rtd)

PVSM, AVSM, VM Air Marshal Ajit Bhavanani (Rtd)

PVSM, AVSM, VM Rear Admiral K. Mohanan (Rtd), AVSM Mr. Pushpindar Singh Chopra Dr . K. Ram Chand Mr. J.K.Sharma Mr. Arunakar Mishra

06 HAL’s 80 glorious years Flying higher and higher

Berlin, Germany Detlef Becker E : dw.becker@arcor.de T : +49 3375 5857590 M : + 491 701626053 Paris, France Marie-Thérèse Bonfigli E : mt.bonfigli@indavia.com M : +33 (0)6 89 20 95 68 Moscow, Russia George Smirnov E : gs1972@yandex.ru M : +7 (906)711-0351 / (495)644-17-33

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HAL: Force Behind Indian Forces

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HAL: Factors of Supreme Dominance

Sunny Jerome Managing Editor Preethi M. Associate Editor David Barnabhas Design For Publishing Articles, Advertisements Editor, Aeromag Asia Aeronautical Society of India Building Suranjandas Road, Off old Madras Road,Bangalore 560075. Karnataka, INDIA Call: +91 94490 61925 Tel: +91 80 43747492 | 25284145 Email: info@aeromag.in www.aeromag.in

35 HAL focused on increasing the pace of LCA production Printed and Published by Sunny Jerome, Managing Editor, Aeromag Asia, Aerosun Media, Aeronautical Society of India Building, Suranjandas Road, Off Old Madras Road,Bangalore 560075, Karnataka.

Printed at Rashtrotthana Mudranalaya, 19/1, K.G.Nagar, Bangalore-19.

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54 Focus is on civil & export segments, says CEO of HAL AC

HAL’s copters soaring to bigger heights

57 Modified IJT Commences Spin Flight Testing

46 Manufacturing a wide variety of specialised products

58 A glittering product line

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Committed to Keep MiG Fleet Combat Ready

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300th ALH (Dhruv) Rolls-out from HAL Hangar

HAL leadership

R MADHAVAN CMD

Alok Verma Director (HR)

Amitabh Bhatt CEO (Bangalore Complex)

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Arup Chatterjee Director (Engineering and R&D)

M.S. Velpari Director (Operations)

S.Anbuvelan CEO, HC

C.B. Ananthakrishnan Director (Finance) & CFO

Bh. V. Seshagiri Rao CEO – MIG Complex

Sajal Prakash CEO, AC

HAL’s 80 glorious years Flying higher and higher Bangalore-headquartered Hindustan Aeronautics Ltd. (HAL) has completed 80 glorious years. As India faces threats in the neighbourhood, a strong defence in the air, sea and on land is the need of the hour. Against this background, HAL has been playing a decisive role by building a strong air force.

HAL in 1940

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H

industan Aeronautics Ltd., Bangalore (HAL) crossed a major milestone on December 21, 2020 when it completed 80 years of making immense contributions to India’s defence and security. India’s defence requirements are enormous.

With hostile neighbours engaged in acts aimed at subverting and weakening the country at every turn, India needs a strong defence in the air, sea and on land. It is in this context that HAL has been playing a decisive role by building a strong air force brick by brick.

Tejas, AMCA projects The crowning glory of HAL’s eight decades is the Light Combat Aircraft (LCA) or Tejas project. The

single-engine, fourth-generation, multirole light fighter has been designed by the Aeronautical Development Agency (ADA) in collaboration with Aircraft Research and the HAL Design Centre for the Indian Air Force and Navy. Tejas, which conducted its first flight on January 4, 2001, has a top speed of 2,205 km per hour and a range of 3,000 km.

Besides planning to export of the fighter to Malayasia, Vietnam, Sri Lanka and Indonesia, HAL will set up maintenance facilities in these countries.

However, the biggest buyer of the aircraft is the Indian Air Force (IAF), which already has 35 Tejas and ordered another 83. With the Tejas currently faring well in operations, various advanced versions are being planned.

Moreover, by 2028, the fifth generation Advanced Multirole Combat Aircraft (AMCA) is expected to take off. India will manufacture this fighter aircraft on its own under the Atmanirbhar Bharat Abhiyan, reducing dependence on foreign companies and promoting the concept of self-reliance as well as ‘Make in India’.

AMCA is scheduled to be unveiled in 2024 and four prototypes are planned initially.

A highlight of the AMCA programme is that it will be a joint venture involving the private sector along with HAL and the Defence Research and Development Organisation (DRDO). At present, work on the AMCA is underway on a war-footing, with the detailed design already finalised. Meanwhile, the search is on for an improved engine.

Other programmes In 1970, HAL set up a separate division exclusively for manufacture of ‘Chetak’ and ‘Cheetah’ helicopters

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in Bangalore under licence from SNIAS, France. Other helicopters built by HAL include the Dhruv, Lancer, Cheetal and Rudra. About 400 Dhruvs, a multipurpose helicopter capable of fulfilling many different roles, have been built so far. The Rudra too is a potent chopper.

Meanwhile, HAL established a new division to manufacture aircraft instruments and accessories at Lucknow. Significantly, arrangements were made with the USSR for the manufacture of accessories for the MiG-21 jet fighter.

Another important step was the design and development of the Basant agricultural aircraft, which was undertaken between 1970 and 1974. Next was the design and development of Ajeet, an improved version of the valiant 1971 war subsonic jet fighter aircraft, Gnat. This project was undertaken between 1972 and 1980. In 1976, projects were sanctioned for the design and development of the HPT-32 elementary piston engine trainer, the Kiran MK II (an improved version of Kiran MK I / IA) and the Ajeet Trainer as well as for an Advanced Light Helicopter.

The Marut HF 24 was a milestone for HAL. The fighter did well in the 1971 war with Pakistan and it even shot down an F-86 Sabre jet at Longewala. At the same time, not a single Marut was shot down by the Pakistanis in many aerial showdowns. About 150 Maruts were in use ultimately, until it was retired in 1990.

The Kaveri engine, developed by Gas Turbine Research Establishment (GTRE) for Tejas, was found unsuitable for the aircraft. However, other uses were found for the engine and it is now used in Unmanned Aerial Vehicles (UAVs).

Meanwhile, the DRDO is planning to set up a new complex to develop jet engines for future Indian fighter aircraft. A completely new jet engine, one that can provide a thrust of 110 kilonewtons, is planned.

The engine, which is expected to come up within seven years of starting work, will be used in the AMCA.

Other important developments have also taken place at HAL. In 1979, after signing a licence agreement with British Aerospace, HAL started manufacturing the ‘Jaguar’ aircraft and with Rolls Royce-Turbomeca for Adour engines. Licence agreements were also inked with various other firms for the manufacture of avionics and accessories.

Later, after entering into a deal with Russia, HAL took up the licenced manufacture of the Sukhoi 30 MKI Aircraft at its Nasik division that was engaged in the manufacture and overhaul of the MiG series aircraft. In February 2002, it was decided to have two divisions at Nasik – the Aircraft Manufacturing Division for Su-30 MKI production and the Aircraft Overhaul Division for the overhaul and upgrade of the MiG series aircraft. In 1982, HAL had started production of the swing-wing MiG-27M aircraft as a follow-up to the MiG-21 BIS project in Nasik.

The move to manufacture AL 31 FP Engine for the SU 30 MK1 aircraft under licence from the Russian manufacturer was given much importance in 2002 with the decision to establish a new division at Koraput. At the same time, the helicopter division in Bangalore, which manufactured Advanced Light Helicopters (ALH) and was engaged in related activities like the making and repair plus overhaul activities of Chetak and Cheetah helicopters and their variants, was transferred to the Barrackpore unit.

Subsequently, a new division was created in Bangalore to carry out ALH overhaul activities.

Space sector HAL is also making immense contributions to India’s space programmes. A separate aerospace division was established in 1988. The company is currently meeting the needs to manufacture aerospace launch vehicles and satellites of ISRO. Infrastructure has also been set up to undertake complete assembly of the strap-on L-40 stage booster. Structures for GSLV Mk.III, Mars Mission and Human crew module have been supplied

by HAL to ISRO.

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Pinnacle of Glory

R MADHAVAN CMD,HAL

In its thrust to evolve as a significant global player in aerospace industry, HAL (Hindustan Aeronautics Limited), the largest Aeronautics Hub in South Asia, has over the last 80 years built up a wide-spectrum, multifaceted aerospace ecosystem in India, developing comprehensive skills in Design, Development, Upgrade, Manufacture and Maintenance of Fighters, Trainers, Helicopters, Transport Aircraft, Engines, Avionic Systems and Accessories. HAL Chairman and Managing Director R MADHAVAN in an in-depth interview with AEROMAG speaks about the indigenous technological advancements, introducing game changers in the fighter fleet, spearheading engine technologies and development mission, overcoming the unprecedented universal challenges thrown up by the Coronavirus Pandemic and the HAL vision for the future. Excerpts: 10

R Madhavan,CMD , HAL with Defence Minister Rajnath Singh HAL turns 80 and it is a glorious milestone in the golden saga of aeronautical industry in India. What are your thoughts on this occasion considering HAL’s decisive role in the thriving aerospace and defence industry in India?

Yes, it is a humungous achievement and a matter of pride for HAL, to be the flag bearer of Aerospace industry in the country, meeting the requirements of defence services, being our prime customers for over 80 years and the credit goes to my team HAL. HAL, since its inception in 1940, has evolved into a large Aeronautics Complex in South Asia. It has built up comprehensive skills in Design, Development, Upgrade, Manufacture and Maintenance of Fighters, Trainers, Helicopters, Transport Aircraft, Engines, Avionic Systems, and accessories. HAL, over the years, has produced over 4150 aircraft, 5200 aero-engines and has carried out over 11,500 overhauls of aircraft and 34,500 overhauls of engine, besides manufacture and overhaul of related accessories and avionics. These include 17 types of aircraft/ helicopters from indigenous R&D and 14 types of aircraft/ helicopters under Transfer of Technology from foreign OEMs. HAL’s major supplies and services are to the Indian Defence Services - IAF, Army, Navy and Coast Guard. The Company has also established a foothold in export in more than 20 countries, having demonstrated its quality and price competitiveness.

HAL is a major partner for the Space Vehicle programs of ISRO. It has also diversified into the Industrial & Marine Gas Turbine business. Over 90 percent of HAL’s current sales are to the Indian Defence Services.

HAL has 20 Production Divisions, 10 R&D Centers and one Facility Management Division. HAL also has 14 Joint ventures (JV), one JV Subsidiary and one wholly owned Subsidiary. HAL is setting up a facility at Tumakuru near Bengaluru to manufacture 3-ton class helicopters.

The platforms currently being manufactured

by HAL towards Defence requirements are Light Combat Aircraft (LCA) -Tejas, the multirole supersonic fighter aircraft Su-30 MKI, Light Transport Aircraft Do-228, Advanced Light Helicopter-Dhruv, Light Combat Helicopter (LCH) and Cheetal Helicopter. The major ongoing R&D programs of the company are Hindustan Turboprop Trainer (HTT-40), Light Utility Helicopter (LUH), LCA Tejas Mk 1A variant, 25 KN turbo fan engine HTFE-25, 1200 KW turboshaft engine HTSE 1200 KW etc.

HAL has developed aerospace ecosystem to boost the growth of industry in the country. Presently HAL has vendor base of over 7150 vendors, which includes over 1950 MSMEs. On an average HAL’s indigenous procurement from MSMEs is around 31%.

HAL has also been instrumental in nurturing a competitive aerospace eco-system in India by way of collaborating with private industries as outsource partners with more than 30% of HAL’s man-hours outsourced including several critical work packages.

HAL believes in inclusive growth and collaborates with private players, government labs and academia to effectively address the strategic needs of Defence Forces through synergizing. HAL aims to be a lead aerospace integrator, primarily through robust private partnership.

HAL has been extensively tying up with Indian private partners in the areas of: • Manufacturing of Detail Parts • Assemblies (Mechanical incl. Hydraulic, fuel accessories, fuselages, wing assemblies, Electrical/ Electronics incl. PCB assemblies, Transformers etc.)

• Composites, Rubber/ Plastic Parts, Tooling • Electrical looms, panels, relay boxes etc.

• Maintenance, Repair and Overhaul activities • Work packages viz. Painting, De-painting,

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dismantling • Ground support/ Ground Handling equipment viz. GHEs/GSEs. • HAL has also started involving private organisations in Quality control activities through the process of Third-Party Inspection (TPI).

HAL has also been engaging the private organisations (including MSMEs) in Design and Development of products and technologies. Some of these major design partnership initiatives include Smart Cockpit Display System, Control & Display Unit, Data Interface Unit, Multi-Function Display for LCH, Solid State Flight Data Recorder for Su-30 MKI etc.

Some of the critical manufacturing work packages outsourced by HAL for major platforms include Structural packages, Rudder, Flaperon, Air Intake, etc. of Su-30MKI aircraft, Centre Fuselage, Rear Fuselage, Wings, Front Fuselage, Air Intake assemblies etc. of LCA and MGB Housing, Gears, Harness, etc. of ALH. As a further success story of public private partnership and the Aerospace Manufacturing Ecosystem development efforts of HAL the first outsourced 'Front Fuselage Assembly' of FOC LCA Tejas was successfully rolled out by Dynamatics Technologies Limited (DTL), Bengaluru and "Rear Fuselage Assembly" from M/s Alpha Tocol Pvt. Ltd., Bengaluru, with necessary approvals from DGAQA in the current fiscal. HAL aspires more and more participation of private partners and building healthy and robust ecosystem in India through its upcoming indigenized programs.

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HAL has been transforming itself from a core manufacturing company to a technology driven one. How do you evaluate the production capabilities and technological advancements of HAL and where does HAL stand internationally?

During 8 decades of HAL’s road map, it has developed capabilities from servicing, manufacturing of aircraft under ToT to Design, Develop, manufacturing, servicing, and midlife upgrades of indigenous platforms.

HAL has developed and proven capabilities in • Design & Development (D&D), manufacturing, overhaul of aircraft, helicopters, aero-engines, related accessories, and avionics.

• Mid-life upgrade solutions for indigenous and licensed platforms • Missiles and Defence Systems Integration on existing platforms • Manufacturing of aerospace structures.

• Precision castings & forgings for aerospace applications.

We are currently pursuing indigenous technological advancements in development of Basic Trainer Aircraft HTT-40, Light Utility Helicopter (LUH) and LCA Mk 1A as second variant of LCA-Tejas with enhanced combat capabilities. To develop the critical aero-engine D&D capability in country, HAL is also developing 1200kW turbo shaft engine and 25kN turbofan engine. We are also working on technologies to enhance combat capabilities of our platforms, such as Active Electronically Scanned Array (AESA) Radar, Air-to-Air Refueling (AAR),

Integrated Architecture & Display System (IADS) for Defence platforms.

Light Utility Helicopter has achieved operational clearance (IAF) and Light Combat Helicopter is already under production. These platforms are examples of HALs design capabilities. They have proved their mettle in highest & environmentally most challenging terrain like in Siachen glacier and are appreciated by our customers.

Our next major R&D programme is IMRH – Indian Multirole Helicopter. We are also actively participating in R&D of AMCA, LCA MKII, which are already in progress. Su30 MKI upgrade is also in pipeline.

We have sufficient capability to exceed the requirement of Indian Armed forces. HAL currently stands at 34th position among the global aerospace companies in terms of revenue. HAL is among a few companies in the world having capability to design & develop indigenous Helicopters.

HAL Products & services are offered internationally to more than 20 countries in the world. I can proudly say that HAL is the only company in the world which is providing product support to specific fleets for more than 40-50 years (Jaguar, Cheetah, Chetak, MiG series Aircraft are few examples to quote). This is possible only because of HAL’s capabilities to practice obsolescence management, provide upgrade solutions and indigenization. It is testimony of HAL design and manufacturing capabilities.

We continue to build our capabilities through investments in upgrading our capabilities in R&D,

Manufacturing, IT enabled application etc.

In a first, a complex fuselage section for a fighter aircraft has been built by a private sector company, when Dynamatic Technologies made the front fuselage for FOC version of LCA. The government is promoting private participation and how does HAL support to bridge the gap with private industry?

HAL has been actively engaging business partners from the private sector even before the advent of “Make in India”, like in its Su30MKI, ALH projects. In respect of LCA, HAL has been successfully able to partner a few private players with capabilities to take up complex systems/ subsystems for manufacture & assembly, which is a commendable achievement since HAL products are highly technology sensitive and capital intensive.

HAL extends the required support to its vendors by spreading awareness of airworthy quality & safety requirements, initial hand-holding and over-theshoulder production supervision to finally turn the supplier into a reliable partner of HAL's value chain.

Furthermore, HAL supplies the raw material, special tools, gauges, Jigs & fixtures besides the necessary technical documents, drawings, process sheets required for manufacture of aircraft components.

HAL also provides the required technical support in respect of First article inspection (FAI) until prove out, Pre dispatch inspection at works during production phase besides support during the certification phase. Not only Front Fuselage from DTL, HAL’s dedicated efforts resulted in delivery of LCA Wings from L&T and LCA Rear Fuselage

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from Alpha Tocol. Some more major assemblies are under fabrication with Private partners.

It is pertinent to note that over the past years, HAL has successfully engaged several private industries, including MSEs, in Design & Development of products/ technologies. HAL assists such MSEs to absorb the requisite technologies and means to improve quality standards required in Aeronautical Industry. Vendor meets are also organized at Divisional/Corporate levels for the private sector industries at various forums to create an awareness of the requirements and various opportunities available at HAL. Air Chief Marshal RKS Bhadauria, Chief of the Air Staff, undertook his maiden flight in HAL designed and developed Light Combat Helicopter (LCH) on 20th November and reviewed the project ahead of its induction to IAF. What is the status of the project and how crucial is the multi-role lightest attack helicopter to IAF? LCH is the first indigenously designed, dedicated combat helicopter, meeting the requirements of Indian Armed Forces. Close to 1800 development flights are carried out cumulatively on 4 Technology Demonstrators till date. Flight testing was carried out at various altitudes from Sea level to High altitudes of Siachen range and at extreme Cold weather, Hot weather conditions and in Desert region.

