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Tarmak007 -- A bold blog on Indian defence: World-Beaters: The fly-by-wire FCS will take India to new heights (Part-III-B)
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We had 4 designers and 4 testers in 1993. No man power, no experience. No tools and 50 per cent of us were ladies. And, the government rule says that if you are woman, you can't work beyond 6 pm. But with all issues revolving around the LCA project, we decided to give everything.
During those days it was a remote building and we were scared to move around after 6, due to snakes. Permission was denied to get our two-wheelers inside, despite all these issues. Once, Dr Kalam came to the lab and he had to encounter a snake. The rest is history. We were given permission to get the vehicles.
We had to a huge challenge to make the design document within 3 months. We used to go home sometimes at 2 am and family life went for a toss. Some of our colleagues left the job due to the tough conditions. We stuck on and from that batch, there are only 3 scientists left, including me. (The others are: Asha Garg, Sc F and Sreekalakumary, Sc E.)
Even we impressed the GE A/C management with our ETS: Gurdev, Group Director
The GE A/C management was very impressed with the systems given by ADE. They even invited us (ADE) to bid for developing such systems for their own projects. This was definitely a never-heard-before in DRDO. A total of 5 such ETS have been built and are the workhorse for ATP, HSI, V&V, PIL open loop/ closed loop, fault free tests at HAL Iron Birds. These systems are operational since 1995 and have been used for all DFCCs & software operational in various LCAs fling so far.
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for the guys who are lying through their teeth that IAF waited 25 years for tejas and all the delays of tejas program is due to the faults of ADA , the above link is a clear rebuttal of their argument,
----------------------------------------------------------------------------------------------------------------------------------------------------
It was none other than philip rajkumar Airmarshal from IAF who was deputed to LCA program who stated in his book, Tejas story, "IAF dropped the ball from 1993 to 2006. It onlt came on board after 2006 and started issuing design changes to suit them , this further delayed the program"
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here is what P Rajkumar (IAF) who was involved with the LCA says -
quote -
Philip Rajkumar on May 1, 2012 at 6:01 am said:
philip rajkumar
I worked in the LCA project for nine years from 17 Sep 1994 to 31 Aug 2003 (actually 17 days short of nine years!). I was deputed to ADA by the IAF to oversee the flight test programme of the Technology Demonstration phase of the project. Having been on both sides of the fence i have a few points to make.
1. Development of a capable aeronautical industry is a small step by small step evolutionary process.Infrastructure and skill sets of the work force have to be built up over decades with considerable effort. All this requires investment of money and managerial resources. Mainly due to financial constraints and lack of vision in the IAF, HAL and the GOI we allowed capabilities built up during the Marut and Kiran programmes to atrophy. While the world leapt ahead with several technological innovations like fly by wire,digital avionics and use of composites for structures HAL did not run a single research programme because it was not the practice to do research unless it was linked to a specicific project.
2.The LCA project is where it is today thanks to one man-Dr VS Arunachalam who as the SA to RM in 1985 had the gumption and clout to go to the GOI and convince them that India could build a fourth generation fighter. It was a leap of faith no doubt.
3. HAL feels wronged about being asked to play second fiddle to ADA. This pique continues to hurt the project even today.
4. Without help from Dassault of France,BAE Systems UK, Lockheed Martin of the USA and Alenia of Italy we would not have succeeded in developing the fly by wire flight control system,glass cockpit,and composite structures for the two TD aircraft.
5. So far the flight safety record of the programme has been good. I pray every day that it remains that way. The loss of an aircraft early in the programme would have surely lead to its closure.
6.All pilots who have flown the aircraft say its handling qualities are very good. It means it is easy to fly and perform the mission.
7.It needs to be put into IAF sevice as soon as possible to gain more experience to iron out bugs which are sure to show up during operational use.
8.Programme management could have been better. IAF is to blame for washing its hands off the project for 20 years from 1986-2006. A management team was put in place at ADA in 2007.
9.Dr Kota Harinarayana and all those who have worked and continue to work have done so with great sincerity and dedication.
10.Indian aeronautics has benefitted immensely from the programme. It is a topic for separate research.
11. It was a rare privilege for me to have been given an opportunity to contribute to the programme by setting up the National Flight Test Centre and putting place a methodology of work which has ensured safety so far.
12. According to me the project can be called a complete success only when the aircraft sees squadron service for a couple of decades. We will have to wait but it is progressing on the right lines and we as a nation have nothing to be ashamed of.
