Punj Lloyd in Defence Brochure 2013... · Conversion of civilian aircraft into aircraft for defence...

Punj Lloyd in Defence

Land Systems | Aviation | Electronics | Engineering

Project experience across 21 countries, a robust operational set up and a renowned international and national clientele, have set Punj Lloyd apart as a provider of turnkey complete services, ensuring timely delivery, world-class execution and uncompromised quality. The Group’s ability to take on the impossible, mobilise people & resources and exceed by international standards of execution have further established its credibility as a trusted and reliable partner globally.

Taking this delivery further, Punj Lloyd brings strong capabilities in Defence with

the aforesaid attributes deeply entrenched in its working. This is combined with

smart technology, innovation, security and intense pride at serving the nation’s

defence needs. The objective clearly is to develop genuine force multipliers that

will contribute to providing a decisive edge to the Indian Armed Forces and build

up a robust indigenous defence industrial base.

Oil & Gas Offshore, Onshore & Offshore Pipelines, Onshore Field Development, Tankage & Terminals

Process Refineries, Polymers & Petrochemicals, Chemicals

Power Thermal, Nuclear, Solar

Utilities Water & Sewage Treatment Facilities, Reservoirs, Centralised Utilities

Infrastructure Subway & Metro Systems, Airports, Highways & Expressways, Bridges, Flyovers & Interchanges, Tunnels & Caverns, Seaports & Terminals

Buildings Hospitality & Leisure, Commercial, Industrial, Institutional & Residential Complexes, Healthcare, Townships & Industrial Parks

Asset Management Asset Preservation & Maintenance

Defence Land Systems, Aviation, Electronics, Engineering Services

SPECTRUM OF BUSINESSES

THE GROUP A GLOBAL

CONGLOMERATE

OUR OBJECTIVE

Punj Lloyd strategically diversified into Defence & Aerospace and has established itself

as a credible player for defence equipment with focus on state of the art technology.

The Group has a multi pronged defence strategy with an objective to:

� Become a supplier of choice to the Indian armed forces

� Be a preferred partner for transfer of technology from global primes by setting up

manufacturing facilities in India

� Be an intrinsic part of the global defence equipment supply chain

� Undertake maintenance, repair and overhaul of defence equipment

� Work in partnership with global primes to meet offset requirements as per

the Indian Defence Procurement Procedure

LICENCES

� Guns, Rockets and Missile Artillery Systems and related equipment

� Electro optical systems, fire control systems, C4I systems and power packs associated

with armoured fighting vehicles

� Conversion of civilian aircraft into aircraft for defence application

� Precision manufacture of aero structures and dynamic components for aviation and

land system products

� Fabrication and manufacture of aero-structure, airframes and accessories using composites

� Manufacturing of small arms

Manufacture of Wheeled Armoured Personnel Carrier (APC)

We manufacture strategic high value components for export

A COMPANY WITHAN ENTREPRENEURIAL SPIRIT…

� Grown from

USD 3 million in 2001

to over USD 2 billion

in 2013

� Presence across

all key business

segments in the EPC

industry

� Presence in 21

countries with main

offices in India,

Singapore, Abu Dhabi

and UK

� Over 28,000

employees worldwide

One of the fastest growing groups in South East Asia, Middle East & India

AEROSPACE Punj Lloyd has the most comprehensive aerospace and aero

structure capabilities in the Indian private sector and is poised

to become India’s production

agency.

The Company holds licences

for manufacture of parts

and accessories for aircraft;

conversion of civilian aircraft into

aircraft for defence applications,

precision manufacture of

aero structures and dynamic

components for aviation, land

system product for defence

application; fabrication and

manufacture of aero-structures,

air frames and accessories using composites.

Apart from the licences held, Punj Lloyd has the capability for

Aerospace Design & Analysis through PL Engineering.

Punj Lloyd is also a major investor in Air Works, India’s leading

private general aviation and MRO Company. It is certified to

undertake up to D level checks on A320, B737 and ATRs, among

others. Air Works has also been contracted to undertake MRO

work on IAF VIP jets as well. This relationship allows Punj Lloyd

access to highly skilled manpower, specialised test equipment,

hangar space and access to an independent runway.

Additional hangar space is being created to take on aircraft

assembly line, should the opportunity arise.

LAND SYSTEMS

Punj Lloyd Group is amongst the

select few private companies that were

granted licences by the Government of

India for:

� Manufacture of guns, rockets, artillery

and missile systems.

� Manufacture of electro optical systems,

fire control systems, C3I systems &

power packs associated with armoured

fighting vehicles (Tanks & ICVs).

� Manufacture and assembly of anti tank/

anti material weapons to include hand

held rocket launchers and weapons of

calibre 12.7 mm and above.

� Design, development, manufacture,

assembly, overhaul and upgrade of

armoured fighting vehicles, other

armoured combat vehicles and

unmanned ground vehicles including

associated systems like turrets, turret

mounts and armaments.

� Assembly & manufacture of small arms.

The Group has agreements with leading

global primes for collaboration in Indian

programmes for a wide range of products

including artillery systems, air defence

gun systems, A-vehicle technology,

assault rifles and carbines.