LCH is integrated with Mission sensors such as Electro Optical system, Helmet Mounted Display System and Weapon systems such as Turret Gun, Rocket & Air to Air Missile system. Weapon firing trials have been completed. LCH has demonstrated its capability to land & take off at 4700m altitude at Siachen with adequate fuel and payload.

The Initial Operational Clearance (IOC) for LCH

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for both Airforce and Army variants have been accorded by CEMILAC. Based on requirement from IAF, 2 LCHs of HAL were deployed at Leh in August 2020 for undertaking operational missions in support of IAF. These helicopters successfully demonstrated quick deployment to forward locations and operations in extreme temperatures prevalent in the area and able to operate in the complete Area of Responsibility (AOR).

With its advanced technologies, stealth features for effective combat roles such as Destruction of Enemy Air Defence, Counter Insurgency, Search and Rescue, Anti-tank, Counter Surface Force Operations etc., deployment of LCH is very much crucial to meet the requirements of the Indian Armed Forces.

There is an initial requirement indicated for 65 LCHs by Indian Air Force & 97 LCHs by Indian Army. The contract for 15 Limited Series Production (LSP) LCHs (10 LCHs for IAF and 5 LCHs for IA) is in advanced stage of finalization. As a proactive measure, HAL has launched production of LSPs and progressed with the equipping & integration activities towards flight tests in anticipation of orders which are expected shortly. Letter of Intent is received from IAF and Indian Army for delivery of five each LCH LSPs pending contract finalization.

Chief of Air Staff made his maiden flight in LCH on 20th Nov 2020 and expressed his satisfaction with the helicopter performance and progress made on the project. His positive feedback encourages HAL to move forward with passion in Design and Development of indigenous Rotary Wing Platforms.

HAL’s Aircraft Research and Design Centre (ARDC) has completed the structural design of the new variant of Light Combat Aircraft, called Tejas

Mk1A. What is the present status of the project and how it will be a game changer for the fighter fleet of India?

There are quite a few new System/Sensors like AESA Radar, EW Suite, DMG etc. and Stores Like ASRAAM to be integrated in LCA Mk1A to enhance the performance and potent of the aircraft. There are also a few improvements and strengthening required on the Structural Design for better operations and maintainability. All these re-design/ modification to design, of not only the structure but also the electrical wiring, cooling system etc. have been completed.

HAL is still awaiting the order from IAF for the Mk1A aircraft but notwithstanding, with internal funds, have progressed the above-mentioned redesign as well as gone ahead in-house development of the various Systems and software. The Mk1A Aircraft when inducted (in 3 years from contract) will be a game changer with its State-of-the-Art Systems and Weapons.

How far is LCA’s naval variant from the induction into the navy and what are the challenges?

LCA Navy has successfully completed the developmental tasks including demonstration of operation from Aircraft Carrier. In January 2020, the LCA Naval prototypes (Trainer and fighter) demonstrated launch and recovery on INS Vikramaditya. During the Shore based test facility (SBTF) trials and Ship trials the aircraft serviceability was proved to be extremely high and was able to sustain the stringent requirements of arrested landings.

The ski jump takeoff with two Derby missiles and two R73 missiles was demonstrated which proves that aircraft can be utilized in air defense roles from the carrier. The aircraft can also be utilized as a lead in trainer fully capable of ship operations too.

Indian Navy has taken a decision to go ahead with the development of a Twin Engine Deck Based Fighter (TEDBF) to replace the Mig29K. The LCA Navy prototype will be used to test the various new structural elements like the Vortex Flap,

Strakes, Stabilator, IFCS Development and Other Combination before the TEDBF prototypes are ready.

Could you please share the current rate of production of LCA Tejas and when will HAL achieve the target rate of 16 LCA fighters per year?

HAL has already augmented production capacity to 10 to 12 LCAs per year by establishing one more production line, at one of our sister division in Bangalore and has also developed partners for supply of major structural assemblies, beside the dedicated production line already established at LCA Tejas Division.

A new facility that is spread across 35 acres and having a built-up area of over 34000 square meter (sq. m.) is being made ready for production of structural assemblies of the advanced variant of Tejas which is LCA Mk1A. The new facility will be in full-fledged operation from FY 2021-22 onwards.

HAL expects the demonstration of 16 aircraft pa capacity from 2022-23 onwards so as to be ready when the deliveries are to be made against 83 LCA order.

In yet another major fillip to indigenous programme, 300th Advanced Light Helicopter (ALH-Dhruv) rolled out from HAL hangar recently.

Could you talk about the latest updates of the project?

Rolling out of 300th ALH is a testimony to the capabilities we have built over years with concerted effort of HAL fraternity and customer support. Currently, HAL is executing 73 ALH contract comprising of 41 Army, 16 IN and 16 CG helicopters.

In the case of Coast Guard and Navy 19 New systems have been integrated on ALH Mk-III which will further enhance capability of ALH for coastal surveillance. The first batch of these helicopters will be delivered to Coast Guard and Navy shortly and we are sure the enhanced capability of these helicopters will add an edge to customer’s operations.

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Out of 73 ALH contract, HAL has already produced 30 ALH for Army, 5 for Navy and 6 for CG. We would complete the rest 32 helicopters by 2022.

While HAL is expecting more orders on ALH, the production of limited series production LCH has already commenced. IAF and Army has already issued Letter of Intent for early delivery of 5 LCH each for operational exploitation at the earliest.

Proactively, production activities have commenced at HAL and first helicopter has commenced ground run. Next four helicopters are also in advance stages of equipping. Already, HAL produced two Light Combat Helicopters (LCH) have been deployed for operations at high altitude (Leh sector) at short notice to support IAF missions in Aug 2020.

LUH has attained operational clearance for the IAF variant. Recently, LUH has also successfully completed hot and high-altitude trials at Leh paving its way for IOC for Army. HAL has also started design and development of IMRH which would be replacement for phasing out Medium Lift Helicopters from Services. We can say that the Product Portfolio of Helicopters by HAL would be truly in line with Government of India initiative of ‘Atmanirbhar Bharat’.

A major challenge faced by Indian aerospace manufacturing sector in the creation of fighters is the development of indigenous engines. What

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are your thoughts on it and how far is India from achieving this long-standing goal?

Design of aircraft power plant is a complex process involving multi-disciplinary activities. The reliability considerations, particularly for aircrafts configured with a single engine, make the design of these power plants even more complex owing to their extreme service conditions. Also, the barriers like high level of investment, longer gestation period, special raw materials, Single Crystal technology, High altitude testing, flying testbed etc. have hindered the engine development programs. Technology acquisition through offset efforts have also been turned down quoting various reasons like export embargo, confidentiality, and critical technologies etc.

However, HAL has so far manufactured over 5100 Engines of 16 Types both for fixed wing and rotary wing platform. Knowledge gained while manufacturing the engines has led HAL to successfully carry out, for the first time in the country, the design develop & produce small gas turbine engines and their components. The products that are designed & developed in the area of aero-engines are 4 kN thrust turbojet engine (PTAE-7) used on Pilotless Target Aircraft (PTA), 110 kW power turbo shaft engine (GTSU-110) for starting the Light Combat Aircraft (LCA) engine and its upgrades, 60 kW starter generator engine for starting AI-20D engine of An-32 aircraft, Air producer engine for starting Adour-811 and 871

engines of Jaguar and Hawk aircrafts, Auxiliary Power Unit for FGFA class aircraft and accessories like air turbine starters, turbo chargers etc.

Realizing the need of indigenous engine technologies and engines we have launched two engine development programs, Hindustan Turbo Fan engine (HTFE-25) of 25 kN thrust for trainer aircraft and UAV’s, and Hindustan Turbo Shaft engine (HTSE-1200) of shaft power rating which can power Light & Medium weight helicopters (3.5 to 6.5 tons in single/ twin engine configuration) For realizing the goal of having an indigenous engine for fighter aircrafts, the best way forward could be a consortium basis with HAL, GTRE, CSIR, Govt. labs, leading premier institutions and private industries as the partners of the project as a national program. Opting of foreign technical collaborator (OEM of Engine) may be explored based on technology gaps existing within country and willingness of foreign OEM to part such technologies without any limitations.

Engine development will be fructifying in India by a concerted effort and amalgamation of learnings from all the agencies. Government has initiated moves to create an aero engine complex in India involving PSUs, Pvt. Industries including MSMEs, Govt labs and academia.

HAL and Tech Mahindra signed a contract worth Rs 400 Cr recently for implementation of Enterprise Resource Planning (ERP) to support HAL’s Project Parivartan. Could you please elaborate on the Project?

Yes, HAL has signed the Project Parivartan contract to upgrade our existing ERP system with the latest version along with related Software licenses, across Divisions, R&D Centres and Offices of HAL. The contract includes supply of necessary hardware, five-year maintenance support, additional licenses considering future expansion etc.

The total duration of the contract is eight and half years including support.

The new solution is aimed at standardization of business processes across HAL Divisions based on industry best practices; integration of PLM at R&D Divisions with Production Divisions; and creating a platform to embrace new technologies like Internet of Things (IOT) & Artificial Intelligence (AI) etc.

We will also implement Supply Chain Management (SCM) with seamless integration of company operations with the Suppliers for procurements, receipts, inventory, and payments. We have a large outsourcing partner’s base which is planned to be integrated in the supply chain to capture real time status of loading of parts on machines, dispatches, and quality inspection. This would result in improved Supplier Relationship Management (SRM). We also intend to provide high-quality customer service

using Customer Relation Management (CRM) capability of the solution and integrating our business with Customers in respect of customer orders, deliveries, AOGs, warranty management etc. Implementing Project Parivartan will help to keep us ahead of the competition with reduced cost of production, turnaround time (TAT) and increased productivity.

What are operational highlights of 2020-21 for HAL so far? What is expectation in current fiscal and what are the goals?

HAL as of date has manufactured 18 new aircraft/ helicopter and 57 new engines during the current fiscal. Additionally, we have also overhauled 97 aircraft/ helicopter and 276 engines during the period.

HAL produced FOC standard LCA Tejas has been inducted into IAF Squadron ‘The Flying Bullets’ (18 Squadron) in May 2020. HAL produced two Light Combat Helicopters (LCH) have been deployed for operations at high altitude (Leh sector) at short notice to support IAF missions in Aug 2020. HAL has also achieved the milestones of producing 150th Dornier aircraft and 300th ALH Dhruv. HAL has also completed the order for RD-33 engines this year from its Koraput Engine factory.

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With the introduction of the new Platforms into the Export Market and aggressive approach in marketing efforts, HAL envisages enhancement in exports in the coming years.

The export arm of HAL is being strengthened to address the upcoming requirements.

In Sep 2020, ground run of first indigenously designed and developed Light Combat HelicopterLimited Series Production (LCH-LSP) has been conducted for which order is still awaited.

In Nov 2020, HAL successfully delivered the biggest Cryogenic propellant tank (C32 LH2) ever fabricated for ISRO much ahead of the contractual schedule.

We expect order finalization for the 83 LCA Mk1A & 15 LCH LSP in the current fiscal. We expect greater contributions from the company towards Atmanirbhar Bharat in terms of further deliveries of indigenous platforms and equipment and greater involvement of the successful public private partnerships.

How did HAL brace for the impact caused by COVID-19? What are the plans post pandemic period?

HAL Divisions across the country were in complete lockdown from 24th Mar 2020 to 19th Apr 2020, baring essential services which continued to work without any interruption, due to the nationwide COVID-19 lockdown in-force as per the government directives. Subsequently, in line with MHA guidelines dated 15th Apr 2020, HAL resumed its operations progressively and by 4th May 2020 with due clearance from local authorities, all the Divisions/ Offices of HAL were operational.

Since the lockdown was country wide, work at HAL outsource partners/ vendors etc. were also held up. This has led to the loss of production hours across the factories completely for over a month, affecting regular production and R&D activities temporarily. It affected the last leg of scheduled activities for the production year 2019-20 and production / ROH of few of the aircraft/helicopters and engines could not be completed. Further, in the month of April of current year 2020-21 also, operations of company were significantly affected.

Approximately, Standard Man hours (SMH) to the tune of 26 lakh has been lost due to the monthlong lockdown of HAL factories.

Resumption of work started with staggered shifts with minimum number of employees in all Divisions.

Subsequently based on modified government guidelines, normalcy has been restored gradually.

HAL works in aeronautical domain, which is highly technology intensive. Also, HAL product spectrum

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includes both ToT as well as indigenous platforms and contain systems/sub-systems/ raw materials etc of foreign origin, used on these platforms. Since the pandemic has caused world-wide lockdown, there is disruption of production at supplier premises and associated delays in supplies, which in-turn has led to production delays at HAL. However, all efforts are being put by the entire HAL team to recover the loss of time through regular follow-up/reviews at various levels as well as putting in additional efforts, wherever feasible.

Even during the lockdown HAL was in constant interaction with the Service HQ’s. Also, our service personnel were deployed to customer bases for support services on requirement basis and were also available on call throughout for any technical support. HAL has received letters of appreciation from various defence establishments for supporting them in the time of Pandemic crises.

We are bracing up to catch up the lost production hours and could do a lot of improvement in the third quarter and we hope to make good the rest before the end of this fiscal year.

Post pandemic we plan lot more digitisation of our processes. Towards this we have embarked on a journey to revive our ERP system through Project Parivartan, which is bound to increase our operational efficiencies and flexibilities.

There is a strong push from the government and the ‘Atmanirbhar Bharat Abhiyan’, the policy formulations and reforms post COVID-19 is giving significant impetus to self-reliance and local production. This is expected to favourably impact the operations of the company. The Defence Services are looking for more indigenous options as compared to import and HAL is expected to greatly benefit from this as there are a slew of indigenous products like LCH, LUH, HTT-40, LCA etc.

Prime Minister Narendra Modi has called for lesser dependence on foreign nations by supporting the 'Aatmanirbhar Bharat' (Self-Reliant India) and 'Make in India' mission. How crucial is HAL's Make-ll program in this regard?

HAL’s Make-II programme is a very crucial step towards supporting the 'Aatmanirbhar Bharat' & ‘Make in India’ mission. HAL’s Make-II (Industry Funded) procedure complies with the Make-II framework promulgated by MoD and envisages the assured order quantity after successful development of items through private vendors. In this regard, HAL has recently implemented Make-II procedure and has hosted items identified for indigenization under Make-II in its website along with the contact details of the nodal officers for indigenization.

HAL has started issuing EOIs for indigenization of these items in a phased manner. List of the items identified for indigenization under Make-II as well

as the available EoIs can be accessed through our website. Indigenization through Make-II procedure will involve a greater number of interested and capable local vendors and thereby help expanding the aerospace & defense eco-system in the country.

India is actively trying to diminish its image as an importer and wants to project itself as an exporter in defence products. How strong is the export arm of HAL and what are the products and services offered?

HAL is making all out efforts to boost Exports in sync with Government's USD 5 billion Defence Export Target to become net exporter of Defence Equipment in the next five years.

So far, HAL's exportable Platforms have been Advanced Light Helicopter (ALH) - Dhruv and Do228 aircraft. In addition, HAL also exports certain work packages and spares.

Presently, in the rotary wing side Advanced Light Helicopter Mk. IV variant- Rudra & Light Combat Helicopter (LCH) and in fixed wing side the Light Combat Aircraft (LCA) - Tejas have been added to the basket of HAL's exportable Platforms.

Soon, Hindustan Turbo Trainer (HTT)-40 and Light Utility Helicopter (LUH) will also be offered in the Export Market.

Further, HAL also started participating in major Global tenders for Defence aviation platforms.

Channel partners are being engaged in prospective countries. Extensive support is being rendered by Indian Missions abroad in Export promotion.

With the introduction of the new Platforms into Export Market and aggressive approach in marketing efforts, HAL envisages enhancement in exports in the coming years.

The export arm of HAL is being strengthened to address the upcoming requirements.

In another 20 years, HAL will reach its centenary.

What is the roadmap ahead and how challenging will it be? Also, what are the visions for HAL during your tenure?

HAL is going to celebrate our centenary with flying colors. The business landscape has been completely changed during last eight decades since inception and HAL has overcome successfully many a challenge in the past. HAL was a private company to start with, later it was taken over by Indian Govt., and currently we are listed company wherein 25% is disinvested with multiple shareholders other than Govt. The road map is incredibly challenging considering external business environment, increased competition in defense aerospace segment unlike earlier, policies of Government with more thrust on private sector participation.

At the same time, proactive policies of Govt., like Atmanirbhar Bharat, Negative list of defense

I take this opportunity to express my gratitude to our customers and partners, whose continued cooperation and collaboration is boosting us to reach 100 years and fly high. equipment for prohibiting imports to encourage use of defense equipment which are made in India, thrust on greater indigenization in Defense contracts with Foreign OEMs, changes in Defense Acquisition Procedure (DAP 2020) etc. along with greater thrust for exports and entry into civil aircraft sector, will provide multiple business opportunities for all of us.

The collaboration (with OEM, Startups, Education & Research Institutes), focusing on futuristic technologies and widening customer base coupled with increased customer delight are most important in the future. We have geared up to take the company to the next orbit through our Vision 2030. Going ahead our focus areas include double digit growth, digital factory (paperless work environment, Industry 4.0, digital interaction with customers & partners etc.), thrust on exports, non-defense products and services, diversification, retention, and nurturing of talented human resources, developing new core competencies to remain the leader in the market etc.

Work culture is most important for company to succeed and in this context driving “market culture” in company is being emphasized.

Further, in view of relaxed FDI norms, HAL is looking for new engagements with foreign OEMs. Co-development of new products & futuristic technologies within short time & low investments to make solution more competitive and attractive from all fronts to potential customers is the key to future success and I strongly believe risk sharing partnership with like-minded Indian & Foreign partners is the important aspect for DPSUs to succeed.

Civil Aerospace sector and UAVs segment has lots of market potential in India. We are making all efforts to explore this arena (where HAL is yet to exploit market potential) through collaboration. We are already partner for SARAS programme of NAL and the Saras Mk II version is in making.

War scenario is likely to change in future and in anticipation HAL is going aggressively to develop technologies in UAV and AI domain through collaboration with private sector partners, startups, and academia.

I take this opportunity to express my gratitude to our customers and partners, whose continued cooperation and collaboration is boosting us to reach 100 years and fly high.

