Chapter 1

About the Organization

DRDO, the R&D wing of the Ministry of Defence came into existence in 1958, with a vision to
empower India with cutting-edge defence technologies. Its mission is to achieve self-reliance in
critical defence technologies and systems by indigenisation and innovation, while equipping the
armed forces with state-of-the-art weapon systems and equipment. The organisation is headed by
the Scientific Advisor to Raksha Mantri (SA to RM), who is also the Secretary, Department of
Defence R&D and Director General R&D and is supported by eight Chief Controllers (CCR&Ds).
The corporate headquarter of DRDO is housed in DRDO Bhawan, an environment friendly
building located at Rajaji Marg, New Delhi. The DRDO has two tier structure, viz. the Corporate
Head Qtrs.’ at New Delhi; and laboratories/establishments, regional centres, field stations, etc.
across the length and breadth of the country.

With a network of 52 laboratories, which are engaged in developing defence technologies

covering various fields, like aeronautics, armaments, electronics, land combat engineering, life
sciences, materials, missiles, and naval systems, DRDO is India's largest and most diverse
research organisation.

The major responsibilities of DRDO are:

• Design, development and lead to production, the state-of-art Sensors, Weapon Systems,
Platforms and allied equipment (Strategic systems, Tactical systems, Dual Use Technologies).
• Research in Life Sciences, to optimize combat effectiveness of soldiers and promote their
well-being, especially in harsh environments.
• Develop infrastructure and highly trained Manpower for strong defence technology base.

DRDO formulates and executes programs of scientific research, design & development in areas
relevant to national security. It also functions as the nodal agency for the execution of major
Defence related programs with the national scientific institutions, PSUs and private agencies. It
has led to the production of world class weapon systems and equipment in accordance with
requirements laid down by the three Services. In addition DRDO assists the Services by rendering
technical advice on matters such as formulation of Staff Requirements, evaluation of systems to
be acquired, fire & explosive safety, mathematical / statistical analysis of operational problems
etc.

Gas Turbine Research Establishment (GTRE) is a laboratory of the Defence Research and
Development Organisation (DRDO). Located in Bangalore, its primary function is research and
development of aero gas-turbines for military aircraft. In addition to making aero gas-turbine
engines, GTRE has also been developing marine gas-turbines also.

The DRDO has tie-ups with many international countries such as France, Russia, Israel, United
States of America etc. for the purpose of testing and developing of aircrafts.

Major Contributions From Each Cluster Of DRDO In Terms Of Products & Systems
Developed/Accepted/Inducted, Technologies Developed And Infrastructures Facilities
Established:

Technologies Developed and

Products & Systems Developed/ Infrastructures Facilities
Cluster
Accepted/ Inducted established.

Aeronautical LCA-Tejas India’s first indigenously A wide range of highly complex

Systems designed developed and produced multi- technologies have been mastered and
role Light Combat Aircrafts (seven) have massive infrastructure created in the
completed 1150 flights. Induction of first process of development of LCA-
squadron of 20 LCAs is scheduled for Tejas, its sub-systems and the Gas
2010-11. The Naval variant of LCA is Turbine Engine-Kaveri.
also likely to roll out by 2010. The other
success stories are Lakshya Pilotless Unstable Aerodynamics, Flight
Target Aircraft, Nishant-Unmanned Arial Control Laws for Unstable
Vehicle, Electronic Warfare Suites, Configuration Aircraft, Fly-by-wire
Radar Warning Receivers including High Digital Flight Control System, Open
Accuracy Direction Finding (HADF) Architecture Mission Avionics,
RWR, Mission computers and avionics Advanced Composite Structure,
 upgrades for several fighter aircrafts. Hardware and Software for
Missile Approach Warning System and Simulators.
Laser Warning System have been
developed and are being fitted on various
military aircrafts and helicopters. As
spin-offs, variants of Kaveri engine are
being developed for propulsion of marine
vessels with great advantages.

