PREFACE The report on the following pages is the outcome of six weeks training at theindustry.

The report is the outcome of the practical knowledge that we acquire during our training. This report presents the brief summary of our industrial training.I had the privilege of receiving such training at

HINDUSTAN AERONAUTICSLIMITED ,LUCKNOW.There could not be a better place to learn

COMPNY PROFILE HINDUSTAN AERONAUTICS LIMITEDLUCKNOW The history of the Indian Aircraft Industry can be traced to the founding of Hindustan Aircraft Limited at Bangalore in December 1940 in association withthe erstwhile princely State of Mysore and late Shri Seth Walchand Hirachand,a n I n d u s t r i a l i s t o f e x t r a - o r d i n a r y v i s i o n . G o v t . o f I n d i a b e c a m e o n e o f i t s shareholders in March 1941 and took over the management in 1942. HindustanA i r c r a f t L i m i t e d w a s m e r g e d w i t h A e r o n a u t i c s I n d i a L i m i t e d a n d A i r c r a f t Manufacturing Depot, Kanpur to form Hindustan Aeronautics Limited (HAL)on 01 st October 1964.Today HAL has got 16 production units and 9 research and design centersspread out in seven different locations in India. Its product track record consistsof 12 types of aircraft from in house R &D and 13 types by license production. HAL has so far produced over 3300 aircraft, 3400 Aeroengines a n d overhauled over 7700 aircraft and 26000 engines .HAL has engaged & succeeded in number of R & D programs for both themilitary and civil aviation sectors. Substantial progress has been made in thecurrent projects like Dhruv -Advanced Light Helicopter (ALH), Tejas -LightCombat Aircraft (LCA), Intermediate Jet Trainer (IJT) and various military andcivil upgrades. The deliveries of Dhruv were effected to Indian Army, Navy, Air Force and Coast Guard in March 2002, in its first year of production which is aunique achievement.HAL has played a significant role for India's space programs in themanufacturing of satellite launch vehicles like PSLV (Polar Satellite LaunchV e h i c l e ) , G S L V ( G e o S t a t i o n a r y L a u n c h V e h i c l e ) , I R S ( I n d i a n R e m o t e Satellite) & INSAT (Indian National Satellite).HAL has also two joint venture companies, BAeHAL Software Limitedand Indo- Russian Aviation Limited (IRAL). Apart from the two, other major diversification projects are Industrial Marine Gas turbine and Airport Services.Several co-production and joint Ventures with international participation areunder consideration.HAL's supplies / services are mainly to Indian Defence Services, CoastGuard and Border Security Force. Transport aircraft and Helicopters have also been supplied to Airlines as well as State Governments of India. The Companyh a s a l s o a c h i e v e d a f o o t h o l d i n e x p o r t i n m o r e t h a n 3 0 c o u n t r i e s , h a v i n g demonstrated its quality and price competitiveness

HAL, has won several International & National Awards for achievementsin R&D, Technology, managerial performance, exports, energy conservation,quality and fulfillment of social responsibilities. M/S Global Rating, United K i n g d o m i n conjunction with The International Information and