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HAL: Force Behind Indian Forces HAL’s future sales is almost exclusively based on indigenously designed and developed products such as the LCA, ALH variants, LCH, LUH, HTT-40, etc and the emphasis on in-house R&D has become stronger than ever. HAL has the strongest R&D set-ups among the DPSUs. With a multitude of the R&D projects undertaken right now, in no time, HAL will be the exclusive destination for catering to all the aviation industry requirement worldwide, says Arup Chatterjee, Director (Engineering and R&D), HAL, in an interview with Aeromag. Excerpts from the interview:

Arup Chatterjee Director (Engineering and R&D) HAL Having over 36 years of wide experience in aerospace industry, how do you analyse the aerospace manufacturing sector in India with prime focus on the contributions of HAL? What are the challenges needed to be resolved?

HAL has contributed immensely not only to the Defence forces but also in establishing an aerospace manufacturing ecospace system in the country in the past 80 years. HAL has manufactured over 4,100 aircrafts (31 types) in the 20 production centres across the country. With a dedicated workforce of more than 26,000, HAL is truly the Force behind the Indian Forces. There are very few companies in the world that can boast of providing end-to-end solutions ie, from design to certification to product support. While HAL is known for aircraft level integration, it is also into development, manufacture and support of aero-engines, aircraft / Avionics systems. This is unique to HAL amongst all global aerospace entities. The kind of infrastructure established by HAL is on par with any international

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company in the aerospace business. While most of the OEMs who had developed and sold helicopters and aircraft to India have stopped supporting the programmes, HAL has risen successfully to the challenge of maintaining the old fleets. If today the Indian Armed Forces are still flying Cheetahs, Chetaks, Jaguars, MiGs and the like, it is because of HAL. HAL has established Centres of Excellence in manufacturing not only within HAL but also facilitated many private sector firms to be the part of the Global supply chain of Aircraft manufacturing.

Prior to 1990, aircraft manufacturing capabilities were primarily limited to HAL and the concept of outsourcing was yet to take shape. When the prototype manufacturing for the LCA project was started in the early 1990’s, a few potential vendors who could take up Conventional and CNC machining were identified and Orders were placed on them to supplement HAL’s production system.

The next major wave of expansion of outsourcing

by HAL began in the first decade of the new millennium with the Su-30 MKI project whereinmore than 40% of the workload (more than 15,000 parts) has been sourced through Private Companies/ MSMEs across India. HAL has developed more than 200 vendors including MSMEs for manufacturing of Su-30MKI parts and assemblies across India. These vendors have upgraded themselves to aerospace industry standards and became part of Aerospace manufacturing Ecosystem in India and some of them have been able to graduate to be part of the global supply chain also.

Private participation was encouraged to develop new / alternate materials, develop processes, develop LRUs, establish manufacturing plants without compromising on quality or safety aspects.

Many of the avionics, electrical & mechanical system which are flying in our platforms have been designed and developed by private vendors.

Presently HAL is throwing up several challenges to Start-ups/MSMEs/Individual Entrepreneurs through iDEX-DIO supporting AtmaNirbhar Bharat concept for their involvement in the aerospace sector.

Almost all of the MSMEs which are the stars of the Indian aerospace manufacturing ecosystem today were initially nurtured by HAL by significant handholding and high level of tolerance to initial failures.

In parallel, several industrial groups such as the Tatas, M&M, L&T, et al established Aerospace verticals and took up manufacturing of airframes (comprising metallic and composites parts) for foreign OEMs.Along with this evolution of the manufacturing ecosystem, HAL has changed its basic approach to Outsourcing from being a source of detail parts to being HAL’s long term partners who will supply sub-assemblies and major assemblies. This new approach is exemplified in the case of the LCA wherein the three major structural assemblies (front, centre& rear fuselages) and the Wing assemblies are supplied by Private sector companies.

Despite these partnerships and opportunities available, private aerospace sector in India faces major challenges including the available business

volumes. The aerospace and defence (A&D) industry involves complex technology, high investment cost, long gestation period, stringent quality requirement, long development cycle and tedious certification process.

Therefore, HAL is closely handholding the private manufacturing partners in the country particularly MSMEs to be matured supply chain partners thereby broadening the aerospace ecosystem in the country on a continuous basis.

The importance of a strong R&D wing is crucial for any company that is active in strategic product manufacturing. How strong are the R&D activities of HAL? What are the latest updates of ongoing projects?

In the present context where HAL’s future Sales is almost exclusively based on indigenously designed and developed products such as the LCA, ALH variants, LCH, LUH, HTT-40, etc. the emphasis on in-house R&D has become stronger than ever. HAL has the strongest R&D set-ups among the DPSUs. The R&D organization of HAL under the aegis of Design Complex is headed by Director (Engineering and R&D) who oversees the activities of 10 R&D Centres. The Centres are focused on development of Fixed Wing and Rotary Wing platforms, manned &unmanned, as well as the airborne equipment such as Engines, Avionics and Mechanical systems.

The non-lapsable R&D Corpus is one of the mechanisms for funding R&D projects. Every year, 10% of the Operating Profit After Tax is credited to the Corpus from which various R&D projects are funded. In addition, project funding is provided from the accumulated Reserves of the Company through approvals as per the DoP. The R&D Centres have not restricted their activity to design and development or upgrades alone. Any platform or a system – whether requirement projected by the Users or an Inhouse development - involves understanding the Operation Requirements (ORs), drawing up of technical requirements, detailed design activity, authentication of the design through extensive analysis using latest analytical software, design

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reviews by specialists and certification authorities, manufacturing of prototypes / technology demonstrators, ground and flight testing, certification. Appropriate User training to operate the Platforms and Systems is another major activity undertaken by these Centres. The R&D Centres have developed the right infrastructure and skill sets with a blend of experienced and young designers to undertake all the activities from the beginning to its logical end. These centres do not limit their activities to product development to cater to immediate customer requirements alone. They are also engaged in development of next generation technologies in their respective domains, under HAL’s internally funded Technology Development initiative. In addition, HAL has set up chairs with premier institutes like IISc&IITs, to bridge academia and industry in research and development.

The Aircraft R&D Centre (ARDC), Rotary Wing R&D Centre (RWRDC) at Bengaluru, Transport Aircraft R&D Centre (TARDC) at Kanpur and Aircraft Upgrade R&D Centre (AURDC) at Nasik are primarily working on design, development and upgrades of fixed wing and rotary wing platforms.

ARDC has associated with ADA in the development and flight testing of TEJAS (LCA) to meet the stringent requirements of the IAF. This multi mission tactical aircraft is upgraded to LCA MK-1A with the latest technology based indigenous Avionics equipment, AESA Radar and EW System and enabled with BVR and ASRAAM missiles.

ARDC jointly with ADA is at present co-developing the navy version of LCA, LCA MK-II, Twin Engine Deck Based Fighter (TEDBF) as well as AMCA. HAL has successfully demonstrated the capability of hot refuelling on HTT-40 and the capability of running switch over of pilots while keeping the engine running. With this, HTT-40 will be the only TurboProp Trainer in the world to have features of running changeover and hot refuelling.HTT-40 has already completed 6 turn spin with Anti Spin Parachute System (ASPS). It is undergoing spin refinement flight trials after removal of ASPS and is in the final stages of certification.After modification of Tail structure, Intermediate Jet Trainer (IJT) has restarted flight trials and it has completed 2 turn spin successfully. At present IJT is undergoing further spin trails. HAL has initiated design and development of CATS (Combat Aircraft Teaming System) wherein large number of unmanned flying assets will be centrally controlled/directed from a mothership.

RWRDC has designed, developed and certified Advanced Light Helicopter - Dhruv, Rudra, Light Combat Helicopter (LCH) and Light Utility Helicopter (LUH). IOC of LCH was accorded by CEMILAC for Indian Air Force and Indian Army during Aug 2017 and Feb 2019 respectively. HAL

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has submitted quotation against RFP for supply of initial batch of 15 LCH against which, order is awaited. Subsequently, after completion of 15 LSP order, HAL will produce 147 helicopters.

Initial Operational Clearance (IOC) of Basic LUH for Indian Air Force was accorded by CEMILAC during February, 2020 and IOC of Army Version is expected to be accorded at Aero-India 2021. Indian Multi Role Helicopter (IMRH) a 13 ton helicopter is another project taken up by this R&D centre.

Preliminary design of Army/Air Force version and Naval version of the IMRH is completed and the Preliminary Project Report (PPR) is forwarded to MoD. With this RWRDC will be a unique centre designing helicopters from 2 ton to 13 ton weight class, a capability very few global R&D centres can boast of. The Centre has evolved ALH from Mark I – conventional cockpit to Mark III / IV equipped with state of the art Glass cockpit, Mission Sensors and Weapon Systems. Further RWRDC has initiated the Civil Certification of LUH and development of a 200 kg Rotary UAV. To cater to the stowage requirements of Naval Ships and Carriers, HAL has taken up the projects of Tail Boom Folding and 2-Segmented Blade Folding. Tail Boom Folding on ALH has already been demonstrated and will be certified soon. The 2-Segmented Blade Folding will be certified by July 2022.

Aerospace System & Equipment R&D Centre (ASERDC) at Lucknow has undertaken design and development of Electrical systems like Master boxes, Control and Protection, Electrical rotating machines, fuel gauging systems, Environment Control Systems, Hydraulic units and Wheels and Brakes to name a few.

Mission & Combat System R&D Centre (MCSRDC) has taken up design and development of Mission Avionics hardware, Mission Software, Algorithms

for Navigation & Weapon Guidance, Integrated Avionics Suite for Jaguar, Simulators, Mission Planning and Debrief Stations, Glass cockpit and AFCS for different helicopter platforms, integration of solid state weapon control system and anti-ship and anti-airfield weapon for Jaguar. Final Operation Clearance (FOC) for Jaguar DARIN-III upgrade including integration of ACMI, RWR, CMDS and weapons was accorded by RCMA in July’19.

Strategic Electronics R&D Centre (SLRDC) at Hyderabad and Aerospace System & Equipment R&D Centre (ASERDC) at Korwa have undertaken design and development of state-of-the art Avionics and Navigation systems, Identification Systems, Radar, Communication Systems, Voice Activated Command Systems, TACAN system, Radio altimeter, IFF transponder, Automatic Identification System, solid state flight data recorders, digital map generator. Civil Certification of some of these items are also being progressed with.

HAL has also initiated Artificial intelligence based projects in collaboration with Institutes of repute.

With a multitude of the R&D projects that are being undertaken by HAL right now, in no time, HAL will be the exclusive destination for catering to all the aviation industry requirement worldwide.

Aero Engines Research and Design Centre has successfully designed and developed small aero engines in operation with the Defence services.

But in terms of engine development HAL still faces numerous challenges. How do you plan to tackle this?

To set the ambience apt to understand the nittygritties of aero engine design, let me give you an insight into the history of aero engine design and development at HAL. HAL embarked on the design in 1960s. Initially

we tried our hands on piston engines like HPE2, HPE-4 and PE-90 etc. The 1V1 kN HJE-2500 engine designated for HJT-16 was designed and the prototype was tested on the testbed. However it did not see the production lines and it could not be integrated on the aircraft for various reasons.

It is 1980s, that HAL really felt the need of indigenous engines and forayed into small gas turbine design. HAL is the only organization in the country, that has so far successfully carried out many small engine design and development projects. The engines are 4 kN thrust turbojet engine (PTAE-7) used on Pilotless Target Aircraft (PTA), 110 kW power turbo shaft engine (GTSU-110/127) for starting the Light Combat Aircraft (LCA) engine and its upgrades, 60 kW starter generator engine for starting AI-20D engine of An-32 aircraft, Air producer engine for starting Adour-811 and 871 engines of Jaguar and Hawk aircrafts, Auxiliary Power Unit for FGFA class aircraft and accessories like air turbine starters, turbo chargers etc.

Harvesting all the learnings of small engines and co-development, today the R&D unit of HAL, AERDC (Aero Engine Research and Design Centre) is tasked to develop two prestigious engines namely; Hindustan Turbo Fan engine (HTFE-25) of 25 kN thrust which can power trainer aircraft, UAV’s, Twin engine small fighter aircraft or regional jets and Hindustan Turbo Shaft engine (HTSE-1200) of shaft power rating which can power Light & Medium weight helicopters (3.5 to 6.5 tonnes in single/ twin engine configuration) Significant progress has been made in both the projects with successful trial runs of 25 kN core engine and 1200 kW Jet mode version engine up to 100% RPM. HAL is confident of achieving the targeted design parameters and productionising these engines.

• However the challenges are many in aero engine design like, • Funding challenges • Technological challenges • Trained man power specific to aviation industry • Testing facilities from component test facility to Flying Test bed • Precision manufacturing and established Vendor base etc.

As a strategy, HAL has earmarked nearly 1000 crores from its internal funds exclusively for Engine Development.

The HTFE-25 and HTSE-1200 engine programs, both of which are in prototype evaluation phase are loaded with some of the concurrent technologies like High Pressure Compressor, Effusion cooled combustor, SX Blades, 3D printed parts, laser shock peening, FADEC, Atomizers, High speed Gearbox etc. In parallel, futuristic developments in

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technology are also in progress, like Afterburner on PTAE and HTFE, Flame propagating nozzles, EHSV and Stepper motor based FMUs etc.

On the material and processes front, HAL is developing SX blades with DMRL for HTSE-1200 engine program. The coating by EBPVD method is also being established with ARCI Hyderabad to be utilized on SX blades. The process has been proven on sample blades. Similarly the Laser shock peening will be utilized through Coventry University UK. We are developing atomizers with IISc. HAL is constantly imparting knowledge to its work force for training its manpower. It is trying to keep abreast with the latest happenings in the field by joining hands with inland and foreign universities like IITs, IISc, Cranfield University etc.

HAL is utilizing the established but limited facilities at NAL, GTRE and other DRDO labs for testing combustor, gas generator turbine, electronic components etc. However we do not have the facilities in the country to test compressors, HP turbines, power turbines of the order of 1 MW and above with matching speeds. Flying test bed and altitude test benches are the two major facilities which have to be established on case to case basis, which demand an investment of the order of 1500+ Crores. These facilities are expected to be established under the proposed AERO ENGINE COMPLEX by MoD as National Test Facilities.

On establishing and handholding the MSMEs, HAL is providing opportunities to be partners in development. There are 70+ vendors with AERDCHAL which are exclusively sensitized for engine development. They are onboard in the development stage itself so that there can be a smooth transition to production stage.

The Aircraft Upgrade Research and Design Centre (AURDC) has vast experience on Su30MKI, MiG series aircraft, which are the backbone of IAF fleet. Could you shed some light onto the latest operations in the centre?

AURDC is carrying out the integration of various indigenous / western weapons thereby enhancing the operational performance, reliability & combat capability of the Su-30 MKI aircraft. Towards this, the classic weapon project, integration of the BrahMosmissile, was developed and demonstrated, which has enhanced the potency of the Su-30 MKI aircraft by many fold is the, without the involvement of the Russian OEM. This weapon integration project was a first case internationally taken up for such a heavy class of weapon on a fighter aircraft. The D&D phase has been completed and HAL has already taken up the series implementation as per IAF requirements. Apart from this project, various new generation missiles and smart bombs developed by DRDO like ASTRA,

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New Generation Anti-Radiation Missiles (NGARM) i.e. Rudram-I, smart bombs like PGKHSLD, new smart Air to Surface Bombs and western weapon like SPICE-2000 are already integrated by AURDC. The integration of indigenous weapons RudramII, Rudram-III and Smart Anti Airfield Weapons (SAAW) has also been undertaken by AURDC. AURDC has also taken up the Development & integration of airborne stores and new systems.

Indigenously developed systems like the VOR/ILS, Radio Altimeter, TACAN, Multi-Function Displays, Solid State FDR, Passive Jamming system, CMDS have been integrated & introduced on Su-30 MKI platform. In addition to this, AURDC is working on projects like introduction of GPS & digital bus at weapon stations, indigenous development of Integrated Standby Instrument System and various other electrical rotables which are presently being procured from foreign OEMs. Also the indigenous content is being enhanced by Indigenisation of mandatory / non-mandatory spares, materials, required for line maintenance of the Su-30 MKI platform and Development of indigenous Tools, Testers and Ground Equipment (TTGE).

In order to make the aircraft available over a very long span, life extension programs for platform operations beyond the OEM specified life, has been launched and this life extension would definitely ensure availability of Su-30 MKI aircraft for a very long time. AURDC is also providing Technical Support to IAF for maintaining fleet serviceability to the highest level.

AURDC has also ventured into the development & Integration of new Systems and weapons and indigenisation activities for Non-HAL platforms like the MiG-29 K/KUB aircraft with the Indian Navy and the MiG-29, IL-76 and Russian Platforms with the Indian Air Force. AURDC along with other R&D centre MCSRDC, has also launched a new program on MiG-29 K of Indian Navy to make it combat potent through introduction of Laser Pod (LDP) and new laser guided bomb. This integration is being achieved though introduction of indigenous HAL Mission Computer and other major systems.

AURDC has also initiated integration of indigenous weapons like ASTRA, Anti Air Field Weapons and

general purpose bombs on MiG-29K of Indian Navy which shall increase the combat capability of this potent platform to the next level.

How does HAL promote the private participation and indigenization in defence and aerospace industry? As an industry expert, how much capable is HAL in promoting India’s export business?

As mentioned earlier in the case of LCA, the private sector has graduated from being suppliers of Detail parts to being long term business partners of HAL through supply of major assemblies and primary structures. HAL has been extensively tying up with Indian private partners in the areas of: • Manufacturing of Detail Parts • Assemblies (Mechanical incl. Hydraulic, fuel accessories, fuselages, wing assemblies, Electrical/Electronics incl. PCB assemblies, Transformers etc.)

• Composites, Rubber/ Plastic Parts, Tooling • Manufacturing of Electrical looms, panels, relay boxes etc.

• Maintenance, Repair and Overhaul activities • Work packages viz. Painting, De-painting, dismantling • Ground support/ Ground Handling equipment viz. GHEs/GSEs. • Design and Development of products and technologies • Quality control activities through “Third Party Inspection” (TPI).