Armament Large numbers of armaments designed Hydro-Pneumatic Suspension, Rocket

Systems and developed by DRDO have been Motor and Thermal Protection
inducted in the armed forces. Over a Composite Propellant
million pieces of 7.62 mm Ishapore Self- Pre-fragmented, Incendiary and
Loading Rifle (SLR) developed by Bomblet Warhead
DRDO were produced till replaced by Electric and Electro-hydraulic
5.56mm INSAS (Indian Small Arms Launcher
System) was made available in fixed &
foldable butt versions of Assault Rifle &
LMG, all firing the same ammunition and
having 70% commonality of parts. Multi-
barrel Rocket System-Pinaka, FSAPDS
ammunition, Influence Mines Mk-I,
Multimode Grenade Under-Barrel
Grenade Launcher, 84 mm light weight
launcher, Bund blasting device, Instant
fire detection & suppression for BMP-II,
.303 inch and 7.62 mm non-lethal bullets
are examples of wide range of products.

Combat Over 50 Main Battle Tank-Arjun Engine Test Facility, Transmission

Vehicle and including 45 for the 1st Arjun Armored Test Facility, Full Injection Pump Test
Engineering Regiment (45 tanks) and 649 Combat Rig, Variable Speed Drive Test
Improved Ajay Tanks equipped with Facility, Variable Speed Drive Test
Explosive Reactive Armour (ERA), Facility, Road Wheel Test Rig, Air
Global Positioning System (GPS), Cleaner Test Rig, Suspension Test
 Integrated Fire Detection & Suppression Facility, Hydraulic Test Bench,
System (IFDSS) & reconfigured Smoke Universal Gear Tester, Ultrasonic
Grenade Discharger (SGD) have been Flaw Detector, Test Facilities for
produced. Other major achievements are Aircraft gearbox, Environmental Test
BHIM-76 Self Propelled 155 mm gun, Facilities consisting of Low
Ex-tank-a combination of T-72 (Ajeya) temperature chamber, Driving rain
Chassis and the most advanced MBT chamber, Water immersion chamber,
Arjun Weapon System, Bridge Layer Dust chamber, Mould growth
Tank Arjun (capability to convert Arjun chamber, Salt spray chamber, Shock
tank to BLT within few hours), Bridge test machine and Bump test machine,
Layer Tank T-72, SARVATRA mobile Test Track Facility, Dry heat chamber
bridge laying system (up to 75 m within and Damp heat for evaluation of
100 minutes), SAKAV 46 m single span structural integrity and performance of
bridge system, MLC70 & MLC 40 electronic and electrical equipment.
Modular Bridges, Carrier Command Post Rapid Prototyping and Prototype
Tracked, BMP-II, Armored Amphibious manufacturing facilities.
Dozer, Mobile Camouflage System A National Centre for Automotive
(integrated in MBT Arjun), NBC Testing (NCAT) at VRDE is equipped
protected Integrated Field Shelter, with state of the art infrastructure for
Remotely Operated Vehicle (Daksh) a testing and certification of defense as
robotic vehicle capable of remotely well as civil vehicles where a modern
handling IED, Riot Control Vehicle, EMC (electro-magnetic compatibility)
Unmanned Ground Vehicle (UGV), test facility, one of the biggest in the
Trackway Expedient Mat Ground world, has been recently added.
Surfacing, Armoured Ambulance BMP-
II, Carrier Mortar Tracked on BMP-II,
Containerized Operation Theatre
Complex on wheels, Ground Support
Vehicles for various indigenous strategic
and tactical missiles, Nishant launcher,
Counter Mine Flail (CMF) on T-72 Tank,
Snow galleries, Micro-pile foundation for
the effective transfer of snow pressure.

