Overhaul Division Bangalore
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Brief History

Welcome to Overhaul Division of HAL (Bangalore Complex).

Overhaul Division, one of the oldest Divisions of HAL was established in December 1940, has been involved from early days in the growth of aircraft industry in India. Between 1942 and 1945, the Division maintained and repaired varieties of aircraft like Liberator, Fortress, Mitchell, Dakota, Curtis Commando and PSY Catalina amphibian aircraft. After 1947, the Division oriented its activities to Major Overhaul of aircraft of Indian Air Force and Indian Navy and rendering 1st and 2nd Line Maintenance support to aircraft at various IAF and Naval Bases.

The Division, with over 70 years of experience in aircraft MRO has serviced over 4000 aircraft of different types and over 6500 Piston Engines.

The Division has since emerged as a world class MRO agency for the maintenance and servicing of state-of-the-art Military aircraft, Piston engine and associated accessories. It also renders highly competent maintenance and retrofit support at user’s works.

Currently it is the only Organization authorized to undertake Major Inspection of Mirage 2000 aircraft outside France. The Division is currently exporting its products and services to Malaysia, Mauritius and Oman.

Spread over an area of more than 10 hectares of land, Overhaul Division is empowered by a highly skilled workforce comprising of more than 1000 personnel supported by over 250 well qualified and experienced Executives.

The Division has a well equipped Accessories Repair / Overhaul Centre with excellent infrastructure to handle sophisticated Mechanical, Pneumatic and Avionic accessories. Highly sensitive testing equipment are employed during Repair / Overhaul of over 900 types of system accessories.

Division’s Quality Certifications

Overhaul Division has the following approvals:
  • Director General of Aeronautical Quality Assurance (DGAQA), MOD, India.
  • M/s. Dassault Aviation, France
  • M/s. BAE Systems, UK.
  • AS 9100B Quality Management Systems.
  • ISO 14001:2004 EMS. 
The Division is equipped with modern facilities which include:
Non-Destructive Testing (NDT) Facilities
The NDT facilities available in the Division include state of the art equipment and approved manpower for identification of surface and sub-surface / internal discontinuities employing the following methods :
  • Ultrasonic Testing
  • Phased Array Ultrasonic Technique
  • Magnetic Particle Inspection
  • Eddy Current Testing
  • Liquid Penetrant Inspection
  • X-Ray / Radiography

Selective Electroplating Process
Overhaul Division has facilities to carry out the following two types of selective electroplating processes :
  • Dalic Brush Plating and
  • Dalic Circulation Plating

Calibration of Test Equipment, Tools and instruments
State-of-the-Art facilities exist in the Division for Calibration of Electrical Measuring Instruments and Precision Mechanical measuring instruments.

The Division carries out calibration of these instruments for other Divisions of HAL and Civil Aviation customers.
Recharging of Liquid Oxygen
Overhaul Division caters to the requirements of Defense Customers and Civil Aviation customers for recharging of Liquid Oxygen Converters.
Reconditioning / Rebuilding of Batteries
Division has built-in facilities for reconditioning and recharging of Batteries required for different aircraft including commercial batteries.
Condition Monitoring Systems
Special facilities exist in the Division for carrying out Contamination Checks on Hydraulic Fluids specification MIL 5606H, aviation turbine fuel DERD 2492. These Contamination checks are carried out not only for internal customers, but also for other external agencies like NAL for their SARAS programme. This helps in estimation of wear rate-life of aircraft components. Facility also exists to check the water content in oil with the help of advanced technology using LASER.
Paint Removal/Painting
Division has built-in facilities both for Paint Removal and special Paint Booths to carry out painting under various painting schemes as applicable for Aircraft and Accessories. All the processes followed at Overhaul Division are Environment Friendly and ISO14001:2004 Certified.
Overhaul Division has partnerships with a number of Approved and Accredited suppliers apart from Original Equipment Manufacturers (OEMs)

Stringent Quality Control Checks are ensured during the approval / acceptance of outsourced components.

Outsourcing is resorted for :
  • Fabrication of project spares identified.
  • Manufacture of Ground Handling Equipment and Ground Support Equipment.
  • Fabrication of Tools and Fixtures.
  • Calibration of Gauges.
  • Jig referencing and Plating Operations.