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The Tejas Debate Continues | TKS' Tales
http://164.100.24.208/ls/CommitteeR/Defence/17threport.pdf
----------------------------------------------------------------------------------------------------------------------------------
The project definition phase of the programme was launched in 1987.
In 1991,
Full Scale Engineering Development (FSED – Phase 1) was launched at a
project cost of Rs. 2188 Cr involving design, production of 2 technology
demonstrators, 2 prototype vehicles, one static test specimen and associated
ground and limited flight tests. This work was completed in 2005.[/QUOTE]
-----------------------------------------------------------------------------------------------------------------------------------------------
We had 4 designers and 4 testers in 1993. No man power, no experience. No tools and 50 per cent of us were ladies. And, the government rule says that if you are woman, you can't work beyond 6 pm. But with all issues revolving around the LCA project, we decided to give everything.
During those days it was a remote building and we were scared to move around after 6, due to snakes. Permission was denied to get our two-wheelers inside, despite all these issues. Once, Dr Kalam came to the lab and he had to encounter a snake. The rest is history. We were given permission to get the vehicles.
We had to a huge challenge to make the design document within 3 months. We used to go home sometimes at 2 am and family life went for a toss. Some of our colleagues left the job due to the tough conditions. We stuck on and from that batch, there are only 3 scientists left, including me. (The others are: Asha Garg, Sc F and Sreekalakumary, Sc E.)
Even we impressed the GE A/C management with our ETS: Gurdev, Group Director
The GE A/C management was very impressed with the systems given by ADE. They even invited us (ADE) to bid for developing such systems for their own projects. This was definitely a never-heard-before in DRDO. A total of 5 such ETS have been built and are the workhorse for ATP, HSI, V&V, PIL open loop/ closed loop, fault free tests at HAL Iron Birds. These systems are operational since 1995 and have been used for all DFCCs & software operational in various LCAs fling so far.
--------------------------------------------------------------------------------------------------------------------------------------------------
for the guys who are lying through their teeth that IAF waited 25 years for tejas and all the delays of tejas program is due to the faults of ADA , the above link is a clear rebuttal of their argument,
----------------------------------------------------------------------------------------------------------------------------------------------------
It was none other than philip rajkumar Airmarshal from IAF who was deputed to LCA program who stated in his book, Tejas story, "IAF dropped the ball from 1993 to 2006. It onlt came on board after 2006 and started issuing design changes to suit them , this further delayed the program"
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
here is what P Rajkumar (IAF) who was involved with the LCA says -
quote -
Philip Rajkumar on May 1, 2012 at 6:01 am said:
philip rajkumar
I worked in the LCA project for nine years from 17 Sep 1994 to 31 Aug 2003 (actually 17 days short of nine years!). I was deputed to ADA by the IAF to oversee the flight test programme of the Technology Demonstration phase of the project. Having been on both sides of the fence i have a few points to make.
1. Development of a capable aeronautical industry is a small step by small step evolutionary process.Infrastructure and skill sets of the work force have to be built up over decades with considerable effort. All this requires investment of money and managerial resources. Mainly due to financial constraints and lack of vision in the IAF, HAL and the GOI we allowed capabilities built up during the Marut and Kiran programmes to atrophy. While the world leapt ahead with several technological innovations like fly by wire,digital avionics and use of composites for structures HAL did not run a single research programme because it was not the practice to do research unless it was linked to a specicific project.
2.The LCA project is where it is today thanks to one man-Dr VS Arunachalam who as the SA to RM in 1985 had the gumption and clout to go to the GOI and convince them that India could build a fourth generation fighter. It was a leap of faith no doubt.
3. HAL feels wronged about being asked to play second fiddle to ADA. This pique continues to hurt the project even today.
4. Without help from Dassault of France,BAE Systems UK, Lockheed Martin of the USA and Alenia of Italy we would not have succeeded in developing the fly by wire flight control system,glass cockpit,and composite structures for the two TD aircraft.
5. So far the flight safety record of the programme has been good. I pray every day that it remains that way. The loss of an aircraft early in the programme would have surely lead to its closure.
6.All pilots who have flown the aircraft say its handling qualities are very good. It means it is easy to fly and perform the mission.
7.It needs to be put into IAF sevice as soon as possible to gain more experience to iron out bugs which are sure to show up during operational use.
8.Programme management could have been better. IAF is to blame for washing its hands off the project for 20 years from 1986-2006. A management team was put in place at ADA in 2007.