The R&D Centres of HAL and some of the Production/MRO Divisions of HAL outsource the development of LRUs to various private companies.

In LUH, for example, the Smart Cockpit Display System, Standby displays, control panels, lighted panels, armour panels, fire detection box, lubricating pumps etc have been designed, developed and manufactured by private vendors. Although the true indigenous content in LRUs is quite modest at present due to the limited semiconductor/electronic components manufacturing capability in India, the situation is expected to improve in the future as the government has identified electronics manufacture as a priority area.

Going forward, HAL intends to expand the

vendor engagement to the Detail Design stage itself. In such a scenario, the vendor will do the Detail Design under HAL supervision, develop the necessary Tooling on their own and then supply the major assemblies. In this model, it is expected that a major part of the upfront investment will be put up by the vendor as a risk-sharing partner and the investment will be amortized over the Production run. Technologically, the Private vendor base in India can readily meet HAL’s expectations in this regard.

As the country acquires more and more indigenous platforms, as part of the Atmanirbhar Bharat, the associated ecosystem of manufacturing and ROH industry partners will get automatically benefitted.

Like the recent approval of 83 LCA Mk1A acquisition, which is going to be a game changer for the indigenous industrial parlance, there are a slew of indigenous products like other LCA Tejas variants, LCH, LUH, HTT-40, etc getting lined-up in offering from HAL, while the Defence Services are now looking for more indigenous options as compared to import and this will favourably impact the entire aerospace manufacturing ecosystem. Thus HAL aspires more and more participation of private partners and building healthy and robust ecosystem in India through its upcoming indigenized programs.

Coming to indigenisation, the indigenisation Cell at HAL head Office and at various Production Divisions regularly interact with potential private vendors by way of one-to-one interaction, conducting seminars / conferences/ exhibitions, participating in the seminars / conferences organized by various industrial bodies, physically as well as through virtual mode. The private vendors during these events are sensitized about the various indigenization opportunities available. They are also familiarised about Indigenisation Procedures, expectation from vendors and support provided

by HAL during indigenisation. More than 85 types of test facilities available at HAL are hosted for utilization by Indian industries on payment basis and is being utilised by both govt organizations and Indian private companies.

While certain Private companies are supplying Parts and Assemblies to foreign OEMs, HAL as on date remains the only Aerospace company capable of exporting Fixed Wing and Rotary Wing platforms.HAL is a major exporter among the DPSUs and HAL’s exportable Platforms have been Advanced Light Helicopter (ALH) - Dhruv and Do-228 aircraft. In addition, HAL also exports certain work packages, spares, services, etc. There are several enquiries from friendly nations for the LCA. Dornier and HTT-40 have tremendous export potential. ALH is already flying in foreign soil. The LCH also has very good export potential because it offers a significant fraction of the Apache’s

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capabilities at a fraction of its cost. Civil version of the LUH also targets the export market. Long term Product Support of the platforms in foreign countries is a challenge that HAL is working on.

Thus we have an array of exportable platforms in the offering from HAL which can significantly boost India’s export business.

HAL has also started participating in major Global tenders for Defence aviation platforms.

Channel partners are being engaged in prospective countries. Extensive support is being rendered by Indian Missions abroad in Export promotion.The export arm of HAL is also being strengthened to address the major upcoming requirements from various countries.

Thus HAL is fully capable in promoting the export business and with the introduction of the new Platforms into Export Market, aggressive approach in marketing efforts, government policy support, etc., HAL envisages significant enhancement in exports in the coming years.

Could you share with us your visions and priorities for HAL during your tenure? What are the goals set to achieve and what is the roadmap ahead?

If we look around us, technology is changing ever so fast with the blink of the eye. What is current today is ancient tomorrow. This is where the importance of R&D Centres comes in. There should be unfettered, unrestricted ideas that need to be thought of, pondered over, validated and converted into a design, all within a certain framework of time.

Considering our Company’s motto of supporting the Indian Armed Forces “Force Behind the Forces”, time is very precious. This means the onus is on us to support our Armed Forces with the very best, state-of-the-art platforms and products. This can be achieved only through a strong and vibrant R&D wing.

My vision is to see every helicopter flying in the Indian Skies shall be from HAL - designed,

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developed and manufactured. The 13 ton IMRH development will complete the entire gamut of military helicopters that will operate in India. Once the civil certification of ALH and LUH is completed, it will enable the fulfillment of this vision as every helicopter flying in the civil sector also, in the future, will be from HAL. After the successful certification of HTT-40 (Basic Trainer), IJT (Intermediate Jet Trainer) and development of Advanced Jet Trainer in the future, Indian skies would not have the need to look to foreign lands for these fixed wing trainer aircraft.

All the aero engines in the fixed wing and rotary wing platforms currently flying in India are designed and developed by Foreign OEMs. With the certification of Aero Engines being developed

by HAL, the fixed wing & rotary wing aircraft developed by HAL shall be powered by HAL Engines only throughout their missions.

On the challenging high altitude terrains of the Indian Army Base Camps, the HAL’s 200 kg. Rotary UAV platform will ensure continuous supply of provisions and equipment at all times in addition to its surveillance and mission roles.

HAL has already ventured into the realization of the futuristic concept of Combat Aircraft Teaming System (CATS), which will effectively tap the complete synergistic potential developed by the manned and unmanned systems in action. The system comprises of a large number of various unmanned flying assets that will be centrally controlled and directed by a manned mothership.

While the mothership stays inside the Indian territory, these autonomous flying assets swarm into the enemy territory and carry out the requisite missions.

All these ventures of HAL are just a few to name. There are innumerable milestones to be accomplished and HAL is all enthusiastically and optimistically set to embark upon this Roller coaster journey into the skies.

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HAL: Factors of Supreme Dominance M.S. Velpari, Director (Operations), HAL, recounts how magnificently HAL, India’s flag bearer in Aerospace Industry, has evolved into a leading global player in Manufacture of Aircraft, Helicopter, Engines, Accessories and Avionics Systems.

He expounds the significant elements of HAL’s futuristic vision for Excellence in Aerospace and Defence - to “Conceive, Indigenise, Collaborate” in this interview with AEROMAG. Excerpts from the interview: M.S. Velpari Director (Operations) HAL

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The history and growth of Hindustan Aeronautics Limited (HAL) is synonymous with the growth of aeronautical industry in India for around eight decades. Could you share with us some of the major achievements of the company in the recent years?

HAL plays significant role in domestic Aerospace industry in terms of service provided to Indian Armed Forces for over 80 years and development of Indian aerospace manufacturing eco-system.

Yes, it’s a great achievement, to be the flag bearer of Aerospace industry and propelling the ‘Make in India’ dream of the country. We are the only company in the country capable to undertake end to end product development from concept to delivery, and also providing life cycle support for the fleets of Indian Defence Services well over 40 years for HAL manufactured as well as bought out platforms.Today, HAL capability spectrum includes: • Manufacture of Aircraft, Helicopter, Engines, Accessories and Avionics Systems • D&D of Platforms, Aero-engines and Accessories and Avionics systems • Maintenance, Repair and Overhaul (MRO) of platforms, aero-engines and systems • Manufacture of Structures for Launch vehicles and Satellites • Aircraft Mid-life upgradation

• Missiles and Defence Systems Integration on existing platforms • D&D and Manufacture of UAVs I would like to mention a few major achievements of the company in the recent years: • HAL became listed company on BSE and NSE. • FOC upgrade of Mirage 2000 and acceptance

by Air HQ • Successful integration of Astra Missile on Su-30 MKI • Successfully flown the LUH from Greenfield Helicopter Manufacturing facility, Tumakuru and also met the timeline given by the Prime Minister of India during foundation stone laying ceremony at Tumakuru on January 3, 2016.

• The HTT-40 basic trainer aircraft has successfully demonstrated 6-turn spin capability. With the spin capability proven, HTT 40 has demonstrated compliance to all the PSQR requirements and is moving towards its final certification.

• The LCA Naval Prototype (NP1) designed jointly by HAL and ADA successfully performed ski jump take-off and arrested hook landing from ship INS Vikramaditya on January 11, 2020. It is the first indigenous aircraft which successfully took-off from ship and landed on a ship. Through this major achievement, India joins the elite club

of five nations who have developed a Naval fighter aircraft. These will be major technological inputs in the development and manufacture of the twin engine deck-based fighter.

• The first aircraft from LCA Mk1 FOC block, ferried-out on May 23, 2020, marking a stupendous feat for both HAL and the Nation.

• Adding to the indigenous engine capability, a 60kW Gas Turbine Engine (GTEG-60), the Auxiliary Power Unit (APU) for the Military Transport aircraft AN-32, designed and developed by HAL AERDC attained operational clearance on May 28, 2020.

With this HAL has entered into the league of select few global agencies having the capability to develop airborne APUs. The control unit of GTEG-60 is also designed and developed in-house by HAL SLRDC. • HAL IISc Skill Development Centre (SDC) established at IISc’s Challakere campus through a video conference on August 13, 2020 inaugurated by the Defence Minister. SDC will impart skills to various beneficiaries ranging from local community members to high-end engineering professionals to usher true ‘Make-in-India’.

• The tail boom folding operation on ALH was successfully demonstrated on ALH Mk-III helicopter on November 7, 2020. In combination with the existing two blade folding, the achieved stowage dimension of ALH (13.5 m in length, 3.5 m in width and 4.1 m in height) meets Indian Navy’s NUH specification. Qualification and certification of the tail boom scheme is under progress.

• Chief of the Air Staff undertook his maiden flight on LCH on November 20, 2020. The flight lasted for about an hour and the Chief said, “The LCH is a potent platform due to excellent D&D efforts and well supported flight test team. The IAF is keenly looking forward to the induction of this aircraft.”

• As a success story of the Aerospace Manufacturing Ecosystem development efforts of HAL and a boost to LCA production, the first outsourced ‘Front Fuselage Assembly’ of FOC LCA Tejas was successfully rolled out by Dynamatics Technologies Limited (DTL), Bengaluru and ‘Rear Fuselge Assembly’ from Alfa Tocol Pvt. Ltd., Bengaluru, with necessary approvals from DGAQA. • The biggest Cryogenic propellant tank (C32 LH2) ever fabricated for ISRO, was made by HAL in Bangalore and was delivered to ISRO on November 28, 2020. The four meter diametric tank is of eight meter length to load 5,755 Kg propellant in the 89 cubic meter volume. Total length of weld carried out in the tank was 115 meter at different stages to such stringent quality requirements.

The LCA project is going through a critical phase and HAL has to ramp up the pace of production to cater to needs of Indian Air Force. Could you share

the latest updates of the project?

I would say the critical phase for the LCA production is already over and now HAL is concentrating on integrator role as we have developed strong vendor base of 500+ production partners towards supplying from detail component to major structure module like wing, front fuselage etc. LCA Tejas is the first aircraft wherein HAL has gone ahead for such level of outsourcing. The same model will be further amplified during execution of 83 order wherein HAL is targeting to enhance the production rate 16 aircraft in a year.

Apart from extensive outsourcing, HAL has created the civil facilities to house the additional production line of LCA to achieve the desired production rate. The additional facility would be spread across 35 acres and have a built up area of 34,893 square metre (sqmt). The phase -1 of the facility is ready and is spread across 24,077 sqmt and would be functional from February 2021.

Specialised facilities for Heat Treatment, special processes and hangars for structural assembly of aircraft are being created in this new Complex of LCA Tejas. Production tooling and productivity improvement initiatives have also been undertaken by adopting latest simulation software packages under capacity augmentation. I hope with these measures HAL would be able to give the desired production rate for LCA Tejas.

You have championed the task of Indigenisation of various parts used in the HAL products. How strong are the indigenisation activities of HAL in various departments? How does the company support Atmanirbhar Bharat vision?

Indigenisation activities are being carried out on a continuous basis across HAL with an aim to ensure self-reliance through reduced dependency

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on foreign OEMs. In fact, Indigenisation is one of the key thrust areas of HAL. Over 95,000 parts used in various HAL products have been indigenised since 1994-95, the highest ever by any of the Defence PSUs in India. HAL has formed dedicated indigenisation department across various HAL Production units to carry out indigenisation activity. Indigenisation Department at Corporate Level coordinates and monitors the indigenisation activities companywide and formulates the policies and procedures in this regard. Therefore, indigenisation activities across various Divisions of HAL are quite strong.

HAL in the last three years had indigenised on an average 1,700 nos. of items and will enhance under the new policies announced by Government of India.

Regarding Atmanirbhar Bharat vision of Government of India, HAL is in the forefront of this initiative. To support Atmanirbhar Bharat, HAL has identified more than 2,500 items for indigenisation during the next five years. These items include over 1,000 items specifically identified for indigenisation under Make-II. HAL’s Make-II procedure is an important step towards self-reliance which is in compliance of the Make-II framework promulgated

by Ministry of Defence and envisages the assured order quantity after successful development of items through private vendors. HAL has started issuing EOIs for indigenisation of items identified against Make-II in a phased manner. HAL has hosted details of items for indigenisation in its website with the contact details of nodal officers responsible for indigenisation.

To further boost Atmanirbhar Bharat, details of imported items being populated on continuous basis by HAL in the Srijan Defence Portal as per the recent initiative by the DPIT, MoD to facilitate

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import substitution through Indian Vendors. HAL also keeps organisng/participating in various seminars, exhibitions and vendor development programmes regularly to promote indigenisation.

To help Indian vendors in carrying out the testing required during the course of Indigenisation, HAL has hosted details of test facilities available at HAL for their probable utilization. In addition, implementation of Public Procurement (Preference to Make in India), Order 2017 of MoD at HAL will go a long way in further import reduction. HAL is also supporting by way of investing in HAL units under the Defence Industrial Corridor. All these steps will support Atmanirbhar Bharat vision and would definitely help expanding the aerospace and defense eco-system in the country.Further, HAL’s Aero India 2021 theme “Conceive, Indigenise and Collaborate” is inspired by the efforts towards Atmanirbhar Bharat Abhiyan.

Could you talk about the latest operations of the Helicopter division of HAL? How strong are the production lines of the company?

Helicopter Complex of HAL has state of art manufacturing and overhaul setup comprising of four divisions and well supported by private players in the ecosystem. Helicopter division is the production division engaged in production of ALH, LCH, Cheetah, Chetak and Cheetal.

Aerospace composites division supports production of helicopters by supplying composites parts for ALH and LCH. Helicopter MRO division caters to maintenance and overhaul of ALH, while Barrackpore division is supporting maintenance and repair requirement of vintage fleet (support is continuing for last six decades) of Cheetah Chetak.

Currently Helicopter division is executing 72 ALH contract comprising of 40 ALH (22 Mk-III and 18

Mk-IV) for Army and 16 MK-III ALH each for Indian Navy (IN) and Indian Coast Guard (ICG).

For the 40 ALH for Army, 22 Mk-III ALH and 7 Mk-IV are already produced. Remaining 11 MK-IV ALH will be completed by 2022. We are ahead of contractual schedule in producing these helicopters.

16 ALH contract of IN and ICG are Mk-III version of ALH but configured with 19 new systems making it a very potent machine for missions important for Indian Navy and Coast Guard. The 19 new systems like Electro Optic Pod, Traffic Collision Avoidance System (TCAS), Surveillance Radar, etc. enhance capability of Mk-III helicopters for surveillance, SAR and interdiction missions for coastal security.

First green helicopter was used for integration of 19 new systems involving sea trials at Kochi, Chennai and Goa. RCMA has issued operational clearance for ALH MK III of IN and ICG on January 20, 2021 and January 23, 2021 respectively. Three ALH MK III helicopters are ready for acceptance of IN and two for ICG. Four more helicopters are scheduled for delivery to IN and five to ICG by March 2021. Remaining helicopters for 16 ALH contract of IN and ICG will be delivered by 2021-22.

HAL has also started production of limited series production (LSP) of LCH pending receipt of contract. Three LCH are planned to be offered to customers for early exploitation based on Letter of Intent. The contract of 15 LSP LCH is in final stage and expected to be signed soon. Delivery of 15 LSP LCH is will be completed by 2022-23. Further order for more than 145 LCH is anticipated.

HAL is also gearing for productionisation of LUH helicopters. Initial operational clearance (IoC) for Air Force LUH has been received and IoC for the Army version is expected soon. It is expected that initial order for 12 LSP LUH shall be awarded followed by 175 for the series production of LUH. HAL has

planned to roll out first LSP LUH in year 2022 from the New Helicopter Factory at Tumakuru. The new Helicopter factory is being established in a land area of 615 acres with Industry 4.0 norms and will cater to production requirements of all future helicopters including LUH. HAL has also taken up design and development of Indian Multirole Helicopter (IMRH) which is a 12-ton class helicopter, planned for both military and civil roles. The military version of IMRH could be used for roles such as Air Transport operations, Combat logistic support in high altitude and in tactical battle area, Carriage of under-slung loads, Casualty evacuation etc. The IMRH will replace Mi-17 fleet of services. Civil helicopter would be suitable for roles like offshore operations, disaster management, VIP transport, coastal security etc.

With lot of pride, I would like to state that all Helicopters requirements of our Armed forces can be met by HAL, since all capabilities for Helicopter development and manufacturing are with HAL and eco-system within the Country. HAL can be a one stop solution for Helicopters of all categories.

What are the highlights of HAL’s export activities?

How does the company support the government’s vision of diminishing the importer image of India?

So far, HAL’s Exportable Platforms have been Advanced Light Helicopter (ALH) Mk III– Dhruv and Do-228 aircraft. Presently, in the rotary wing side ALH-Mk-IV and Light Combat Helicopter (LCH) and in the fixed wing segment Light Combat Aircraft (LCA)-Tejas have also been added to the basket of HAL’s exportable Aircraft Platforms. In the near future, Hindustan Turbo Trainer (HTT)-40 and Light Utility Helicopter (LUH) will also be pitched in the export market.

HAL is planning to move to platform supplier from

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existing Tier-I, II supplier of Aerospace segment.

HAL has adopted multi-pronged approach and envisages the enhancement in Exports in the coming years.for enhancing exports. The major activities are: Export Strategy: HAL has drawn up an elaborate Export strategy.