MarketingC e n t e r ( I I M C ) h a s a w a r d e d t h e I N T E R N A T I O N A L G O L D M E D A L AWARD AT THE INTERNATIONAL SUMMIT (GL O B A L R A T I N G LEADERS 2003) LONDON, UK to M/s. Hindustan Aeronautics Limited for Corporate Achievement in Quality and Efficiency. HAL was also presented theINTERNATIONAL ARCH OF EUROPE AWARD IN GOLD CATEGORYi n r e c o g n i t i o n f o r i t s c o m m i t m e n t t o Q u a l i t y , L e a d e r s h i p , t e c h n o l o g y & Innovation. At National level, HAL won the top award institutedby SCOPE( S t a n d i n g C o n f e r e n c e o f P u b l i c E n t e r p r i s e s ) T h e " G O L D T R O P H Y " f o r excellence in Public Sector Management.The Company scaled new heights in the financial year 2002-2003 with aturn over of Rs. 3120 Crores and export of Rs. 103.89 Crores.To become a globally competitive aerospace industry while working as aninstrument for achieving self reliance in design, manufacture and maintenanceof A e r o s p a c e e q u i p m e n t , c i v i l t r a n s p o r t a i r c r a f t , h e l i c o p t e r a n d m i s s i l e s a n d diversifying to related areas, managing the business on commercial lines in aclimate of growing professional competence.In the six decades, HAL has spread its wing to cover various activities inthe areas of Design, Development, Manufacture and Maintenance. Today HALhas 16 production divisions spread over at Bangalore, Nasik, Koraput, Kanpur,Lucknow, Korwa, Hyderabad and Barrackpore. These divisions are fully backed by nine Design Centres, which are co-located with the productiondivisions. These centres are engaged in the Design and Development of combataircraft, helicopter, Aeroengine, Engine Test Beds, Aircraft communication and Navigation systems and Accessories of mechanical and fuel systems andinstruments. Its product track record consists of 12 types of aircraft from inhouse R &D and 13 types by license production. HAL has so far produced over 3300 aircraft, 3400 Aeroengines and overhauled over 7700 aircraft and 26000engines.The current programme are series production of ALH and delivery to our defence and civil customers, production of Jaguar, the deep penetration strikeaircraft, Dornier Do-228, Multi Mission Aircraft and LANCER the Light Attack Helicopter and upgrades of MiG-21 BiS, MiG-27 M and Jaguar. With thesigning of Inter Governmental Agreement and General Contract the licensemanufacture of SU MkI has been launched. HAL is the major design partner for aircraft and system / equipment aswell as for system integration of Light Combat Aircraft (LCA) whichsuccessfully completed the first block of flights.The new initiative in R & Dwill include an Intermediate Jet Trainer ( IJT ), a trainer for the 21st century,Light Observation Helicopter, replacement for Cheetah and Chetak Helicopter and a Light Attack Helicopter, a follow- on project for ALH.Partnership for coproduction of ATR-42, an invitation from Airbus to participate in A-380 project,and the new project to design and develop a Multirole Transport Aircraft (100seater) are signs of growth for the largely military aircraft manufacturingcompany in the commercially competitive aerospace industry.Designcapabilities, modern facilities and skills combined with competitive pricing and prompt deliveries, make HAL a valuable partner for challenging programmes inAerospace and related fields. MAJOR PRODUCTS OF THE H.A.L. DIVISION The major products of the Division are: Undercarriage systems

Wheels and Brake systems Hydraulic Systems Aircraft and Engine Fuel Systems Panel Instruments (Barometric and gyroscopic) Electric Power Generation and Control systems Environmental control systems. Flight Control Actuators Ground Support Equipment and test Rigs. Main Customers i)Indian Air Force, Army, Navy, Coast Guard, BSFii)Defence R&D Laboratories and Deptt of Space;iii)Civil Aviation, State Govt., Ordnance Factories, Corporate Sectors;iv)Flying Academies & Educational Institutions;v)Airlines, Air Taxi, Air Cargo;vi)Overseas customers for civil and military applications

ORGANISATIONALGROWTH OF HAL Expansion of Nasik Division asAircraft Manufacturing &Overhaul DivisionEstablishment of SUKHOIENGINE DIVISION at Koraput 2 Establishment of Airport Service Center for coordinating theoperation of HAL airport Bangalore 2000 Establishment of Industrial &marine Gas Turbine Division for aero derivative gas turbines/industrial engines 1998 Establishment of AEROSPACE DIVISION for structure of Aerospace Launch Vehicles 1988 Establishment of KORWA DIVISION for AdvancedAvionics 1982 Establishment of FOUNDARY & FORGE DIVISIONat Bangalore 1 Establishment of HELICOPTER DIVISION at Bangalore 1 Establishment of LUCKHNOWDIVISION for Accessories &instrumentsEstablishment of HINDUSTAN AERONAUTIC LIMITED bymerging of 3 companies 1 Establishment of Aeronautics India LTD. At Nasik, Koraput & Hyderabad for MiG Airframe, Engines & Avionics