Electronic & Artillery Combat Command Control Technologies for achieving High
Computer System-ACCCS. Indian Doppler Radar Accuracy Direction Finding, High
Systems INDRA-I & II. Rajendra - multifunction Power Jamming, Voice Recognition
phased array radar. Super Vision and Voice Print Analysis
Maritime Patrol Radar (SV-2000 Data/image Fusion, Jam-Resistant
MPAR). Avalanche Victim Detector Data Link
(AVD), Battle Field Surveillance Radar- C I Systems, Satellite Communication,
BFSR, a man-portable, battlefield and Secrecy Systems, Multifunction
perimeter surveillance radar has been electronic scanning radars, Parallel
produced in large numbers. Electronic processing, 1- µ CMOS Fabrication
Warfare systems SAMUKTA & Technology,
SANGRAHA for Army and Navy 3D-
CAR (Central Acquisition Radar) GaAs Crystal Growth Facility,
medium range Early Warning Sensor – Molecular Beam Epitaxy System, Ion
Revathi for Navy. Weapon Locating – Implantation system, Electron Beam
Radar. EON 51-Electro-optic Fire Contro Micro Lithography system, MOCVD
System. Briefcase SATCOM Terminal. system , Mask Fabrication Facility,
Sectel (Secure Telephone). Sujav - a Fab line for fabrication of MMIC,
compact communication electronic UHV Processing Stations, Precision
warfare suit. Integrated Weapon System Machining Facilities, Single Point
Simulation. Eye Safe Lasers. Laser Diamond Turning (SPDT) Micro-
Designator. PRF Code Recognition machining Facility
Device for decoding the PRF codes of
laser target designators. Laser Warning
Sensor. Palmtop Green Microchip Laser
Module. Passive Q-Switching. EOCM-
Class Laser System for both anti-sensor
as well as dazzling applications with an
operational range of 2.5 km. 6.5 KW
pulsed X-band and 10kW pulsed Ku band
Coupled-Cavities TWT for airborne
radars, S-band 130 KW (pulsed)
Coupled-cavity TWT.

Life Sciences Life Support Systems for Army, Navy Life Support Technologies. NBC
Systems and Air force Personnel. Combat Free Defence Technologies. Military
 Fall system capable to withstand the nutrition - (fresh and processed foods
harsh conditions of free fall from 30,000 technologies). Military Psychology &
ft. NBC Canister. Water Poison Personnel Selection. Man-Machine
Detection Kit. Portable Decontamination interface. Technology for removal of
Apparatus. NBC Filters/ Ventilation fluoride from water. Technology for
systems. CW Type A/B De-Arsenification of water.
Decontamination kit/ Solution. Herbal Technology for removal of Iron from
Anti-oxidant supplement. High Altitude water. Technology for storage of
adapted & fast growing Broiler Sheep. potatoes under extreme cold.
Bio diesel production. Cold tolerant
hybrid vegetables. Genetically
engineered cold tolerant vegetables.
Hyperbaric oxygen therapy Chamber
(Samudrasuta). One man High Altitude
Pulmonary Oedema (HAPO) chamber.
Heating Gloves & Socks for extreme cold
conditions. Self-contained self-heating
system to warm Ready – to Eat packed
foods at 650 C. Long shelf life ready to
eat packaged food. Bio-digestor for
treatment of human waste for extreme
cold -also being introduced in Indian
Railway Coaches to avoid soiling of
tracks. Multi-Insect Repellent DEPA.
Computerized Pilot Selection System
(CPSS). NBC and high altitude medical
products.

Materials AB Class Steel for Naval Applications, Technologies related to Composite

Titanium Sponge. High Temperature Armor, Special Steels for the Navy,
Titanium Alloys for Aerospace Cast Airfoils for Gas Turbines,
applications. NBC Recce Vehicle. NBC Titanium Alloys, Rare Earth Metal-
Protective Clothing/Permeable Suites, based High Energy Magnets, Armour
NBC water purification system. for Fighting Vehicles, NBC
Camouflage Pattern Generation Software. Protection, Camouflage and Stealth,
 Synthetic Camouflage Net. Mobile Desert Systems and Radiation
medical post for Navy. Extreme cold Instrumentation.
weather Clothing systems. Blast
Protection Suits. Synthetic Life Jacket.
Anti-Riot Polycarbonate Shield. Anti-
Riot Helmet. Brake pads for Aircrafts.
Heavy alloy Armor Penetrator Rods.
Jackal Armor. Kanchan Armor.
Hydraulic Pipeline for Submarine
Applications. Investment Casting of
turbine components etc.