Extensive Market study has been done and Target Countries in four regions - SAARC, South East Asia, Africa and Indian Ocean regions - have been identified for export of HAL Products and Services.

In addition Latin America and Middle East countries are also being explored for possible Business opportunities.

In October 2020, eight select countries have been allocated to HAL by Export Promotion Cell (EPC), MoD, for promotion of Products and Services of entire Indian Defence Industry.

Notwithstanding the above, Global RFI/RFPs are also being tracked and responded wherever HAL Platform/Products matches the requirement.

Marketing & Distribution / Service network abroad:

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As on date, HAL has engaged Channel Partners in several of the shortlisted Target Countries. The engagement of Channel Partners/Marketing Agent/ Distributors/Business Development Consultants for promotion of Export business in other target Countries are in process, on an on-going basis.

Interaction with Defence Attaches / Missions: Regular interactions with the Defence Attaches / Indian Missions in the target countries. Regular interactive sessions with Foreign Defence Attaches / Foreign Missions are also being conducted in order to establish rapport and formal network for gathering Business Intelligence.

Foreign Supplier Registration: In order to track / receive Global RFI/RFPs directly from the customer, HAL has registered in the procurement portals of various Countries.

Registration in other countries is also being done on on-going basis.

Export through G-2-G route: Export opportunity is also being pursued through G-2-G channel in certain target countries which

follows G-2-G route for Platforms namely Do-228 and ALH. The effort includes exports utilizing GoI Line of Credit (LOC).

Branding & Promotion: As part of Brand building and Promotion for reaching out to prospective customers, HAL has been participating in prestigious International Air Shows and Exhibitions considering the business opportunities in the region. Also HAL is the Nodal Agency for organising Aero India and Defexpo, which helps to project the Company’s Brand Image.

Flying display by joint participation with IAF and other Stake holders like ADA to showcase the capabilities of HAL Products to Overseas Customers is also being undertaken.

International Certification of HAL Platforms for Civil use: The process of obtaining International Certification is in progress and this will help HAL Platforms export in the civil market.

Interactions with EASA, Germany was held along with DGCA. In-principle consent was received that DGCA could give type certification for HAL built Do-228. Similarly EASA certification for Dhruv-ALH is also being progressed.

Efforts in other diversified areas: HAL has also been tapping other potential areas for enhancement in export sales apart from sale of Platforms and ROH Business such as: • Pilot Training.

• Aircraft Upgrades.

• Indigenous upgrade on Licensed platform.

• Design Work Packages • Export of indigenously Designed and Developed Avionics With the focused approach and varied offering of Platforms in several niche areas coupled with associated products realized through backward integration (eg. Avionics, Accessories and Engines), HAL is slowly but steadily expanding its basket of offerings which are leading to reduced dependence on imports of such items.

With about 35 years of experience in the areas of manufacturing, assembly, design, indigenisation and other management functions, in both fixed and rotary wing platforms, how do you assess the progress of HAL’s operations? What are you visions and priorities for the company?

Let me recall the famous words of former Indian President Dr. APJ Abdul Kalam: “Dream, Dream, Dream, Dreams transform into thoughts and thoughts result in action” I have dreamt about vision of achieving selfreliance in Defense through HAL very early in my

professional carrier. A phenomenal number of 1,850 types of Castings, Forgings Rolled Rings and Rubber Products were indigenised under my guidance in spite of challenges in terms of technology and industry ecosystem in those olden days. Many technologies which are being discussed today were implemented quietly early by me and my team in HAL. My vision is to make India self-reliant in defence.

Self-reliance could be possible only through innovation, technology development (in key areas like Power Plant and Artificial Intelligence), industrial collaboration and supportive Government Policies. HAL would continue to play prime role in this direction.

We all should transform this into thoughts and act proactively to realize this dream through collaboration among industries (including MSMEs and Startups), Research centres and academia.

Aligning with this greater initiative, HAL has put in place Vision-2030 along with strategies and priorities of implementation during next 10 years. I would like to emphasize on a few important areas of focus in this regard.

Achieving double digit growth: HAL is consistently growing in range of around 6-7% and target is to achieve double digit in next 6-7 years. This will be quite challenging considering the fact that orders in defence segment always follow sinusoidal curve and significant value of sales of HAL is from Indian defence segment. We have contemplated certain actions in this regard to counter this challenge.

First Maharatna DPSU: HAL has vision to become first Defence Maharatna PSU, before 2030.

Expand Product portfolio and Diversification:

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To support our growth plan, HAL intent to expand Products and Service offerings to domestic and international customers. We are equally focusing on other market segments mainly commercial and export markets apart from Indian defence.

Certain areas of realignment and diversification in Aerospace and allied Business are being worked out.

The Covid-19 epidemic has caused disruption in Industrial market forecasts throughout the world and even to achieve pre-Covid level estimates, it takes at least a year from now. Future is always dynamic and HAL strategies will be agile enough to handle such unprecedented challenges.

Apart from others, there are key opportunities for growth and diversification in the long run mainly in UAV segment, Civil Aircraft MRO services and consultancy services. These will be also focus areas.

We have lined up quite a substantial workload towards design and development projects and production orders to this great organisation. We are back with full flow now, as you see from the platform lined up for design, development and deliveries apart for existing like ones LCA MK1A, LCH, LUH, HTT-40, IJT (spin trails under progress), LCA MK-II, AMCA, TEDBF and IMRH. Many of these projects are in final design phase/ entering into production/ production stageare being given utmost importance.

Geostrategic Reach: In line with the Government’s vision for CPSEs to increase Geostrategic Reach, HAL has envisioned to increase its Geostrategic Reach in select countries.

Selling products and services in the select countries and setting up Marketing Offices/ third party service providers outside India is envisioned for expanding and supporting export business.

Innovation and Technology development As a mentioned earlier, Innovation and Technology development are most important drivers of achieving self-reliance under Atmanirbhar Mission of Government of India. As country and company, this is game changer and make greater impact as compared to transfer of technologies from foreign OEMs. The war scenario is going to change in future and greater emphasis will be on unmanned systems and artificial intelligence.

HALs R&D efforts will be in this direction to develop Combat Air Teaming system and its elements through in-house development and through partnership with other organisations.

Engine technology is also prime driver to become self-reliant and HAL’s two projects on engine development in respect of fixed wing and Rotary wing are going in full swing and they are sure to get certified.

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HAL is also going to take the lead role in development and production of high thrust engine for India’s future fighter projects like AMCA (in collaboration with DRDO).

We have many in-house R&D projects like Indian Multi-Role Helicopter (IMRH), Civil Certification of Light Utility Helicopters, UAVs etc in pipeline.

I am proud to highlight that with development of IMRH, India will be one of hardly 5-6 countries in the world, which has achieved milestone of design and development of all class of Helicopters.

We are working closely with IITs, Startups apart from DRDO labs in terms of technology development in various fronts including artificial intelligence.

Customers and Shareholders Delight: Most importantly whatever we innovate, produce and supply shall keep our customers happy in terms of performance (operational superiority), cost and timelines of products/services.

We are implementing many initiatives in this regard to improve operational efficiencies, cost reduction, futuristic technology development which makes our products differentiated with competitors, project management, talent management, continuous training and mentoring of our valued human resources, digitization, deployment of Industry 4 and many more.

After sales support management is key for customer delight and we are aiming to digitize many things in this regard in cooperation with customers, which will improve tracking, response time and set priorities and strategies to ensure continued support to end customers.

HAL is already listed company with disinvestment of about 25%. We have to add value to our investors/shareholders in terms of return and increase market capitalization.

I am sure focused vision and agile strategies will take HAL to become a lead global player while keeping our customers, partners, shareholders and employees happy.

In conclusion, I can say that, HAL has progressed significantly in many frontiers of technology, operations, after sales support etc since its inception and continue to strive for the best in our endeavour to be a leader in Aerospace and Defence and preferred choice of our esteemed customers.

We will aim and achieve to deliver “Excellence in Aerospace and Defence” in years to come.

HAL focused on increasing the pace of LCA production

Amitabh Bhatt CEO (Bangalore Complex) HAL Established in 1940 and having manufactured over 2000 aircraft, the Aircraft Division of Bangalore Complex (BC), is one of the oldest divisions of HAL. Could you share with us some of the major achievements?

Tracing its roots back to 1941, Aircraft Division, Bangalore complex was initially involved in major repair and overhaul of various aircraft, now builds military training and fighter aircraft.

Aircraft Division over the years has acquired the know-how, developed infrastructure required to manufacture variety of fixed wing Military trainer aircraft. Aircraft Division along with Overhaul division with their vast experience is providing maintenance, repair, and overhaul (MRO) services including Upgrade of aircraft to improve field operations and extend the life of legacy military aircraft (40+ years) to maintain the fleet.

The highly skilled field service teams positioned at Aircraft Division deliver high performance at preventive maintenance to maintain operational and high serviceability of the Aircraft. For achieving this, the division have worked tirelessly towards mitigating obsolescence issues by indigenizing

LCA- Tejas Division of the HAL Bangalore Complex was established in the year 2014 exclusively for the manufacture of LCA Tejas aircraft. In LCA Tejas project, HAL built technologies from scratch including an industrial base (due to technology denial) in spite of shortage of skilled workforce. The division is currently undertaking efforts to expand production capacity from 8 to 16 aircraft per year through the creation of new state-of-the-art manufacturing facility at Bengaluru. It would be spread across 35 acres and has a built up area of nearly 35000 square metres. The phase-1 of this facility is ready and it is being created to produce the LCA trainer aircraft, LCA Tejas aircraft variants and also as a dedicated export facility, said Amitabh Bhatt, Chief Executive Officer (Bangalore Complex), Hindustan Aeronautics Limited (HAL). In an interview with Aeromag, he talks about the operations of HAL - Bangalore Complex.

equipment or by stockpiling inventories or by finding alternate vendors for equipment for which OEMs have stopped production long ago.

Aircraft division has produced its first license aircraft Vampire (rather HAL’s first aircraft), under license from M/s. De Havilland Company, U.K. in 1950 and then Gnat Aircraft from M/s. Folland Ltd., U.K. in 1956. Subsequently the division produced the indigenous Marut Aircraft (HF-24) in 1961. Thereafter the saga continued with the production of Ajeet, Kiran, PTA Lakshya indigenous aircraft followed by Jaguar & Hawk aircraft under transfer of technology from BAES, UK. Currently, Aircraft Division is also manufacturing LCA Tejas aircraft.

Aircraft division also has capability in export of its precision aero-structure components viz. Forward Passenger door for Airbus A-320, Gun bay door for F-18 to Boeing, Uplock box assembly for B-777, aircraft components for B-757 & B-737 aircraft, Weapons bay door for P8I, Shoulder & center line pylons for Tornado fighter aircraft, Horizontal stabilizer for Fokker-50, G-150 rear fuselage & B-737 cargo conversion kit to IAI, etc.,.

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The Hawk-Advanced Jet Trainer is the most prestigious product of the aircraft division. What are the highlights of its operational capabilities and where does Hawk stand globally?

Hawk Mk-132 aircraft is being produced at HAL under license from BAES, UK. Hawk Mk-132 is a transonic tandem-seat multi-purpose aircraft, powered by a single Rolls Royce Adour Mk-871 turbo fan engine with a minimum take-off static thrust of 25.5 kN at sea level.

Hawk Mk-132 aircraft provides basic and advanced training to the pilots. Hawk Mk-132 aircraft also performs aerobatic maneuvers.

HAL has manufactured and delivered 99 nos. of Hawk Mk-132 aircraft to Indian Air Force and Indian Navy and has the capability of providing comprehensive product support like supply of spares, aircraft servicing including repair and overhaul.

At present Hawk is the widely used aircraft for the advanced training role. This aircraft is being used in UK, Australia, Oman, Finland, Saudi Arabia, Indonesia, Malaysia, South Africa, UAE etc., Recently HAL has kicked off the spin testing of jet trainer that is planned as a replacement for IAF’s ageing Kiran aircraft fleet. What are the latest updates of the project?

Intermediate Jet Trainer (IJT) is indigenously designed and developed by Aircraft R&D Centre (ARDC), HAL to replace the ageing Kiran aircraft fleet. Developmental Flight testing has been completed in the entire flight (Speed & Altitudes) and load (‘g’) envelopes. Developmental Flight testing for systems performance, armaments, drop tank carriage and jettison, hot weather, sea level trials etc. are completed.

Challenges are not unusual during ab-initio

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design and development of any aircraft and IJT is no exception. Several technical challenges were encountered and adequately addressed during the development phase.

The sole unfinished task towards certification of aircraft is demonstration of its spin characteristics.

Based on the recommendation from a reputed aerospace engineering consultancy, two aircraft were suitably modified.

Spin, being an extremely risky maneuver, it is mandatory to install ASPS (Anti spin parachute system) before spin flights are undertaken on prototypes. It is to ensure that the aircraft is recovered in case the controls are unsuccessful, to recover from spin. ASPS system was installed.

Ground and flight streaming of parachutes were successfully completed in Oct 2020. Spin flight trials have since resumed in Nov 2020 and the flight test data analysis is in progress.

Over the past seven decades, the Engine Division has collaborated with global companies in the area of design, development, manufacture and maintenance of various aero engines but even now India is facing challenges in terms of aircraft engine development? What are the challenges and how can we resolve it?

Engine Division, Bangalore established in the year 1955 is involved in manufacturing and maintenance of various aero engines under License (Transfer of Technology) from OEMs of European and USA origin. Major aero engines manufactured/ repaired/ overhauled by Engine Division include aero-engine Orpheus for Kiran Aircraft, Dart for Avro aircraft, PTAE-7 for the pilotless target aircraft, Adour Mk-811/ 804 for Jaguar Aircraft, Adour Mk871 for Hawk Mk-132 Aircraft, Artouste III B for Cheetah/ Chetak Helicopter, Garrett TPE331-5 for Dornier Do-228 Aircraft and Shakti for ALH Dhruv

Helicopter.

In most of these transfer of technology contracts, manufacturing technologies i.e machining knowhow, AIT (Assembly, Inspection and Testing), repair/ overhaul technologies were granted to HAL. The associated design activities are carried out by OEMs and are retained with them. Also, core Engine parts, critical castings/ forgings and LRUs are kept with the engine OEM’s under the zone of restricted/ proprietary items. Therefore, even today, most of the critical core engines components/ castings are being imported from foreign OEMs. Engine Design Bureau (EDB) of Engine DivisionHAL did attempt to design and develop small aero engines. Few products which resulted in the process are the 4 kN thrust turbojet engine (PTAE7) used on Pilotless Target Aircraft (PTA), 110 kW power turbo shaft engine (GTSU-110) for starting the Light Combat Aircraft (LCA) engine and its upgrades, Auxiliary Power Unit for FGFA class aircraft and accessories like air turbine starters, turbo chargers etc. EDB also collaborated with M/s Safran Helicopter Engines (then Turbomeca), France for the co-development of Shakti Engine, a 1000 kW shaft engine for the Dhruv helicopter and contributed for development of some of the accessories.

Today the R&D unit AERDC (Aero Engine Research and Design Centre) is engaged in Design and Development programs for fixed wing and rotary wing platforms namely: a) Hindustan Turbo Fan engine (HTFE-25) of 25 kN thrust which can power trainer aircraft, UAV’s, Twin engine small fighter aircraft or regional jets and b) Hindustan Turbo Shaft engine (HTSE-1200) of shaft power rating which can power Light &

Medium weight helicopters (3.5 to 6.5 tonnes in single/ twin engine configuration) HAL is confident of achieving the targeted design parameters towards productionisation of these engines.

Development of military Aero-engines from abinitio design is a technologically complex task.

Only a handful of manufacturers have been able to achieve global standards and stature. Few challenges in the field of new engine development are critical technologies like Raw Material technologies for engine turbine blades, turbine discs, Casting technologies for blades, Forging technologies for discs, Coating/ Surface treatment technologies for turbine blades, Technologies for Controls like Full Authority Digital Electronic control (FADEC), Technologies for engine Accessories like Fuel pump etc. Further, availability of testing facilities and flying platform, require extremely high investment accompanied with high risk and longer gestation period.

In India, very few agencies viz. GTRE, AERDCHAL, NAL, have attained capability in the design & development of Aero-engines, after working for more than five decades.

HAL is keen for fruitful collaborations on potential business partnership with GTRE/ DRDO, CSIR, Govt Labs, leading premier institutions and private industry with Govt funding. We are open for foreign technical collaborations for critical technologies in the field of aero engines.

With the progress achieved so far on the indigenous development of Turbo-shaft and Turbo-Fan engines, HAL is confident, indigenous development of Aero-Engine would pave way for future Fixed Wing & Rotary Wing aircraft in the coming years.

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The LCA Tejas Division of BC is the principal partner in the LCA programme with Aeronautical Development Agency (ADA).

How strong are the production capabilities of the division and what is the present status of LCA production?

LCA- Tejas Division was established in the year 2014 exclusively for the manufacture of LCA Tejas aircraft. As you may be aware, in LCA Tejas project, we had build technologies from scratch including an industrial base (due to technology denial) in spite of shortage of skilled workforce.

Progressively, the manufacturing infrastructure has been established to produce at the rate of 8 aircraft per annum. The division is currently undertaking efforts to expand production capacity from 8 to 16 aircraft per year through the creation of new state-of-theart manufacturing facility at Bengaluru.

This facility would be spread across 35 acres and has a built up area of nearly 35000 square meter. The phase-1 of this facility is ready and is spread across over

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24000 square meter. This facility is being created to produce the LCA trainer aircraft, LCA Tejas aircraft variants and also as a dedicated export facility. Further, this facility is being geared up for handling structural assemblies of LCA Mk-1A. Facilities such as paint shop, modern storage racking system, environment controlled structural hangar, robotic drilling facility, fuel slushing hangar, drop tank hangar extension, rain water test facility and dedicated captive power supply for division have been established to streamline production.

Coming to the current production status, LCA division has delivered 16 LCA fighter aircraft in IOC configuration and also started supply of 16 LCA fighter aircraft in FOC configuration to IAF squadrons.

HAL is also supporting these squadrons established at Customer bases.

With Two decades of experience in private sector, you know how important it is to augment the involvement of

private player in the aerospace industry. What are BC’s activities to support government’s vision of increasing private participation?