1 Establishment of aircraftManufacture DEPOT atKanpur for HS-748 1960 Establishment of Engine Division atBangalore 1956Hindustan Aircraft Limited at Bangalore1940

HAL ACCESSORIES DIVISION - LUCKNOW The Division was established in 1970 with the primary objective of m a n u f a c t u r i n g s y s t e m s a n d a c c e s s o r i e s f o r v a r i o u s a i r c r a f t , h e l i c o p t e r s a n d engines with a view to attain self-sufficiency in this field in the country. TheD i v i s i o n s t a r t e d w i t h t h e m a n u f a c t u r e o f h yd r o - m e c h a n i c a l a c c e s s o r i e s a n d instruments under license for Marut and Kiran aircraft. This was followed byl i c e n s e m a n u f a c t u r e o f a c c e s s o r i e s f o r M i G 2 1 a i r c r a f t , C h e e t a h / C h e t a k helicopters, Dornier and other defense applications. Additionally repair ando v e r h a u l o f L u c k n o w m a n u f a c t u r e d a c c e s s o r i e s a s w e l l a s t h o s e f i t t e d o n directly purchased aircraft, such as Mirage and Sea Harrier was undertaken. At present, it is manufacturing, repairing and overhauling more than 800 differenttypes of systems and accessories under license. The range of items cover unitsfor hydraulics, engine fuel system, environment control system, pressurizations ys t e m , g y r o s c o p i c i n s t r u m e n t s , b a r o m e t r i c i n s t r u m e n t s , e l e c t r i c a l s ys t e m items, undercarriages, and electronic items. The number of licensors exceedstwenty.From inception, the Division has laid emphasis on developing indigenouscapability through design and development of various systems and accessories.T h i s capability has culminated in indigenous de sign and development of av a r i e t y o f s ys t e m s a n d a c c e s s o r i e s f o r t h e L i g h t C o m b a t A i r c r a f t ( L C A ) , Advanced Light Helicopter (all versions i.e. Army, Airforce, Navy & Civil) andI n t e r m e d i a t e J e t T r a i n e r ( I J T - 3 6 ) . T h e D i v i s i o n h a s a l s o d e v e l o p e d a n d h a s made successful strides into the area of Microprocessor based control systems.Design and Development capabilities include Environmental Control Systems& Pneumatics, Fuel Management, Engine Fuel Control & aircraft fuel systems,M i c r o p r o c e s s o r b a s e d C o n t r o l l e r s , H y d r a u l i c S y s t e m & P o w e r C o n t r o l s , Wheels and Brakes, Cockpit instruments and sensors, Gyroscopes, ElectricalPower Control Protection, Navigation and Display, Land Navigation, Groundsupport equipment, Dedicated Test rigs, and Computerised test equipment. TheDivision has diversified in other defence applications like tanks and armouredv e h i c l e s f o r A r m y, a n d t o o k c o m m e r c i a l a p p l i c a t i o n s o f H yd r a u l i c i t e m s , Gyroscopic Equipment, Special Purpose Test Equipment & Ground Support Equipment.The Division has also made steady progress in the area of Exports. Therange of products and services available for exports include:1 . R o t a b l e s a n d s p a r e s o f J a g u a r I n t e r n a t i o n a l a n d C h e e t a h ( L a m a ) , C h e t a k (Alouette) Helicopters;2. Ground Support Equipment for MiG 23, 27, 29 Mirage-2000, Jaguar, LCA, Su-30, Sea-Harrier, Dornier DO-228, Avro HS-748, Cheetah, Chetak, MI-17, and