9.Dr Kota Harinarayana and all those who have worked and continue to work have done so with great sincerity and dedication.
10.Indian aeronautics has benefitted immensely from the programme. It is a topic for separate research.
11. It was a rare privilege for me to have been given an opportunity to contribute to the programme by setting up the National Flight Test Centre and putting place a methodology of work which has ensured safety so far.
12. According to me the project can be called a complete success only when the aircraft sees squadron service for a couple of decades. We will have to wait but it is progressing on the right lines and we as a nation have nothing to be ashamed of.
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
The Tejas Debate Continues | TKS' Tales
http://164.100.24.208/ls/CommitteeR/Defence/17threport.pdf
----------------------------------------------------------------------------------------------------------------------------------
The project definition phase of the programme was launched in 1987.
In 1991,
Full Scale Engineering Development (FSED – Phase 1) was launched at a
project cost of Rs. 2188 Cr involving design, production of 2 technology
demonstrators, 2 prototype vehicles, one static test specimen and associated
ground and limited flight tests. This work was completed in 2005.[/QUOTE]
In 1999, FSED-Phase 2 was launched at a project cost of Rs. 3302 Cr involving
3 additional prototype vehicles (including a trainer variant) and production of 8
aircraft under limited series production.
Currently, two TDs and two prototype vehicles (PVs) are undergoing flight
evaluation and a cumulative of 567 flights have been completed as of end Oct
06 covering a flight envelope of 1.4 Mach and 15 Km altitude.
The trainer
variant : is under build and is expected to be ready for engine ground run by
Dec 2006. Further a programme for design and development of naval variant of
LCA has been launched subsequently in 2003 at a project cost of Rs.949 Cr
involving development of two prototypes.
During examination of Demands for Grants (2004-05), the Committee were
informed that initial operational clearance of Light Combat Aircraft (LCA) is planned by
2006 and final operational clearance by 2008. In Action Taken Reply to the same
Report, the Ministry furnished revised schedule stating that initial operational
clearance of LCA would be over by March 2007 and final operational clearance by
2009.
During examination of Demands for Grants (2005-06), the Committee were
informed that initial operational clearance would be over by the year 2010. In Action
Taken Reply to this Report, the Ministry informed that initial operational clearance is
planned by 2008 and final operational configuration by 2010.
5.4 The Ministry has furnished reasons for delay in induction of Light Combat
Aircraft (LCA) as under:
Reasons for delay in Full Scale Engineering Development (FSED) of LCA are
"¢ Technology difficulties
"¢ Non availability of systems design & high safety standards
Foreign Exchange crunch of 1991
"¢ Revision of development strategy by increasing indigenous content in
aircraft & ground facilities
"¢ Sanctions imposed by USA in 1998
"¢ Redesign of Composite Wings to cater for Weapon definition changes
specified by Indian Air Force (IAF) during Jan 04.
"¢ Indigenous development & integration of Obsolescence-free Open
Architecture Avionics Systems
"¢ Integration of interim Electronic Warfare (EW) equipment specified by
IAF during 2005
"¢ Extensive on ground evaluation, simulation & testing of indigenous
equipment, systems, software & aircraft.
"¢ Extensive Independent Verification & Validation (IV & V) of complex
airborne software to ensure fight safety
"¢ Co-ordination & integration effort by many work centres to type certify
indigenous equipment systems.
The present status of this project is as given below:
"¢ Confidence in LCA as a flying machine is high and IAF has placed
procurement order for 20 LCA with the manufacturing agency (M/s
Hindustan Aeronautics Ltd.) for inducting one LCA Squadron into
operational service. Production Phase of LCA has also been initiated
concurrently with FSED Phase to gain time advantage.
"¢ There was no cost over-run in LCA FSED Phase 1 programme. As on
date, there is no cost over-run in LCA FSED Phase 2 Programme also.
43
"¢ Production Standard LCA comprises 65% of indigenous equipment (Line
Replaceable Units).
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Following is the reply of the government in parliament regarding LCA program,
Reply of the Government
The programme of indigenous development of Light Combat Aircraft (LCA) had been
initiated in August"Ÿ 1983 with the Government sanction of an interim development cost of Rs
560.00 Cr.
This sanction was to initiate the programme and carry out Project Definition Phase (PDP). After completing the PDP, the report was submitted to Government and proposal to build 07 prototypes was made. The Government of India split the programme into TechnicalDevelopment Phase and Operational Vehicle Development Phase.