Bangalore complex, HAL is fully committed to support government’s vision of private industry participation in aerospace. LCA, “Jewel in the India Sky” program is a good example for “Aatmanirbhar Bharat”. LCA Tejas program follows the system integrator model and has created a national aerospace ecosystem with the participation of approximately 140 Design agencies and 100 production agencies (which also include private industry participation) which encompasses all the facets of aircraft design and manufacturing. In addition, it is estimated that as the LCA MK1A program kicks-off, it will generate additional jobs across the country in the private sector.

HAL has already assumed the role of an umbrella organization which fosters local industry and drives skill development of young Indian work force.

For the first time in the nation’s

aerospace history, HAL has partnered with Indian private players to manufacture aircraft fuselage and wings. Electrical looms and rotables of the home – grown fighter has a high level of contribution from Indian private industry.

How did BC survive the operational and service challenges posed by the Covid-19 pandemic? Could you share with us your visions and priorities for BC over the next few years?

Covid-19: HAL was under lockdown due to Covid-19 pandemic from 24th March to 27th April 2020 and re-opened on 28th April 2020 as “..HAL is stated to be providing essential support service to Indian Air Force (IAF) for maintaining Operational preparedness…’’ (as per MHA (Ministry of Home affairs) guidelines).

National/ State Covid-19 directives and Standard Operating Procedures have been enforced in our offices/ shops and these include staggered shifts, suspension of biometric attendance and sanitization of all work areas in between and during the shift frequently. Widespread publicity and circulation of Do’s and Don’ts to bring awareness among the employees. Masks and gloves have been distributed to employees and wearing of mask at workplace is practiced. The workplaces and tools are disinfected using safe disinfectants. Hand

sanitizers are placed at entry and common areas in offices/ workplaces. Thermal screening for body temperature of all personnel is done at the entry points. Also, HAL has introduced an IT platform for agile video conferencing and online e-files to minimize the physical interaction.

Covid-19 pandemic has seriously affected the following: a) The production activities of various aircraft, aerospace and engine programs at HAL was seriously affected. The production target planned in the beginning of the year was calibrated to adjust with the limitations brought into HAL operations due to the pandemic. Subsequent to re-starting of operations, the manpower is distributed across shifts which leads to discontinuity in manpower intensive operations such as riveting, layout of Composite components etc. b) The humungous supply chain of HAL was affected due to delays injected by Covid-19 pandemic. Detailed parts of various aircraft and engine program are outsourced to private vendors across India. Some of these vendors have just started their operations and is affecting supply of major parts (like Fuselages) for LCA production.

Further, deputation of HAL inspection teams to these vendors is affected due to the quarantine norms. Also, the realization of supplied parts by

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our private partners was delayed due to inter-state travel restrictions as per government mandated guidelines. Line Replaceable Units (LRUs) and Spares from Sister Division’s was also delayed due to logistic issues c) Raw Materials/ Spares supply from foreign source are delayed due to suspension of international flights/ operations. Major foreign suppliers had indicated that Covid -19 epidemic constitutes Force Majeure event which would potentially affect their scheduled deliveries and activities to HAL due to disruption in their supply chain. This is especially affecting the supplies from USA, UK and France. d) Deployment of HAL repair teams to bases of IAF, IN and Indian Army for providing customer support was affected due to the quarantine norms.

HAL is continuously communicating with its partners regarding status of their operations post lock down and their plan for supply of items to HAL. Few suppliers are yet to communicate their revised schedules as they assess the delay with their sub-contractors for supply of the parts post lockdown.

Way forward for future Production : Bengaluru Complex established in the year 1940

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has now grown to eight Production Units and two Service Units. The priorities/ future plan of the divisions of Bangalore Complex are as follows: Aircraft division is planning to enhance its export capability for precision aero-structure components.

LCA Division is planning to enhance its production capacity from 8 to 16 aircraft per annum and gearing up for manufacture of LCA Mk1A aircraft.

Overhaul Division established in 1940 facilitates Repair and Overhaul services for the Mirage 2000, Kiran, Jaguar and Hawk Mk-132 aircraft and also undertakes the Jaguar Darin-III and Mirage 2000 upgrades, apart from servicing of various types of rotables of aircraft and helicopters. With its successful expertise gained over 7 decades, the Overhaul division is geared for up-gradation of future IAF fleets of Hawk, LCA variants.

Engine Division shall export precision engine parts to major foreign OEMs including Maintenance, Repair and Overhaul (MRO) of engines in the coming years.

Industrial Marine Gas Turbine Division (IMGT) involved in the manufacture repair and overhaul of industrial and marine gas turbines which are typically used in power plants and marine vessels is also planning to enhance its operations and services to various shipyards.

With robust manufacturing facilities, the Foundry and Forge Division established in 1974 is capable of manufacturing of rolled rings, castings, forgings, ceramic brake pads, bimetallic sector for brakes and rubber components to meet domestic and export markets.

With capabilities established at the Aerospace Division in 1988 the Division has immense potential to manufacture of light alloy structures and assemblies for satellites and advanced launch vehicles for future space missions of the Indian Space Research Organisation (ISRO).

The Airport Services Centre established in 2000 is fully equipped with advanced take-off and landing facilities, duly complied with regulations of International Civil Aviation Organization (ICAO) in terms of maintenance of Air-field, Air Traffic Control and allied services at HAL airport to meet anticipated domestic airport operations of Bangalore.

With anticipated production orders of indigenous fighter aircraft viz. LCA Mk-1A, Mk-II, AMCA, HAL’s Bengaluru Complex has a full potential for Production, Repair and Overhaul of Aircraft and Engines apart from the Aircraft of Indian and Western origin.

With demonstrated presence and growth of domestic Aerospace market, it is expected that Production Units of Bangalore Complex will surely have opportunities to develop its export market, progressively.

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HAL’s copters soaring to bigger heights The Helicopter Complex (HC) of Hindustan Aeronautics Limited (HAL) enjoys a glittering track record, having designed and developed products such as ALH, which will match any helicopter of its class in the world.

S Anbuvelan, CEO of the complex, elaborates on its functioning, capabilities and prospects.

S.Anbuvelan CEO, HC - HAL

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The helicopter division, established in 1970, is celebrating its golden jubilee and the division has been the backbone of India’s chopper manufacturing industry over these decades. Could you share with us some the major milestones in the success journey?

The beginning of the manufacture of Helicopters in HAL dates back to June 1962 when the license agreement was signed with M/s. SNIAS (formerly M/s. SUD Aviation).

Major milestones in this journey can be mentioned as below: • 1970: Helicopter Division was formed, License agreement for Cheetah (Lama SA - 315B) signed with M/s. SNIAS. Till date we have produced more than 350 Chetak and more than 270 Cheetah helicopters.

• 1992: First Flight of 1st prototype of Indigenous ALH. • 2001 : Delivery of 1st LSP ALH (Dhruv) to Indian Army • 2007: Order received for 159 ALH. • 2010: First Flight of 1st prototype of LCH. • 2012: Export order for 3 Cheetals to Afghanistan Air force • 2013: Deployment of ALH Mk. III to Maldives • 2016: Maiden Flight of LUH PT-1 • 2016: Foundation stone laid for new Helicopter Factory at Tumakuru by Hon. Prime Minister of India • 2017: Order received for supply of 73 ALH to IN, ICG & Army. First time ever PBL (performance Based Logistics) contract signed with ICG • 2018: Dhruv fleet crossed the milestone of 2, 00,000 flying hours.

• 2018: 159 ALH Contract- Production activities completed • 2019: 6 ALH signaled out ahead of schedule of

73 ALH contract • 2019: Initial Operational Clearance of LCH-LSP for IAF and Indian Army accorded • 2020: Initial operational Clearance of LUH for Indian Air Force accorded • 2020: 1st LSP LCH Produced • 2020: 300th ALH Produced • 2020: Upgraded Civil ALH produced for DGCA certification • 2020: Certification of 19 New system on ALH completed, 8 ALH with 19 new systems produced for Indian Navy and Indian Coast Guard.

The first batch of Advanced Light Helicopter (ALH) Dhruv Mk. III, customized for coastal security, is slated for delivery to Indian Navy (IN) and Indian

Coast Guard (ICG) shortly. Being an expert who played a major role in the production of ALH, how do you validate the operational capabilities of the Dhruv variants compared to other light helicopters globally?

30th August 1992 was a historic moment for HAL when the first prototype of Advanced Light Helicopter (ALH) took to the skies for its maiden flight. When the ALH soared to the skies, it also carried along with it, the hopes and aspirations of the nation which was taking its first step in the indigenous design & development of helicopters.

From that day, ALH has never looked back and has evolved into a world class helicopter with its unparalleled performance. From Mk. I to Mk. IV the evolution has been phenomenal and could be

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possible due to hard work of HAL fraternity backed by tremendous support of customer who gave vital feedbacks from field to improve upon.

Current certification of 19 new systems for ICG and Indian Navy is a testimony to the excellent team work we have exhibited. You would appreciate that even widespread pandemic could not deter our zeal and we could finish sea trials of these systems this year. These helicopters are best suited for coastal security & surveillance and will match any helicopter in the world.

ALH is one of the best helicopters in its class and comparable to any contemporary helicopter in its class. It has proven its mettle in high altitude operations, offshore operations, law enforcement operations, various relief work during like flood, earthquake etc. You would appreciate that the serviceability of ALH for a fleet of over 250 is now close to 70% (considered very healthy) and is further improving.

HAL Rudra, with its rocket and turret guns, is a potent attack helicopter of armed forces, but the

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delay in production has been a concern. How do you intend to speed up the production and what is the present status of the project?

There was delay in the initial batches of Rudra the Mk. IV version of ALH due to new engine (Shakti) certification and weapon integration. Now production of Rudra is quite stable, in fact we are ahead of contractual delivery schedule in 73 ALH contract signed in 2017. 4 WSI which are part of 9 WSI to be delivered by August 2021 has already been signalled out by HAL. We are expecting more orders to utilise our full capacity.

Could you elaborate on MRO services offered by the HC? How strong is HC’s MRO facilities and reliance on latest technologies?

Helicopter complex takes care of MRO of Cheetah, Chetak, Cheetal and ALH helicopters. Helicopter Division and Barrackpore Division together support Cheetah Chetak and Cheetal fleet. You would appreciate that HAL has been successfully maintaining this vintage fleet for more than 6 decades now when even OEM Airbus support is

negligible.

Helicopter MRO Division is the dedicated division to cater to the requirements of a growing fleet of ALH. More than 250 ALH are in fleet today comprising of 4 versions.

MRO division is equipped with latest facilities for repair and overhaul of mechanical, electrical and avionics systems.

We are operating with hub and spoke model for quick turnaround of helicopters. Insitu repair teams are always available at key locations provide support to customers. MRO Hub has been established at Mamun and Missamari to cater to far flung area of Army forward bases.

Analytics is an important aspect of MRO which helps in understanding and estimating requirement in advance. MRO is delving into this aspect with help of IT tools to improve turnaround time.

For the first time we have also contracted with ICG on PBL- Performance Based Logistics. As per PBL contract for the16 ICG ALH, HAL needs to maintain an Overall Fleet Availability of 75% for a fleet of 16 ALH operating 540 hours per Helicopter per year from 04 bases for a period of 6.5 years. This will pave way for further PBL contracts for other customers also.

What are the initiatives by HC to enhance the involvement of private sector in aerospace industry?

HAL believes in inclusive growth through participation of private sector. HAL has been handholding to develop private partners as aerospace standard manufacturers.

More than 2300 vendors are there across India to support HAL’s endeavor now. However, most of these vendors are Tier III or Tier II suppliers, we are looking forward to have more Tier I suppliers who share risk with us to accelerate the growth.

Indigenous Development of systems and equipments is one very important aspect which we giving a thrust and looking forward to more participation from private sector. We are even paying the development cost of such indigenisation.

Aerospace Composites Division is one of the top high volume producers of advanced composite aerospace products in the country. What are the operational updates of the facility which is a strategic business unit (SBU) of HAL? Aerospace composites manufacturing is niche area and we have state of art facilities for advance manufacturing in Aerospace Composites Division – ACD. Presently ACD is engaged in manufacturing composite parts for ALH, LUH, LCH, and LCA programs. It is also manufacturing parts for ISRO programs.

How did the Covid-19 affect the operations of HC?

Could you share with us your visions and priorities for HAL during your tenure? What is the roadmap ahead for the Helicopter Complex?

The current year started with lockdown due to widespread Covid 19 pandemic, however, we could resume our operations from 24th April much ahead when lockdown was lifted. We have seen several hundreds of our employees getting infected or quarantined initially. However, situation is under control now and we have learnt to work along with this pandemic. We have been impacted due to foreign supplies on some counts as OEMs could not supply it in time. The biggest setback was delay in sea trials of 19 new systems, but now it is behind us thanks to great teamwork by all stakeholders.

We are presently producing ALH for 73 ALH contract. We will complete this production by 2022. Meanwhile, limited series production of LCH has been launched. We may supply 15 of these by 2022-23. We are expecting orders on LUH as all certification work has been completed. Indications are that LSP order for 12 LUH will be initiated soon.

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Manufacturing a wide variety of specialised products In addition to aircrafts and helicopters, Bangalore-headquartered Hindustan Aeronautics Limited (HAL) manufactures advanced power plants; avionics equipment; systems and accessories; aerospace-related devices and a host of materials also

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he product portfolio of India’s top aerospace and defence public sector undertaking Hindustan Aeronautics Limited (HAL) includes a wide variety of items apart from aircraft and helicopters. They include power plants; avionics equipment; systems and accessories; aerospace-related devices and a host of materials.

The following is an overview of this section of HAL’s output.

Power plants The Jaguar aircraft is powered by two Adour MK 804 / MK 811 engines. MK 811 engines are manufactured by HAL since 1981 under licence from RR/TM (Rolls Royce Turbomeca). Adour MK 804 Engines are also overhauled and repaired under this licence.

Moreover, HAL manufactures, overhauls and repairs the Garrett TPE 331-5 turbo-prop engine for various customers under licence from Garrett Engine Division of Honey Well Company (formerly, Allied Signal Aerospace Company, USA) since 1988. It belongs to one of the most popular series of small turbo-prop engines powering a large number of commuter and corporate aircraft such as Dornier DO-228. Apart from its simplicity of design and superior performance, the engine features a propeller control system, anti-icing and foreign object damage resistance, reverse thrust and negative torque sensing facilities.

AL-31FP, also built by HAL, 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 maneuverability of the aircraft.

At the same time, Artouste III B engine powers both Cheetah and Chetak helicopters. Manufacture of the engine commenced in 1962 under licence from Turbomeca, France. More than 665 engines have been manufactured and 2,950 engines overhauled and repaired for various customers.

Shakti and PTAE-7 are other engines built by HAL. Meanwhile, LM 2500 engine is light weight and compact with high thermal efficiency. It is used for naval vessels and commercial ships as well as industrial applications. The LM 2500 - derived from

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the TF 39 Military and CF 6 commercial aircraft engine family - is a compact, high performance turbine for marine propulsion systems and industrial power plants. In order to provide maximum reliability, increased life of parts and outstanding performance, it incorporates the latest development in design technology and corrosion-resistant material for engine components.

The LM 2500 Gas Turbine has been selected by 24 naval establishments around the world and powers a broad spectrum of ships ranging from 230 tons to 55,000 tons displacements. This gas turbine has also other applications such as power generation, compressor application. ONGC, Mumbai has five of these units operating on its off-shore platforms.

Avionics Under this category, HAL produces Inertial Navigation Systems, Auto Stabilizers, Headup Displays, Laser-range Systems, Flight Data Recorders, Communication Equipment, Radio Navigation Equipment, Air Borne Secondary Radar, Missile Inertial Navigation, Radar Computers and Ground Radars.

AD Korwa Division is engaged in the manufacturing and repairing of various Avionics Systems for fitment on different Western, Indigenous and Russian-origin aircraft platforms.

Western Origin Avionics are fitted on Su-30MKI, Hawk, Jaguar and LCA. Some of the products in this segment are: Inertial Navigation System (INS) uses an inertial platform with a compactly-packed fast computer for generating in-flight navigation and weaponaiming parameters.

Weapon Control System (HUDWAC) , Microprocessor-based head-up Display & Sighting System and Combined Map and Electronic Display (COMED) are other products. The Head-down display is a cockpit-mounted navigational aid with multifunction facilities. It displays the ground map as stored in a filmstrip superimposed with symbols

generated in a CRT. Similarly, Flight Data Recorder (FDR), is installed in the aircraft to monitor, process and record signals from avionics systems and sensors for subsequent analysis on the ground.

Laser Ranger and Marked Target Seeker (LRMTS) is mounted on the nose of the aircraft to provide accurate range of enemy targets for weapon delivery commutation and forms an integral part of the attack system.

Auto-stabiliser System (AUTOSTAB) improves the handling characteristics of the basic aircraft by providing damping inputs to the control surfaces for additional stability about the aircraft pitch, roll and yaw axis.

Multi-Functional Display (MFD) is a small LCD screen used to display information to the pilot in numerous configurable ways. It is available in different sizes and nature.

Meanwhile, Digital Map Generator (DMG) is used for generation of Digital Map to be displayed on MFD. It superimposes symbology over digitized map.

Head-Up Display System (HUD) is an electro optical device that projects flight information on a combiner glass for the pilot’s head-up viewing.

At the same time, Inertial Navigation and Global Positioning System (INGPS) with an embedded GPS receiver provides an aircraft’s peripheral equipment with all necessary inertial inputs.

Solid State Flight Data Recorder (SSFDR) is used to record flight parameters and voice for post incident/ accident analysis to investigate and establish cause.

Russian-origin avionics fitted on MiG-27M and Su-30MKI include: Integrated Navigation and sighting Complex (44 LK System); Inertial Navigation and Attack System of MiG-27M Aircraft, which accomplishes both navigational and attack functions and Flight Data Recorder (UZL TESTER). Opto-Electric Sighting and Navigation Complex (OEPrNK-30MK-03), Complex Signaling System (KISS-2-10M-1), Alarm Warning and

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Advisory Signaling System (SAS-6-11M), Automatic Air Intake Regulating System (ARV-40A) and Icing Signaling Device (SO-121VM) are other products.