Indigenous Manufacture of Components

Overhaul Division also manufactures some of the Aircraft and Helicopter components in-house.
  • Overhaul Division has been accredited with AS 9100C Quality Management Systems certificate by DEKRA Certification.
  • Overhaul Division has been certified with ISO 14001:2004 Environmental Management Systems by BIS.
  • The Division is Honoured with a special award from the Chief of Air Staff, IAF in Nov 2002 in recognition of its yeoman services.
  • The Division bagged the “Best Customer Services Award” for the year 2002-2003.
  • The Division is Honoured with Safety Award “Utthama Surakasha Puraskara"  by National Safety Council Karnataka Chapter, Bangalore for Best Safety Performance and Management Systems during the year 2009-2010.

Apart from the various services rendered by Overhaul Division, it also undertakes supply of Ground Servicing, Ground Handling and Test Equipment such as :
  • Ground Power Unit (GPU)
  • Aircraft Towing Arm
  • Hydraulic Recycling Rig
  • Air Conditioning Rig
  • Liquid Oxygen Dispenser
  • Pyrometric Test Set
  • IFF Tester
  • Pilot Access Ladder for Mirage 2000
Major Servicing of Aircraft
 For over seven decades, Overhaul Division has been a leading Military Aircraft Maintenance, Repair and Overhaul organization in India. Spread over an area of 10 hectares of land, our maintenance facilities comprise of 5 Hangars and 16 Independent Bays exclusively for offering MRO services to aircraft and accessories. All hangars are equipped with modern Ground Support, Ground Handling Equipment and Testers conforming to the DGAQA specifications.  We also possess a runway adjacent to our Division convenient   to conduct Taxi Checks, Flight Trials etc.

With such extensive and efficient facilities, we are able to provide total Maintenance, Repair and Overhaul Support to aircraft ranging from Piston Engine aircraft to the State-of-the-Art aircraft like Mirage 2000.

Apart from regular Maintenance, Repair and Overhaul, we also cater to special component level structural repairs on airframe like Tail Plane, Flaps, Under-Carriage Door, Engine Bay Door, Air Intakes, Fin, Rudder, Bird Hit Repairs on Fuselage and Wings, Honeycomb Panel, Integral Fuel Tank Repairs and Replacement of Flexible Fuel Tanks. Our capabilities include Aircraft Major Structural Inspection/Repair, Defect Investigation/Repair, NDT Repairs, Estimation of CG on modified aircraft, Paint Removal and Painting of Aircraft, Nose Cone Repairs, AOG Repairs etc.

We also undertake the compliance of the Company Special Technical Instruction (CSTI), Company Service Instruction (CSI) and Compliance of Modifications as per Standard of Preparation (SOP) for Enhancement of Role and Life of the aircraft components and to ensure Reliability. The Engineering Support and Maintenance activities are rendered by a host of highly skilled technicians and qualified Engineers trained at various Original Equipment Manufacturers.
Maintenance Support to Customers on site
Overhaul Division provides maintenance support to Military aircraft at various Customer bases of IAF and also the Kiran and Sea Harrier Aircraft at Goa Naval base.

In addition to the maintenance of aircraft at Outstation Bases, the Division also undertakes the repair of Aircraft, Engines, Retro-Compliance of Modifications and Snag Rectification at the Operating Units on ‘as and when’ required basis.
Aircraft MRO

  • Major Servicing of Jaguar Aircraft and Accessories.
  • Deputation of Technical Experts  for I and II line Servicing at Jaguar Aircraft Operating bases.
  • Belly Landing Repairs , Battle Damage Repairs  and Bird Strike Repairs.
  • Up gradation of Aircraft  from NAVWASS  to DARIN II  /DARIN III as per Customers’ requirement.
  • Compliance of VOR/ILS/TACAN  and Fatigue  Index modification based on Customers’ requirement, Connector change etc.
  • ECM capabilities enhancement by compliance of RWR mod, SPJ mod., Laser Designated Pod,  Counter Measure Dispensing System (CMDS),  Cockpit Laser Designation System (CLDS).

For Further Details Please Contact:

General Manager
Overhaul Division

Hindustan Aeronautics Limited
P.O. Vimanapura
Bangalore - 560 017
Karnataka State

Telephone : +91 -080 - 22313639
Fax : +91 -080 - 22311181
E-mail : gm.ohl@hal-india.com

Customer Services and Marketing:

Telephone / Fax : +91 -080 - 22318225.
E-mail : cs.ohl@hal-india.com