Missile & Surface-to-surface strategic missile Technologies for indigenous

Strategic systems Agni I (700 km), Agni II (2000 development, testing & production of
Systems: km) and Agni III (3000 km). Prithvi Fiber Optics Gyro, Ring Laser Gyro,
series of surface-to-surface missiles. Accelerometers, Inertial/ Autonomous
BrahMos Supersonic Cruise Missiles for Navigation Systems, MEMS and
Army and Navy. Dhanush-ship launched MEMS based sensors, Directional
SS missile. Akash – multi-directional, warheads, Direct Action Trajectory
multi-target SAM area defense weapon and Altitude Control System, Long
rd
system. Nag – 3 generation anti-tank range Solid Rocket Motors,
missile. Air Defense System against Smokeless Propellant, Composite
ballistic missiles of up to 2000 km class, Rocket Motor casings, , Carbon
both low altitude and high altitude (80 Composite Re-entry Vehicles,
km). RINS- Ring Laser Gyro based INS- Composite Radomes, Seals and jet
GPS-GLONASS for long range missiles vanes for under water Launch system,
and Aircrafts. Millimeter Wave Seeker. Pre-fragmented and Submunition
MINGS- MEMS based Hybrid Warheads. Technologies for
Navigation System. Computerized war Command Guidance, Ram Rocket
games for Army & Air force. Propulsion, Multi Target Engagement,
Twin-engine Liquid Propulsion
Stabilization of Launch Platform for
Moving Ship.
 Multi-band Radar Seeker Test facility,
Electro-magnetic Pulse facility,
Electro-hydraulic servo valve Limited
Production facility, Solid Propellant
Processing facility.

Naval Systems Ship-borne sonar HUMSA. Air borne Sonar Technology. Homing
dunking sonar MIHIR. Submarine-sonar Technology. Pump jet Propulsion.
USHUS. Torpedo Advanced Light TAL. Signal Processing for Target
Torpedoes-Fire Control System and Classification.
Advanced Experimental. Advanced
Panoramic Sonar Hull mounted The floating laboratory - INS
(APSOH). PACHENDRIYA - integrated Sagardhwani, Underwater Acoustics
submarine sonar and tactical fire control Research Facility. Hydrodynamic Test
system. Underwater Telephone (UWT). Facilities: High Speed Towing Tank
TADPOLE sono buoy high altitude (HSTT). Cavitation Tunnel. Wind
deployable sonar. Auto-controlled Tunnel. Acoustic. Shock, Noise and
Carbon Dioxide Control System. Vibration Test Facilities. Under Water
Impressed Current Cathodic Protection Ranges. Torpedo Engineering Centre.
System for Ship hull. Indium Activated Electrical Propulsion Test Centre
Aluminum Galvanic Sacrificial alloy Materials and Acoustic Simulated Test
system. Poly-LIST Dockblock - a (MATS) facility. Cluster computing
substitute for teak wood used for dry facility to provide system level
docking of ships. Heavy duty non-skid simulation of sonar systems–
paint. 250 Kw Silver Oxide-Zinc Battery, DARPAN. Prototype Manufacturing
IR Suppression System For Naval Facility.
Platforms.
 Products of DRDO

Fig 1.1 Light Combat Aircraft (LCA)

Fig 1.2 Nirbhay Cruise Missile

 Fig 1.3 Arjun Mk II 2

Fig 1.4 Lakshya Unmanned Aerial Vehicle

Fig 1.5 Insas Assault Rifle

Fig 1.6 Agni-II missile

 Fig 1.7 Brahmos Missile

Fig 1.8 Manik (Small Turbofan Engine)

Chapter 2
About The Department

Gas Turbine Research Centre (GTRC) took its birth at No.4 BRD Air Force Station, Kanpur in
1959 with 8 Engineers / Scientists and about 20 Technicians.

The First indigenously developed centrifugal type gas turbine engine of 1000 kg thrust was tested
in 1961.

GTRC was moved to Bangalore, brought under the banner of DRDO, and was re-named as GTRE
in November 1961.
In Early 1960s Re-engineering of RD-9F engine, a candidate power plant for the HF-24 aircraft
was carried-out in association with HAL. 1700 K Re-heat system developed for Orpheus 703
engine.