ALH.3. Repair and Overhaul of aircraft accessories of MiG series, Jaguar International,Cheetah (Lama), Chetak (Alouette) and Dornier. The Division today has a prime name in the aviation world and a number o f international companies are interested to join hands with it for future projects.H.A.L. accessory division , Luknow is divided into three main factories namely1. Mechanical Factory2. Instrument Factory3. Fuel Factory INSTRUMENT FACTROY This factory deals with the testing and assembly of electronics instrumentsused in aircraft e.g. Altimeter,RMI, Gyro-magnetics compass , black box etc.This INSTRUMENT FACTORY is further divided into four units which are asfollows: CLEAN ROOMS ASSEMBLY AND TEST SHOP 2 & 3 ELECTRO ROTATING MACHINES GROUND LAND NAVIGATION SYSTEM SHOP (G.L.N.S Shop) Clean room In Clean room those subunits are assembled and tested that are sensitive todust, temperature and humidity. All these parameters are kept under control because these can have adverse effect on their functional efficiency.The required specification for the instruments assembled and tested aredifferent .so Clean room is further subdivided into three units. The followingchart is given for the classification of clean room.

Flight Instruments As pilot flew there aircraft with only "needle, ball and airspeed". This isrefered to the compass, a level, and a speedometer or airspeed indicator. Nowthese are still in use, but added with a few things to keep up with technologicaladvances and flight research. What does a pilot want to know? Airspeed,altitude, heading, rate of turn, feet per minute in climb or descent, and theattitude of the airplane as compared to the horizon.

These are the basic six instruments. Here's a review of the Basic Sixinstruments found in the cockpit of any plane. Their position varies, but thesesix are always there Fig.1. The Basic Six Instrument inside any cockpit Fig.2 . The basic six irspeedAltimeter VerticalSpeedIndicator AttitudeIndicator Direction alGyroTurn Indicator

The flight instruments give the pilot feedback on the three axes and hisown skill and coordination. Instructors like to cover them up, just to see howwell a pilot can fly by the seat of his or her pants or strictly by "feel". Theinstructors also like to place a "view limiting device" on the pilot to ensure thatthe pilot is relying on the instruments alone and not using outside visualreferences. Pilots must trust the instruments since the human body often givesfalse sensations. That is why there are redundant instrument systems.As these flight instruments were basically based on the principle of GYRO. So also sometimes these are called GYROSCOPIC INSTRUMENTS. Gyroscopic Systems and Instruments GENERAL

The gyro instruments include the heading indicator, attitude indicator andturn coordinator (or turn-and-slip indicator). Each contains a gyro rotor driven by air or electricity and each makes use of the gyroscopic principles to displaythe attitude of the aircraft. It is important that instrument pilots understand thegyro instruments and the principles governing their operation. PRINCIPLES 1 . R I G I D I T Y I N S P A C E : The primary trait of a rotating gyro rotor is rigidity in space, or gyroscopic inertia. Newton's First Law states in part: "A body in motion tendsto move in a constant speed and direction unless disturbed by some externalforce". The spinning rotor inside a gyro instrument maintains a constantattitude in space as long as no outside forces change its motion. This stabilityincreases if the rotor has great mass and speed. Thus, the gyros in aircraftinstruments are constructed of heavy materials and designed to spin rapidly(approximately 15,000 rpm for the attitude indicator and 10,000 rpm for theheading indicator).

Fig.3. Universally Mounted Gyro The heading indicator and attitude indicator use gyros as anunchanging reference in space. Once the gyros are spinning, they stay inconstant positions with respect to the horizon or direction. The aircraft headingand attitude can then be compared to these stable references. For example, therotor of the universally mounted gyro (See Universally Mounted Gyro figure,on the right) remains in the same position even if the surrounding gimbals, or circular frames, are moved. If the rotor axis represents the natural horizon or adirection such as magnetic north, it provides a stable reference for instrumentflying. 2. PRECESSI ON:Another characteristic of gyros is precession, which is the tilting or turningof the gyro axis as a result of applied forces. When a deflective force is appliedto the rim of a stationary gyro rotor, the rotor moves in the direction of theforce. When the rotor is spinning, however, the same forces causes the rotor tomove in a different direction, as though the force had been applied to a point90 around the rim in the direction of rotation (See the Precession Force figure, below right). This turning movement, or precession, places the rotor in a new plane of rotation, parallel to the applied force