UAV Systems manufactured by HAL include Multimission Optronics Stabilised Platform (MOSP), an electro-optical payload which provides video images of the targets with the capability of acquiring and tracking targets under varying weather and visibility conditions; Vertical Gyro Unit (VGU), comprising an artificial horizon sensor which determines the UAV pitch and roll angles about the lateral and longitudinal axes respectively; Air Data Unit (ADU), which is a Dual Function Sensor for measurement of altitude and air speed data; and Rate Gyro Unit (RGU), a miniature solid state device (sensor) based on a piezo-electric vibratory gyroscope which uses low power oscillating quartz tuning fork sensors to sense angular velocity.

Systems and accessories Under this category, HAL manufactures Hydraulic systems, Wheels and Brake Systems, Flight Control Systems, Ejector Release Units, Panel Instruments, Gyroscopic/Barometric instruments, Oxygen Systems, Fuel Management System and Hydraulic Pumps.

These products are built at HAL’s Accessories Division in Lucknow and the current manufacturing range includes, Hydraulic Systems and Power Control equipment such as Hydraulic Pumps, Accumulators, Actuators, Electro-selectors, Bootstrap Reservoirs and various types of valves.

Environmental Control Systems include Cold Air Unit, Water Extractors, Non-Return Valves and Venturies. Instruments such as electrical indicators, fuel quantity and flow metering instruments, sensors and switches, barometric instruments, gyroscopic instruments and electromechanical instruments are made.

Moreover, Electrical Power Generation and Control Systems such as AC/DC Generator, Control and Protection Units, AC and DC Master Box, Inverters, Transformer Rectifier Unit and Actuators are other products.

Main and Nose Undercarriage, Main and Nose

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Wheel and Brake System LRUs are another set of items built by HAL. Similarly, the company makes Dedicated Test Rigs, custom-built Fuel/Hydraulic Test Rigs and Electrical Test Rigs.

Aerospace HAL is also involved in another crucial sector, Aerospace, for which the company produces Structures, Tanks and Cryogenic Engines.

The Aerospace Division is engaged in the manufacture of aluminum alloy riveted structures and welded tankages of conical, cylindrical and other shapes with different types of detailed parts such as sheets, rings, brackets, stiffeners, bulkheads, panel bolts, nuts, rivets etc. Some of the important structures manufactured are Heat Shield Assembly, Nose Cone Assembly and Tank and Shrouds used in satellites.

Products of aerospace division include PSLV (Polar satellite launch vehicle), GSLV (Geo-synchronous satellite launch vehicle) MK II, GSLV MK III, Indian Remote Sensing Satellite and Indian National Satellite.

Materials Yet another significant part of HAL’s product lineup comprises materials such as Castings, General Forgings, Precision Forgings, Powder Metallurgy, Rubber Products, Rolled Rings and Composites.

These products are made at the Foundry & Forge Division, Bangalore, which has the infrastructure and expertise to manufacture radiographic-quality castings to international standards. The division offers a wide range of Aluminium and Magnesium Alloys to stringent specifications of customers.

HAL’s General Forge Shop is the only one in India with the capability specifications of shape, size weight and number. The shop has, since the early sixties, manufactured forgings in a variety of alloys in many complex configurations.

Meanwhile, a combination of state-of-the-art facilities and traditional hand skills has enabled the Precision Forgings Section to engineer quality into its high technology products. Aluminium Alloys, Nickel Base Alloys, Steels, Titanium Alloys and

Precision Forgings (Non-Blades) are among the materials manufactured.

The Powder Metallurgy Unit at HAL is also the only one-of-its-kind in India to manufacture a range of sintered friction and anti-friction materials such as copper and iron-based brake pads and bimetallic anti-friction bearings and bushes for aircraft. The DGAQA and DGCA have approved the unit for design, development, manufacture and testing of military and civilian aircraft brake pads.

Precision rubber items and metal rubber bonded components such as gaskets, seals, o-rings, bellows, sleeves, diaphragms, and shock mounts are also manufactured to stringent aeronautical standards.

The components with high performance ratings include nitrile, neoprene, silicone, flurocarbon and flurosilicone rubbers to suit operational requirements of aircraft or helicopters in the areas of gear boxes, fuel systems, engines, electrical circuits, vibration damping and structures.

Four decades of serving the high technology segment of industry and zeal to offer an extended range of products motivated the division to diversify into the manufacture of seamless rolled rings. The Ring Rolling facility has a state-of-the-art ring rolling mill incorporating the latest technology, including computerised control of operation and laser measuring device.

The unit has also the expertise and technology for manufacture of rings in marging steel, a strategic material used for defence and aerospace applications, with close control of hot working and heat treatment process parameters.

Aerospace Composites Division (erstwhile Composites Manufacturing Division) was conceived during the designing stage of Light Combat Aircraft (LCA) & Advanced Light Helicopter (ALH) and has experience in manufacturing and realizing aircraft structures made of composites. Over the years, the scope and role of the facility was defined and refined from an Advanced Composites Shop to a Centre of Excellence. The division became fully functional as a Composites Manufacturing Division from April 2007 and a Strategic Business Unit (SBU) of HAL.

Currently, the division is engaged in the manufacture of the composite structural parts for ALH, LCA, Light Combat Helicopter (LCH), Light Utility Helicopter (LUH) and PSLV/GSLV. With average production rates of several thousand composite parts annually for many of its products, Aerospace Composites Division is one of the top, high volume producers of advanced composite aerospace products in the country.

The Division has high-tech facilities for CAD / CAM manufacture; CAD (Tool Design); CATIA / UG(NX6) Work Stations; 5 Axis Special Purpose CNC Machining Centers and CNC Shot Peening (Surface Enhancement), among others. Products manufactured currently are composite components for ALH; Hinge-less Main Rotor Blade, Bearing less Tail Rotor Blade, Main Rotor Hub Plate, Anti Resonance Isolation System (ARIS), Torque Plate, Rescue Hoist Beam, major structural components like cockpit, doors, tail boom, end plate, cowling etc.

Composite components for LCH are also produced. Major structural and dynamic parts of LCH are made out of advanced composite materials.

Another set of products comprises composite components for LCA. Aerospace Composites Division (ACD) has successfully manufactured and produced state-of-the-art Primary Structural Components for Tejas (LCA) using advanced composites materials. A few examples are control surfaces using co-cured construction, fuselage doors, hatches using sandwich and monolithic construction and large wing skin panels / airbrake skins. ACD has specialized in manufacture of Carbon Fibre Composites (CFC) wing assembly details parts consisting of a number of CFC spars, monolithic skin panels etc.

In addition, ACD builds Flexible Rubberized Fuel Tanks for Advanced Light Helicopter.

Maintenance and repair of composite assemblies, compliance of modification and technical instructions, accident and incident investigations and training of customer's personnel are other functions.

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Committed to Keep MiG Fleet Combat Ready HAL has fully supported maintenance and operations of the MiG21/27 aircraft fleet since 1966 albeit the closing of lines by OEM later. Last 50 years HAL has been manufacturing, overhauling, and upgrading the MiG Series aircraft which have served as the backbone of IAF. All the facilities from structural build up to avionics manufacture and repair is fully available and operational.

The indigenous development, manufacturing and repair of various aggregates has also helped HAL to achieve this colossal task, says Bh. V. Seshagiri Rao , CEO – MIG Complex, HAL. In an interview with Aeromag, he talks about the operations and achievements of the complex.

Bh. V. Seshagiri Rao CEO – MIG Complex, HAL Established in 1964, the Aircraft Manufacturing Division, Nasik, plays a decisive role in HAL’s manufacturing capabilities. Could you share with us some of the major highlights of the division over these decades?

Nasik Division started off with License manufacture of MiG-21FL aircraft & K-13 Missiles.

Over the decades Nasik Division has manufactured more than 900 fighter aircraft which includes MiG-21s, MiG-27s and Su-30 MKIs. The Repair & Overhaul (ROH) with upgrades & modifications of more than 1900 fighter aircraft has also been achieved over the period. The Division was also responsible for introducing various modifications to enhance the lethal capabilities of these fighters that form the backbone of IAF strike force.

During this process, the Division has progressed on the technology front from manufacture of 2.5

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Generation Fighter Aircraft to the present day 4.5 Generation Fighter Aircraft.

Presently the ROH of Su-30MKI aircraft is the major program under execution at Nasik Division and it is heartening to share that HAL is the first enterprise in the world to setup the Repair and Overhaul (ROH) Facility for complete Su-30MKI aircraft including engine and aggregates.

Against the ROH cycle time of 36 months envisaged by Russian Side, Nasik Division is working on cutting down the cycle time and was able to achieve 15 months ROH cycle time, during ROH of 50th aircraft in PY 2020-21. This will ensure a quick turnaround of aircraft thereby increasing effective utilisation of aircrafts’ Total Technical Life (TTL).

The structural modification on Su-30 MKI aircraft has been successfully carried out by Nasik Division towards integration of Article ‘A’ deployment with

technology and design scheme developed by inhouse specialists.

Besides the core production activities, some of the other recent achievements which are worth appreciation are: a) A 15MW (AC) Solar Plant has been commissioned and synchronised with National Grid

by AOD, Nasik resulting in saving in Power bill for the Division to the tune of Rs20 Crs per annum. b) Nasik Division has received in-principle approval for manufacture of Bombs and Airborne missiles for airborne platforms from DDP, MoD. c) Activities have started towards venturing into Civil MRO segment d) Private-Public Partnership while executing the Manufacturing/ ROH of Su-30MKI aircraft wherein a number of MSME vendors were brought on board and assisted in nurturing their skill sets.

Su-30 MKI is considered the most lethal asset of IAF and MC’s aircraft manufacturing division in Nasik, is entrusted with its production and maintenance. Could you talk about the production capabilities of MC in this regard and how can the pace of production be increased?

Nasik manufactures the Airframe and is a prime integrator. Koraput Division produces the Engines, Lucknow Division supplies Hydraulic, Pneumatic & Fuel Aggregates; Hyderabad Division supplies the radio and radar systems; Korwa Division supplies Navigation aggregates of Avionics Suite.

MiG Complex is equipped with state of the

art technologies and infrastructure viz; Titanium Welding Facility , Sheet Metal facilities, CNC setup, Heat treatment, plating & painting, functional testing of aggregates, aircraft equipping & painting and flight testing etc,. at Nasik Division and Manned Chamber welding, Single Crystal blade casting, Vibro drilling of High pressure and Low pressure Turbine disc, Hot iso-static pressing, Isothermal forming, Electron beam welding etc., at Koraput Division.

HAL has absorbed the ToT for manufacturing of complete Su-30MKI aircraft from raw material phase including its engine, aggregates and avionics and delivered 219 Su-30 MKI aircraft till date.

The ROH program of Su-30 MKI aircraft was started simultaneously in 2014-15. Division has taken up enhancement of ROH facilities to roll out maximum ROH aircraft and meet the operational requirements of IAF. To pace-up the ROH production, apart from enhancement of facilities, re-allocation of resources is also being carried out, considering completion of the manufacturing program of Su-30MKI in PY 2020-21.

During the execution of the manufacturing program, an effective vendor eco-system was developed through subcontracting which is being utilized towards Su-30 ROH production.

Besides, the making of Su-30 MKI, the overhaul of the ageing MiG aircraft fleet of India is a major task. How strong are the overhaul facilities and capabilities?

HAL has fully supported maintenance and

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operations of the MiG-21/27 aircraft fleet since 1966 albeit the closing of lines by OEM later. Last 50 years HAL has been manufacturing, overhauling and upgrading the MiG Series aircraft which have served as the backbone of IAF. All the facilities from structural build up to avionics manufacture and repair is fully available and operational. The indigenous development, manufacturing and repair of various aggregates has also helped HAL to achieve this colossal task.

The requirement of IAF for overhaul of MiG -21 aircraft has been concluded with delivery of the final batch of aircraft from Nasik in the year 2020.

However, site repairs and Rotable Tasks for ROH towards support of the fleet will continue till the phase out of fleet.

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. Could you shed some light onto the operations of the division?

Koraput Division has the distinction of being marked as the Division with state of the art facilities which are essential for manufacturing of the most complicated and intricate rotable of the aircraft i.e the Aero-engine.

At present RD-33 Series-3 and AL-31 FP engines are being manufactured and overhauled in the Koraput Division. The R-25 engine for MiG-21 aircraft is also being overhauled. The manufacturing of AL-31FP engine for Su-30 MKI is being carried out from the raw material stage and the Division has mastered & improved various critical technologies involved in aero-engine manufacturing and the facilities are now being augmented to fulfil the IAF requirements of Overhaul.

Additionally the Division has been carrying out several modifications and life extension of

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aggregates of aero engines. In-house facility for manufacturing of engine forgings & castings is also established in the Division. The Division also supports critical programs of DRDO. The establishment of facilities for ROH of RD33MK engine are being planned as per requirements of Indian Navy.

Export of MiG spares to foreign countries is a main activity of the Nasik Aircraft Manufacturing Division of MC. What are the highlights of the export arm and who are the major clients?

The export Contract for MiG-21 spares was concluded in the year 1996 with major clients being the Asian Countries. Since then Nasik and Koraput Divisions are exporting the spares and services for MiG -21 aircraft and R-25 engines. Though there has been an emphasis on exports but the major thrust upon HAL is to provide support to Indian Air Force. Recently HAL has signed a MOU with Rosoboronexport, the State arms exporter of Russia for export of spares of Su-30MKI aircraft to friendly third countries.

How has the Covid-19 pandemic affected the operations of MC? Covid-19 impact: The norms of carrying out operations in line with strict guidelines issued by the GoI and continuing the support to Indian Air Force during the pandemic period was a real challenge to HAL. However specific measures have been put in place to overcome the various limitations that emerged viz., allocation of manpower into three shifts to adhere to the norms of social distancing, organising transport with all precautions, etc., The supply of spares from Russia was affected which had impacted our production as well as ROH lines.

However, MiG complex is mitigating the effect of the pandemic through the dedicated and sincere efforts of the Koraput and Nasik Teams by adopting all the safety guidelines and self-discipline. The set target for 2019-20 was successfully achieved and we are on our way to conclude PY 2020-21 on the positive note as well.

The pandemic taught us new ways of communication and accomplished tasks economically and made us more proficient in adopting various technologies that enable quicker solutions. The same needs to be practised to minimise our input costs and maximise our profits. In the field of quality, the pre-dispatch inspections, stage inspections are now managed through video conferences wherever necessary.

This has once again highlighted the need of self reliance and we are striving to localise the spares production by utilising the various initiatives that have been formulated by Government of India like Make-II, Raw Material indigenisation through MIDHANI, etc., Our efforts are directed in fulfilling the objectives set by our Hon’ble Prime Minister through “Atmanirbhar” Drive. Towards Su-30 ROH, HAL team has indigenised 4843 part out of 7597 making it 63.75%. This is a major step towards “Atmanirbhar” as well as towards reducing FE content. Further efforts are being made to become self-reliant.

Even during the Covid-19 pandemic, teams were deputed to IAF Stations by Nasik Division in order to support the operational requirements of IAF. Strict protocols were followed and a lot of assistance was provided by IAF towards the same.

Could you share with us your visions and priorities for MC during your tenure and what are the major objectives?

The Business scenario we operate in is now highly challenging and changing faster than ever. Hence it is necessary for us to be more Customer centric and Output oriented. Formulation of stringent systems and control measures in areas like Quality, Production and Planning are our prime focus.

Nasik Division is taking steps for Business diversification i.e Manufacturing, Testing and integration of Bombs and Missiles, foray into MRO of Civil aircraft and helicopters, undertake repair of imported Missile systems of IAF. This needs a consistent coordination with prospective Customers and Government agencies.

Our priority and focus will be on timely commencement of new projects being assigned to MiG Complex like manufacturing of HTT-40 aircraft, LCA parts & wing assembly, Mirage wing strengthening and setting up of ROH facility for RD-33MK engine.

Enhancement of ROH facilities in Nasik and Koraput Division are accelerated in order to achieve minimum cycle times to meet demanding needs of IAF. We are sure the MiG Complex will play a vital role to support the needs of our Services. We will be a prominent agency in the Civil MRO market by harnessing our capabilities of skilled manpower and infrastructure with that of private industries marketing and business development skills and domain knowledge !!!

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Focus is on civil & export segments, says CEO of HAL AC Accessories Complex (AC) of India’s top public sector aerospace and defence firm Hindustan Aeronautics Limited (HAL) has a very significant role in meeting the Aircraft/Helicopter/ Engine production schedules as these are feeding divisions and supplying accessories to all platforms of western, Russian and Indian origin, being produced by HAL. Over the years, the Divisions of the complex have evolved to maintain the latest standards regarding technological prowess and indigenous capabilities.

Do-228 aircraft, the most prestigious product of AC, is best suited for shorthaul operations, which is the need of Indian civil aviation for increasing regional and remote area connectivity. Sajal Prakash, CEO, HAL Accessories Complex (AC), elaborates on the functioning of the AC and future developments.

Sajal Prakash CEO, AC - HAL The Accessories Division has been fulfilling its prime objective of manufacturing aircraft systems and accessories for aircrafts, helicopters and engine over these decades. Could you share with us the success journey and major achievements?

The Accessories Complex comprises three Accessories Divisions (at Lucknow, Korwa and Hyderabad) and one Transport Aircraft Division (at Kanpur).

In Lucknow, we are producing as well as doing repair & overhaul of more than 1400 types of accessories of different aircraft platforms.

Accessories Division, Lucknow is catering for Fuel system accessories, Mechanical accessories and Instrumentation accessories for both internal and external customers. Avionics Divisions Korwa and Hyderabad are dealing with avionics system accessories s.a. Flight Data Recorders, Inertial Navigation & Global Positioning Systems and Radar Navigations & Computers. At TAD, Kanpur we are making Do-228 and servicing HS-748, An-32 and UAVs. Accessories complex of HAL has a very significant role in meeting the Aircraft/Helicopter/ Engine

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production schedules as these are feeding divisions and supplying accessories to all platforms of western, Russian and Indian origin, being produced

by HAL. All the Divisions of the Accessories Complex are AS9100 D & NABL accredited. Plans are in pipeline to acquire Nadcap certification. Moreover, we have co-located Design Centers with each of the Divisions to offer solutions across the complete spectrum of D&D, Production and R/OH. Over the years, the Divisions of the complex have evolved to keep themselves state of the art in terms of technological prowess and indigenous capabilities.