Research was carried out in the 1970s on Reheat for Orpheus 703 Engine was type certified as air-
worthy in December 1973. Series of research projects carried-out on engine optimization studies
mostly related to development of advanced components and systems such as transonic
compressors, annular combustors, high temperature turbines, catalytic ignition systems, control
systems etc.

During the1980s GTRE proceeded to design and develop the GTX series of engines with flat
rating concept which was successfully demonstrated.
Recent Developments.
GTRE proceeded to design and develop the GTX series of engines with flat rating concept which
was successfully demonstrated. Initial sanction for the development of GTX-35-VS was given
With redesigned compressor, six full engines and one core engine were built and
successfully tested at altitude conditions and the performance evaluated.

The marine version of this engine for the Navy was conceived and the first prototype was
successfully integrated and tested at Naval Dockyard, Visakhapatnam.

Kaveri prototype engines were subjected to Acceptance Test Procedures (ATP) at GTRE,
before sending them to Moscow, Russia for Altitude Test and Flying Test Bed (FTB) trials.
73 hours of Altitude Testing was conducted at Central Institute of Aviation Motors (CIAM),
Russia in 2009-10 and the performance and operability of the engine were verified. 57 hours of
Flight Tests were completed in IL-76 aircraft at Russia covering altitude up to 12 km and Mach
no. 0.7 in 2010-11. About 2900 hours of testing completed at ground and altitude conditions as
on date.

GTRE is at present working on eight Technology projects and one AR&DB project titled 'Gas
Turbine Enabling Technology (GATET)'. GTRE is an ISO 9001:2008 certified establishment.

Areas Of Work

 Conceptual design and performance prediction of gas turbine engines & sub-systems to
meet the aero & marine requirements.
1. Real-time simulation for performance verification and control system design.
2. Internal CFD of turbo machinery.
3. Aerodynamic, Thermal & Structural Design.
4. Vibration and Rotor Dynamic Analysis.
5. Materials and Life Prediction.

 Design, Development, Testing and Evaluation of :

1. Fan and Compressor.
2. Combustor.
3. Turbine.
4. Afterburner & Exhaust Nozzle.
5. Rotor support & Internal Flow system.
6. Accessory Drive Gear Box.

 Digital Engine Control System:

1. Design, Development and Testing of Control Laws.
2. Modelling and Simulation of Electro-hydraulic Servo Systems.
3. Design, Development, Testing & Evaluation of Hydro Mechanical Systems &
Digital Electronic Controller.
4. Hardware-in-loop Simulation and Testing.
 Design, Development and Testing of Advanced Data Acquisition System for Engine and
Components Testing.

 Gas Turbine Engine Instrumentation.

 Advance Manufacturing and Quality Assurance.

 Testing to meet Certification of Engine & Sub-systems.

 Aircraft-Engine Integration.

 Ship-Engine Integration.

 Development of Techniques for Fatigue Life Evaluation and Residual Life Assessment of
Aero-engine Turbines.

Products of the Gas Turbine Research Establishment

 GTX 37 Series Demonstrator engines.

 Kaveri Aero Engine demonstrators.
 Kaveri Marine Engine Demonstrator.
 Full Authority Digital Engine Control System (FADEC) for Kaveri Engine & its derivatives.
 Turbocharger for Battle Tank.
 Engine Life Counter.
 Air Turbine Starter.
 Data Acquisition System for gas turbine engine testing.
 HF-24 Afterburner.
 MANIK Engine
 Fig 2.1 GTRE GTX-35VS Kaveri (Airborne)

Fig 2.2Kaveri Marine Gas Turbine (KMGT) [Naval]

Chapter 3.0

Tasks Performed

3.1 INTRODUCTION

ICING is a surface phenomenon which is characterized by the formation of ice on the surface
under icing conditions.

Aircraft icing results in severe an aerodynamic and mechanical effect that compromises the flight
safety and its performance.

Icing on the aircraft has the following effects:

 Decrease in lift
 Increase in drag
 Reduction in control efficiency and performance of the aircraft