The Full Scale Engineering
Development Programme Phase-I (LCA FSED Phase-I) was sanctioned in April"Ÿ1993 at a cost
of Rs 2188 Cr (including the interim sanction of Rs 560 Cr given in 1983). The scope of FSED
Phase-I was to demonstrate the technologies so that a decision could be taken to build
operational proto-vehicles at a later stage.
LCA FSED Phase-I was completed on 31 Mar 2004. While Phase-I programme was in progress, the Government decided to concurrently go ahead with the build of operational proto vehicles.
The scope of FSED Phase-2 was to build three prototypes of operational aircrafts including a trainer and also to build the infrastructure required for producing 08 aircrafts per year and build eight Limited Series Production (LSP) aircrafts. Government sanctioned FSED Phase-II of the programme at a total cost of Rs 3301.78 Cr on 20 Nov"Ÿ2001.
The Phase-II programme has been split into two phases namely, Initial Operational Clearance (IOC) and Final Operational Clearance (FOC). Standard of preparation of operational aircraft was finalized in 2004 with changes in weapons,sensors and avionics to meet the IAF requirements and overcome obsolescence. (Original design was made in 1990s). This contributes to additional time and revised cost for Phase-II.
Governing body of ADA in its 41st meeting held on 22 Nov 2007 had detail review of the
Programme and deliberated on achievements vis-Ã -vis objectives of LCA FSED Phase-II
programme and recommended the extension of FSED Phase-II likely date of completion till 31
Dec 2012 (IOC by Dec 2010 & FOC by Dec 2012) with GE-F404-IN20 Engine and to develop
& productionise the Mark 2 variant of Tejas aircraft and also recommended the constitution of Cost Revision Committee to assess additional requirement of funds.
The need for extension of PDC for LCA FSED Phase-II was due to :
ï‚· Complexity of the system design and very high safety standards lead to extensive testing to ensure flight safety.
ï‚· Incorporating the configuration changes (for example R60 close Combat Missile (CCM)
was replaced by R73E CCM which required design modifications) to keep the aircraft
contemporary
ï‚· Due to non-availability of indigenous "žKaveri Engine"Ÿ design changes were carried out to
accommodate GE404 engine of USA.
ï‚· Change in the development strategy of Radar and associated changes on the aircraft.
ï‚· Major development activity of Avionics was undertaken in order to make aircraft
contemporary, which took time but yielded results (for example, development of obsolescence
free open architecture avionics system).
ï‚· US sanctions imposed in 1998 also led to delay in importing certain items and
developing alternate equipment, since vendors identification and development to production
cycle took time. The need for revision of FSED Phase-II fund sanction was mainly due to :
ï‚· To neutralize the effect of inflation/delivery point cost against the sanctioned level at
2001 and the increase in manpower cost of HAL.
ï‚· To meet the programme management expenditure due to extended time line till Dec 2012
ï‚· Maintain and operate 10-15 aircraft for four years upto 2012
ï‚· To maintain & upgrade the design, development and test facilities upto 2012, in keeping with modern technology.
ï‚· To complete the activities which were not costed in the original estimates.
Cost Revision Committee after careful consideration of the projections made and taking into account the increase in the cost of material, manpower, additional activities to complete the IOC & FOC, maintenance of facilities and expanded scope of the programme etc.
, recommended additional fund of Rs 2475.78 Cr for completing FSED Phase-II activities with PDC Dec 2012, Rs 2431.55 Cr for developing Tejas Mark 2 with alternate engine (LCA FSED Phase-III Programme) and Rs 395.65 Cr for Technology Development Programme (Total additional funds of Rs 5302.98 Cr).
Recommendations of the Cost Revision Committee was accepted by Government and in November 2009, sanction was accorded for continuing Full Scale Engineering Development of LCA till Dec 2018 with an additional cost of Rs 5302.98 Cr.LCA (Tejas) Programme is progressing satisfactorily as per schedule mutually agreed with IAF to meet their requirements.
Flight Test phase on nine Tejas aircrafts to obtain IOC for Tejas, which is mandatory for induction of Tejas into IAF is in advanced stage. Establishment of Tejas production facilities for the production rate of eight aircrafts per annum is progressing concurrently with development activities. On 31 Mar 2006, IAF has executed the contract with HAL for production of 20 Tejas aircraft (series production) powered by GE-F404-IN20 engines in IOC configuration and production activities are in progress. Follow on order of another 20 aircraft is in an advanced stage of negotiation between IAF and Hindustan Aeronautics Limited (HAL).
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