Under your leadership, Transport Aircraft Division, Kanpur has overcome multiple challenges and emerged much stronger besides consistently meeting annual targets of all financial & physical parameters.

What are the latest operational highlights?

TAD started its journey of manufacturing transport aircraft from raw material stage, way back in 1962 with production of HS-748 (AVRO) aircraft.

89 aircraft were produced till 1984. The aircraft

are still being exploited by IAF and BSF. We are maintaining the fleet for more than 55 years.

TAD is manufacturing transport category aircraft (Do-228) for last 35 years. The Division has worldclass infrastructure and capabilities for manufacture, repair, maintenance & overhaul of aircraft. The Division has performed consistently well all along as a result of the untiring devotion of its vibrant workforce. Division recently delivered its 150th Do-228 aircraft to Indian Navy, equipped with a latest state-of-the-art Glass cockpit for enhancing operational capability of the platform. Defense customers have continually reposed faith & trust in the Division’s products. Division has made all the supplies (aircraft and associate services) ahead of the contracted schedule.

Division would soon be carrying out the Mid-life upgrade on 17 Do-228 aircraft operated by Indian Coast Guard to impart the latest technological features to the platform, which will enable the Coast Guard to increase the overall effectiveness of its Do-228 fleet in meeting the present day coastal surveillance needs.

In addition to this, Division has manufactured two Do 228 aircraft in Civil version to support Govt initiatives of Regional Connectivity Scheme (RCS). Division is having all the DGCA approvals required for Design, Manufacturing, Servicing and training activities related to Do 228 aircraft. These approvals are CAR 21G, CAR 21JA , CAR 145 and CAR 147. Civil Aviation Authority of Nepal (CAAN) has accorded approval to TAD for Maintenance of Do 228 aircraft.

TAD has exported Do 228 aircraft to Mauritius and Seychelles also which are extensively utilized by

them on important missions.

The most prestigious product of AC is the Dornier Do-228 aircraft. In the coming years, there would be a demand for over 200 aircraft under UDAN scheme and HAL Dornier has great opportunity to be a part of it by marking its signature in civil aviation. How does HAL look at this?

The Do-228 is an exceptional product coming out of HAL. It has proved its mettle with the Defence Forces of the country since 1983 in variety of roles and will continue to serve for many years to come. It has been a proven workhorse in the most critical & demanding situations with excellent safety record. In past, ten Do-228 aircraft had served with Vayudoot airlines, connecting more than 100 inland destinations. Seeing this potential of Do-228 aircraft and as a notable contribution to Govt of India’s mission to boost regional air connectivity in the country, HAL forayed into civil aviation market with upgraded civil version of Do-228 aircraft.

The aircraft is DGCA certified. Do-228 aircraft is best suited for short haul operations, which in present times, is the need of Indian civil aviation for increasing regional and remote area connectivity. For the two Do-228 aircraft initially produced, contract has been signed to lease these aircraft to M/s Turbo Aviation Pvt. Ltd., a Hyderabad-based regional airline, who are intending to start RCS–UDAN operations connecting Capital City of Lucknow to around 15 destinations in Uttar Pradesh. Efforts are also being made to fly these aircraft in NorthEastern states under UDAN scheme by Alliance Air, a subsidiary of Air India. Other operators have also evinced great interest in this indigenous ‘Make-in-

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India’ platform. The country would be seeing quite a good number of Civil Do-228s in its skies in years to come meeting regional aviation needs. Civil aviation is a challenging space, and with the continuing Government support, Do-228 would undoubtedly be the most preferred choice for airlines/regional operators in future.

How does AC support augmenting the participation of private industry in aerospace manufacturing industry?

HAL believes in inclusive growth and has been instrumental in developing a strong and vibrant aerospace and defence manufacturing ecosystem in the country. The vendors developed by HAL through hand holding have now evolved to cater to the aerospace industry requirements and are integrated with Indian and global aerospace manufacturing ecosystem.

Further, Long term business agreements (LTBAs) are also considered to ensure the active private industry participation and continued business for vendors developed by HAL. Accessories complex has developed a tiered vendor base of capable manufacturers. Atma Nirbhar Abhiyan supporting the indigenous industry will be a boost to these vendor development initiatives and will go a long way in retaining the skills developed in HAL and MSMEs, while gainfully utilizing the experienced manpower & protecting the manufacturing ecosystem.

The avionics divisions of AC have indigenously developed several types of Avionics systems and have been overhauling it. Could you elaborate on the operational highlights?

Avionics Division, Hyderabad is supporting fleets like Su-30, LCA, Dornier, ALH, Jaguar Darin-III, Mirage Upg, LCH, Chetak etc., for manufacturing and repair. Indigenously developed Communication, Navigation, Airborne Radar and Aircraft computers are fitted on almost all fighters, trainers and

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helicopters of Indian defence services. The division has the distinction of being able to replace imported systems on many platforms with Indigenous systems like VOR/ILS and TACAN on HAWK AJT. Some of the Systems like Radio Altimeters developed

by SLRDC are best in the class with respect to similar systems available worldwide. Additionally, the division is supporting fleets like MIG-21, AN32, Kiran, Avro, Cheetah etc. extending their operational life by deploying skilled manpower & dedicated infrastructural setup overcoming severe obsolescence issues.

Korwa Division is an Avionics unit presently engaged in manufacturing and ROH of various Avionics Systems for fitment on various aircraft platforms such as Jaguar DARIN-I, II & III versions, Su-30MKI, LCA, Dornier-228, Hawk, Cheetah, Cheetal and Chetak. The product range includes Solid State Flight Data Recorder (SSFDR), Inertial Navigation Global Positioning System (INGPS), Sensors like Gyros and Accelerometers for fitment in INS system of Missiles like Brahmos among others.

Many of these are indigenously developed and proven on various platforms.

TAD Kanpur is establishing an assembly facility for a second line of Advanced Light Helicopter production in order to ramp-up the production capacity. What are the latest updates?

Supporting line for Advanced Light Helicopter that was earlier planned at Kanpur, has now been established at Naini Aerospace Limited at Prayagraj which is wholly-owned subsidiary of HAL. Presently, it is involved in manufacturing of Structural assemblies and Cable looms for ALH. How did AC overcome the impact of Covid-19?

Could you share with us your visions and priorities for AC during your tenure?

AC and HAL at large caters majorly to the requirement of defence services and hence the pandemic did not have much impact on the demand

Modified IJT Commences Spin Flight Testing

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he indigenous Intermediate Jet Trainer (IJT) designed and developed by HAL to replace the ageing Kiran aircraft fleet of the IAF commenced spin flight testing in Bengaluru. The flight was piloted by HAL’s test pilots Gp. Capt H.V. Thakur (Retd) and Wg. Cdr P. Avasti (Retd).

The spin testing of an aircraft is the most crucial phase of its flight testing. Accordingly, the testing will be gradually progressed to assess the behaviour of the aircraft till six turn spins to either side to meet the targeted requirement The IJT has already been tested to its full envelope in terms of speed, altitude and load factor (‘g’ envelope) and has also been integrated with drop tanks as well as bombs. For spin test,

HAL redesigned the aircraft by moving the vertical tail aft and extending the rudder surface. These changes for ensuring a satisfactory spin behaviour required extensive redesign of the rear fuselage and the rudder. The changes have been incorporated in two aircraft with the involvement and clearance from certification agencies at every stage. Post modification, the two aircraft underwent significant flight tests to assess the general handling with the new configuration of fin and rudder. These aircraft have now been incorporated with the necessary safety devices (Anti-Spin Parachute Systems).

During the first flight, initially the aircraft was taken through one turn spin to the left and right hand sides to test the spin characteristics.

side of the business as the defence requirements are based on long-term projections towards national security. However, COVID-19 has impacted the company in terms of Supply chain disruptions, failing of vendors to produce/ship goods, limited working hours, lockdown restrictions on schedule deliveries etc.

In the post-pandemic scenario, the Company is contemplating new norms to manage smooth supply chain and safety requirements such as: · Production in the environment of social distancing. · Inculcating hygiene and safety habits by the employees. · New norms for coordination with customers for test and trials.

· Identifying key suppliers, vulnerable to crisis in the short and medium term. · Virtual Meetings / Production Reviews · Paperless Office VISION In line with the vision of Company to be significant global player in the aerospace industry, my vision is to transform the Accessories complex to achieve customer delight through latest technology and business excellence. The accessories complex has been and shall always be the mission success partner to our customers. Moreover, my focus would be to diversify our business in civil and export segments in addition to the existing defence business in order to achieve growth year-by-year.

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A glittering product line Hindustan Aeronautics Limited has been at the forefront of India’s indigenisation efforts, building some among the best aircraft and helicopters in the world.

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ndia’s premier aerospace and defence public sector undertaking Hindustan Aeronautics Limited (HAL) manufactures a wide range of products from advanced fighter jets to various industrial materials. However, the most well-known items in the company’s product portfolio are the aircraft and helicopters. Here is a glance at the current production lineup in this category.

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Tejas Also known as India’s indigenous Light Combat Aircraft (LCA), Tejas is a single-engine, light weight, highly agile and multi-role supersonic fighter. A landmark project of the country, it has quadruplex digital fly-by-wire Flight Control System (FCS) with associated advanced flight control laws. The aircraft with delta wing is designed for ‘air combat’ and ‘offensive air support’ with ‘reconnaissance’ and

‘anti-ship’ as its secondary roles. Extensive use of advanced composites in the airframe gives a high strength-to-weight ratio, long fatigue life and low radar signatures. Aeronautical Development Agency is the designated project manager for the development of LCA. Hawk A tandem-seat aircraft for ground attack, flying training and weapon training, the Hawk has a low wing and an all-metal structure and is powered by an Adour Mk 871 turbofan engine. The aircraft has an integrated navigation /attack system and radio and inertial navigation systems. The aircraft is cleared for instrument (IFR) flying and for solo instrument flying from the front cockpit only.

SU-30 MKI A twin-seater, multi-role, long range fighter / bomber / air superiority aircraft, Sukhoi SU-30 MKI is among the most advanced products of HAL. IJT Meanwhile, the Intermediate Jet Trainer (IJT), christened as HJT-36, has been indigenously designed and developed by HAL to replace the ageing fleet of KIRAN Jet Trainer aircraft in service with Indian Air Force (IAF) for Stage II training of its pilots. IJT will be fitted with AL-55i Jet engines produced in-house at Engine Division, Koraput.

IJT incorporates the simplicity necessary for ease of conversion from Basic Piston Trainer and the sophistication required for quick conversion to the complexities of an Advanced Jet Trainer.

The roles of IJT include pilot training, general flying, navigation formation flying, instrument & cloud flying, basic air-to-ground and air-to-air weapon aiming, tactical flying and night flying.

versatile multi-purpose light transport aircraft. It has been developed specifically to meet the manifold requirements of utility and commuter transport, third-level services and air-taxi operations, Coast Guard duties and maritime surveillance.

Dornier has been deployed for roles such as maritime surveillance, pollution prevention, troop transport, aerial survey, search & rescue, commuter transport, calibration of airport NAV-COM aids, remote sensing applications, casualty evacuation, executive transport and cargo & logistics support.

Dornier Dornier, or HAL-DO-228, is a 19-seater highly

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deployment of forces, logistic air support, search & rescue and training.

According to HAL data, more than 200 Dhruvs are operating with Indian Defence Forces. Moreover, the company is executing an order for 159 Dhruv helicopters from Indian Army and IAF which is under supply. Further, HAL has bagged orders for 73 ALH in 2017 from Army, Coast Guard and Navy for ALH Mk-III & Mk-IV variants. Dhruv has also been supplied to Nepal Army, Mauritius Police and Maldives. In addition, the copter is being operated by civil customers such as ONGC, GSI, Government of Jharkhand and paramilitary forces, including BSF.

Dhruv An indigenously designed and developed Advanced Light Helicopter (ALH), Dhruv is a twin engine, multi-role, multi-mission new generation helicopter in the 5.5-ton weight class. The basic helicopter is produced in skid and wheeled versions.

Dhruv is ‘type-certified’ for military operations by the Centre for Military Airworthiness Certification (CEMILAC) and civil operations by the Directorate General of Civil Aviation (DGCA).

Certification of the utility military variant was completed in 2002 and that of the civil variant in 2004. The deliveries of production series helicopters commenced from 2001-02 onwards.

The major variants of Dhruv are classified as Dhruv Mk-I, Mk-II, Mk-III & Mk-IV. Dhruv has been utilized for passenger / commuter roles, VIP travel, casualty evacuation, under slung load, rapid

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ALH Sarang Sarang – the ALH (Dhruv) display team of the IAF - was formed in October 2003 with the aim of showcasing the excellent agility, controllability and maneuverability of ALH. Sarang is the Sanskrit word for peacock and the team epitomizes the beauty and grace of the majestic bird during its flying displays.

The Sarang team has exhibited its capability at prestigious air shows such as Aero India, Paris, Farnborough, Berlin, Singapore, Al-Ain etc. The team has also performed during various events of national and international significance such as Air Force Day, National Defence Academy passing out parade and others. The team displays its skill and versatility with single cross, dolphin leap, double cross etc.

HTT-40 The training aircraft has roles such as basic flying training, aerobatics, instrument flying, navigation, night flying and close formation.

Cheetah HAL signed a licence agreement for Cheetah with M/s SNIAS in 1970 and the first Cheetah manufactured from raw materials was delivered in 1976-77. The Cheetah helicopter, which is identical to LAMA SA 315B helicopter of Eurocopter, France, is a high performance helicopter designed for operation over a very wide range of weight, centre of gravity and altitude conditions. The five- seater Cheetah is versatile, multi-role, multi-purpose, highly maneuverable and rugged in construction. It holds the world record in high altitude flying among all categories of helicopters.

Cheetah is suitable for commuting, observation, surveillance, logistics support, rescue operations and high altitude missions. Till now, HAL has produced and sold more than 275 of these versatile helicopters which are in service both in India and abroad. Recently, HAL has received orders for Cheetah helicopters from Namibia.

Lancer In the 1990s, HAL developed a light attack helicopter ‘Lancer’ as a cost-effective airmobile area weapon system. The basic structure of the lancer is derived from the reliable and proven Cheetah helicopter. The helicopter has bulletproof front panels and crew seat.

Optimized for anti-insurgency operations, close air support, suppression of enemy fire, attack on vehicular convoys, destruction of enemy machine gun positions and anti-armour applications, Lancer carries two jettisonable combination gun-cumrocket pods, one each on right and left side on suspension points located on the armament pylon.

Moreover, a gun sight is provided for accurate aiming and firing by the pilot.

Cheetal A re-engined version of the Cheetah helicopter, Cheetal was developed under a project initiated in 2002 with the aim of enhancing the high altitude operational capabilities and maintainability as well as providing a mid-life upgrade for safe and reliable operations.

Rudra Rudra is the weaponised version of the ALH Dhruv designed and developed by HAL to meet the requirements of the Indian Army and IAF. The multi-role helicopter of 5.8-ton class is powered by two Shakti engines. Rudra’s roles are anti-tank missions, scout, fire support, armed reconnaissance & surveillance, escort and EW platform.

LCH At the same time, HAL’s Light Combat Helicopter (LCH) was proposed to meet IAF’s requirement of a dedicated light helicopter for combat operations.

LCH has maximum possible commonality with ALH. LCH with a narrow fuselage has pilot and copilot/gunner in tandem configuration incorporating a number of stealth features, armour protection, night attack capability and crashworthy landing gear for better survivability.

Future products Light Utility Helicopter (LUH) has been designed and developed as a replacement for Cheetah and Chetak helicopters. LUH is a new generation helicopter in the 3-Ton class incorporating stateof-the-art technology features like glass cockpit with Multi-Function Displays (MFD) and powered by a single Turbo Shaft engine with sufficient power margin to cater to demanding high altitude missions. LUH will meet the emerging needs in this class of helicopters in the coming decades. It will be capable of flying at 220 kmph, have a service ceiling of 6.5 km and a range of 350 km with 500

kg payload.

Other futuristic projects of HAL include, UAV, RUAV and Sport.

Export division Highlighting HAL’s success in international cooperation, the company’s export division has achieved a breakthrough by bagging an export contract from Airbus Industries France, for the supply of forward passenger doors for A320 / A321. The division’s performance in the supply of export packages has been credited with ‘No rejection’ and ‘No delay’ at most competitive prices. Meanwhile, the Aircraft Division of HAL is an established exporter to Boeing, USA and IAI, Israel.

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300th ALH (Dhruv) Rollsout from HAL Hangar

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n yet another major fillip to indigenous programme, 300th Advanced Light Helicopter (ALH-Dhruv) rolled out from HAL hangar on September 29,2020 .

Speaking on the occasion, R Madhavan, CMD, HAL said ALH never looked back from the day when the prototype took its maiden flight on August 30, 1992 and has evolved into a world class helicopter with its unparalleled performance.

“The evolution from ALH Mark-I to MarkIV has been phenomenal and is a boost to the indigenous design and development of helicopters”, he added.

The Roll-out certificate of the 300th helicopter was handed over to G. V. S. Bhaskar, Chief Executive Officer, Helicopter Complex by Y K Sharma, Additional Director General (South

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Zone), Directorate General of Aeronautical Quality Assurance (DGAQA) at a programme held at HAL’s Helicopter Division.

Bhaskar said ‘Rolling-out of 300th ALH is a testimony to the capabilities HAL has built over the years with concerted efforts of employees and customer support. “With more ALH getting inducted into the services our focus on customer support is ever increasing. With over 2,80,000 flying hours ALH has proven to be a multirole helicopter for Any Mission, Any Place, Any Time”, he said.

Currently, HAL is producing 73 ALHs contracted for Army (41), Indian Navy (16) and Indian Coast Guard (16). Out of this, 38 ALHs have already been produced and the remaining will be completed by 2022.

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Aeromag Asia, Aeronautical Society of India Building, Suranjandas Road, Off Old Madras Road, Bangalore 560075, Karnataka.

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