Ten new shops and existing facilities like pipeline overhaul, plating/process and shops of Aircraft Manufacturing Divisions are extensively used during the overhaul (ROH). Tentative Repair Technical Documents (RTD) were received from Russia. During the overhaul process, the technologies have been finalised with the help of Russian and HAL experts. There are 2478 number of tasks/technology process to execute the complete overhaul of aircraft. Online system for tracking/monitoring of parts are also established.
After overhaul (ROH), the first Su-30MKI aircraft - SB 027 is ready for the service of the nation and as a result of the establishment of ROH facilities, the serviceability levels of Su-30 MKI fleet will enhance greatly resulting in strengthening of the Indian Air Defence capabilities.
The twin-seater, long range, multi-role, air superiority Su-30 MKI aircraft are being overhauled at HAL Nashik for the first time in the world on completion of the specified TBO (Time between Overhaul) life, given to it after manufacturing. During overhaul, an aircraft undergoes stripping to skeleton level, checking and reconditioning of each and every repairable component, incorporating more than 600 modifications, replacing the non-repairable defective/life expired components and finally rebuilding it to original configuration of latest standard of Su 30 MKI aircraft.
During overhaul more than 10000 lines of unique part numbers, amounting to nearly 75000 quantities are processed, reconditioned, repaired, overhauled and assembled back on the aircraft. After successful testing of various systems on ground and in air, as per stipulated flight profiles, the aircraft is certified to fly for next assigned TBO life. At present, the TTL (Total Technical Life) of the aircraft is 6000hrs/25 years.
Overhauling process starts when aircraft along with document is received in ARS (Aircraft Receiving Section), incoming test are performed and de-painting of total structure is done.
During aircraft dismantling, major components such as engines, wings, control surfaces are dismantled first and detail dismantling to remove various aggregates/pipelines, flight control rods /bell cranks, fabricated and standard parts etc. are carried out thereafter. The parts dismantled and pre-surveyed are sent to the concerned overhaul shops for further operations/processes.
Aggregates of various systems such as Mechanical system, Landing Gear system, Aircraft Armament system, Aeronautical Equipment system, Electrical systems, Avionics systems are overhauled to give it new TBO life. Broadly, the procedure involved are dismantling, fault finding, part reconditioning/replacement, assembly and testing. Seven hundred and forty such variety of aggregates are involved from all overhauling shops of Nasik and sister Divisions.
HAL teams from project planning, technologists, shop floor personnel, production engineering, quality, maintenance personnel, etc. exhibited high level of professionalism to establish Su-30ROH facilities, technology proving, mastering and freezing of technology, concurrently. Specialists from Russia supported and contributed in the process.
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