VISVESVARAYA TECHNOLOGICAL UNIVERSITY

“Jnana Sangama”, belgaum-590014, Karnataka

An Internship Report on
“MAINTENANCE REPAIR AND OVERHAUL”
Submitted in partial fulfilment of the requirement for the award of the degree of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

Submitted by

HEMALATHA G

1DB16ME425

Internship carried out at

HINDUSTAN AERONAUTICS LIMITED

INTERNAL GUIDE EXTERNAL GUIDE

Dr. JAYALAKSHMI.N Mr.K.K.BASAVARAJU
Associate professor. Deputy Manager
Dept of Mechanical Engineering, MRO, Final Assy.
DBIT, Bangalore HAL, Bangalore

Department of mechanical engineering

DON BOSCO INSTITUTE OF TECHNOLOGY

Kumbalagodu, Mysore road, Bangalore-560074

 DON BOSCO INSTITUTE OF TECHNOLOGY
Kumbalagodu, Mysore road, Bangalore- 560074

DEPARTMENT OF MECHANICAL ENGINEERING

DECLARATION

I, HEMALATHA G bearing USN: 1DB16ME425, student of final year B.E, Department

of Mechanical Engineering, Don Bosco Institute of Technology, declare that the

Internship work entitled “MAINTENANCE, REPAIR, AND OVERHAUL” has been carried

out by me at “HINDUSTAN AERONAUTICS LIMITED” and submitted in partial fulfilment

of the course requirements for the award of degree in Bachelor of Engineering in

Mechanical Engineering, of Visvesvaraya Technological University, Belagavi, during the

academic year 2018-2019. The matter embodied in this report has not been submitted

to any other university or institution for the award of any other degree or diploma.

Place: Bangalore NAME: HEMALATHA G

Date: USN: 1DB16ME425

 DON BOSCO INSTITUTE OF TECHNOLOGY
Kumbalagodu, Mysore road, Bangalore- 560074

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Certified that the internship report entitled “maintenance repair and overhaul” carried out
by HEMALATHA G (1DB16ME425), bonafide student of Don Bosco Institute of
Technology, Bangalore in partial fulfilment for the award of bachelor of engineering in
mechanical engineering of the Visvesvaraya Technological University, Belgaum during the
year 2018-2019. It is certified that all corrections/suggestions indicated during internal
assessment have been incorporated in the report. The internship report has been approved as
it satisfies the academic requirements for the award of degree.

Internal Guide External Guide

Dr.Jayalakshmi.N Mr.K.K.Basavaraju
Associate professor. Deputy Manager
Dept, Mechanical Engineering MRO,Final Assy,
DBIT, Bangalore HAL, Bangalore

HOD Principal
Dr.Nagaraj.N Dr.Murallidhar Rao
Professor and head Principal
Dept, Mechanical Engg DBIT, Bangalore

Examiners Signature with date

1.

2.
 ACKNOWLEDGEMENT

It is indeed a great pleasure for me to present this internship training report on

Helicopter MRO Division carried out at HAL Bangalore, as a part of curriculum of
Bachelor of Engineering (Mechanical Engineering) degree.

I take this golden opportunity to thank all my mentors at HAL who with their support and
venerated guidance made this training a real success.

I express my sincere thanks to officers of HAL who in spite of their busy schedules have lent
their precious time for helping out me to understand various systems used in HAL.

My heartfelt gratitude to Mr.K K.BASAVARAJU Deputy manager MRO,FinalAssy,Mr.

HARISH and Mr. MUTHURAMAN of transmission department, and most importantly
Mr.BHEEMANNA KUBAKADDI and SHANMUGAM who helped me in completing my
internship training.
EXECUTIVE SUMMARY
Hindustan Aeronautics Limited is a major public sector undertaking engaged in
the design, manufacture and overhaul of variety of aviation products from small aircraft to
sophisticated fighters, transport aircraft, their power plants, avionics and accessories.
Today HAL has 16 production units and 9 research and design centers spread over at
Bangalore, Nasik, Koraput, Kanpur, Lucknow, Korwa, Hyderabad and Barrackpore. Its
products track record consists of 12 types of aircraft from in house R & D and 13 types by
license production. The company has well trained, highly skilled and experienced personal
belonging to Production, Management, Quality, Finance, Customer services and Commercial
activity. With particular reference to Aero Engines, HAL has two dedicated production
centers at Bangalore and Koraput. HAL has so far produced about 3352 aircraft (which
include 11 types of indigenous design), 3583 engines and overhaul over 8141 aircraft and
27267 engines.
1. Understanding of integration of working of various departments in the company to
achieve sound and errorless production of helicopters.
2. Enhancement of working and problem solving skills.
3. Knowledge regarding the working of helicopters i.e., aerodynamics, the structure of
helicopter, the engine, the control unit, power transmission etc.
4. Implementation of advanced technologies in manufacturing.
5. Effective time management skills.

The objective of the study is to identify the strength and weakness of the organization
analyzing the function of each department and study the growth, objectives and achievements
of each department. During this study various department heads were met and relevant data
were collected. Various factors like company’s profile, quality of products, marketing
strategies adopted by H.A.L and after sales service facilities was observed. Based on the
information collected SWOT analysis was prepared.
 CONTENTS

CHATER NO. CHAPTER NAME PAGE NO

1. COMPANY PROFILE 1-4

2. DIVISIONS OF HAL 5

3. AREA OF STUDY 6-48

4. OUTPUT OF THE INTRENSHIP 49

 LIST OF FIGURES
Figure1.1: Organisational growth of HAL ……………………………..Page. 3

Figure 3.10: Turbo Meca TM 333 2B2 Engine…………………………Page. 8

Figure 3.11: Digital Engine Control Unit (DECU)……………………..Page. 11

Figure 3.12: Working principle of gas turbine cycle…………………....Page. 14

Figure 3.13: Hydraulics system ………………………………………...Page.15

Figure 3.14: Block diagram of DHRUV control hydraulic system…….Page.16

Figure 3.15: Hydraulic Pump……………………………………………Page. 17

Figure 3.16: Hydraulic Package…………………………………………Page. 18

Figure 3.17: Package operations and schematic representation…...…….Page. 21

Figure 3.18: Hydraulic Actuator………………………………………...Page. 21

Figure 3.19: Main components hydraulic actuator…………………...…Page. 22

Figure 3.20: Bernoulli’s Principle……………………………………....Page. 23

Figure 3.21: Forces in action during flight……………………………...Page. 24

Figure 3.22: Transmission system………………………………………Page. 25

Figure 3.23: Main Gear Box (MGB)……………………………………Page. 26

Figure 3.24: Auxiliary Gear Box (AGB).………………………………Page. 26

Figure 3.25: Intermediate Gear Box (IGB)...…………………………...Page. 27

Figure 3.26: Tail Gear Box (TGB)………………………………………Page. 28

Figure 3.27: Tail rotor system……………………………………………Page. 29

Figure 3.28: Dual needle Tachometer of main gear system……………..Page. 30

Figure 3.29: Main Rotor System………………………………………...Page.30

Figure 3.30: Skid Version……………………………………………….Page.34

Figure 3.31: Wheel Version……………………………………………..Page.35

Figure 3.32: Mark1 display……………………………………………...Page. 36

Figure 3.33: Mark2 display……………………………………………...Page. 36

Figure 3.34& 3.35: DHRUV & RUDRA in Indian Army………………Page. 38&42

Figure 3.36: Monolithic construction …………………..……………… Page. 45