Artillery, Air Defence Systems, Small Arms, Armoured Vehicles, Power Pack, Maintenance, Repair & Overhaul, Upgrade

Aero-structures, Precision Manufacturing, Modification & MRO of Aircraft

Design, Analysis & Simulation, Prototyping, Technical Publications, Embedded Systems,Ruggedised Hardware

Land Systems

Prime Contractor for

Part of the Global Supply Chain

Licensed Manufacturer of

MRO & Upgrades Offset Partner

Aerospace

Engineering Services & Electronics

FOCUSAREAS

Upgrade of the 130 mm gun to 155 mm/45 cal

Strategic Investor in Air Works

� General Aviation

Maintenance,

Air Works

� Air Livery is a

subsidiary for

aircraft painting

� Airline MRO

� Fleet Management

& Aircraft Charters

� Avionics

� FBO, Crew Sourcing

and Training

Punj Lloyd Aviation

� Licensed to modify

civilian aircraft for

defence applications

& manufacture of

aero components and

avionics

� Operating the Group’s

fleet of Gulfstream

aircraft

� Planned investments

in aircraft components

and avionics facility

PL Engineering

� Highly qualified,

experienced and

versatile engineers in

Gurgaon

� Regional offices in UK,

Singapore, Abu Dhabi

Manufacturing & Systems Integration Division, Gwalior

� State of the art, world

class manufacturing

facility on 65 acres

of land, capable

of machining,

fabrication & system

integration of

defence & aerospace

components

AEROSPACE INITIATIVES

CAPABILITY ACROSS THE VALUE CHAIN

Product Design and Development

Simulation and Analysis

Prototyping and Manufacturing

MROServices

Bangalore MRO-Strategic Investor in Air Works

GwaliorManufacturing and Systems Integration Division

GurgaonEngineering Services

ACCESS TO HANGARS AND RUNWAY NEAR BANGALORE THROUGH ITS ASSOCIATION - AIRWORKS

� Runway of 7,000 x 150 ft capable of handling

Airbus A330-200

� Present capabilities include line, base and

AOG support for ATR 42/72, Boeing 737 series

and Airbus 320 series (End 2009) aircraft

� Approved to service over 40 different types

of aircraft

AERO EURO ENGINEERING A JOINT VENTURE COMPANY OF PL ENGINEERING

� Structure & Design Analysis

� Multi Skills/ATA : Structure,

Mechanical Systems, Electrical

Systems, Cabin Interiors, DMU

Integration

� Build to take over big work

packages

� Upgrades/Retrofits

� Non specific work & Certification

� Embedded Electronics

� Quality & Programme

Management

� Concessions

� Technical Publications

� FAA 145/EASA 145 maintenance

organisation certification for Boeing/ATR

� Dedicated aircraft painting facility

� Assembly, retrofit and integration of

sub assemblies onto aircraft platforms

� Engine refurbishment and overhaul

� Component and accessory repairs

Punj Lloyd’s strategy is to establish itself as:

� Prime contractor to Indian armed forces for ‘Make India’ programmes

� Vendor to Indian DPSUs

� Tier 1 supplier to global defence electronics majors

� Partner of choice for global primes for transfer of technology

Punj Lloyd intends to set up world class facilities in collaboration with

suitable partners to develop and deliver:

� Communication & Network Solutions

� Tactical Communication Networks

� Battlefield Management Systems

� Surveillance Systems

� Sighting Systems

� Radar

� Avionics

� Sensors

� Ruggedised electronic equipment and parts

DEFENCE ELECTRONICS

AS 9100C Certified

MANUFACTURING AND SYSTEMS INTEGRATION DIVISION

MANUFACTURING & SYSTEMS INTEGRATION DIVISION

Punj Lloyd has set up top of the line fabrication and assembly facility for defence systems

in Gwalior on 65 acres of land, capable of machining, welding & fabrication of land system

components, assembly, integration and testing of weapons, maintenance and repair facility

for existing weapons of the Indian Army.

Plant & Machinery � 5 Axes Double Column Gantry Milling

Machine

� 5 Axes Floor Type Machining Centre

� 5 Axes Horizontal Machining Centre

� 5 Axes Mill Turn

� 4 Axes Turn Mill

� Water Jet Cutting Machine

� CAR Bottom Furnace

� TIG/MIG Welding

� Laboratory Equipment including CMM,

Micro Hardness Tester, Spectrometer etc.

Manufacturing Facility � Executing world class, lean

& flexible manufacturing

� AS 9100C Certified

� ERP Systems

� World class Test Laboratory

� Compliance to all mandatory

standards

� Management Systems

� Capability to handle exotic

metals and composites

Manufacturing Capabilities � Prototyping

� Heat Treatment

� Heavy Engineering & Fabrication

� Assembly and Integration

� Precision Machining

� Inspection & Testing

� Capable of being scaled to meet

Oil & Gas, Nuclear, Power -

sector requirements

� Spares and after sales support

Table Size

5 x 1.5 m

Rotary Table Diameter

1.6 m

Stroke

XYZ = 8 x 2 x 1 m

Quill Axes

700 mm

Table Size

8 x 3.5 m

Stroke

XYZ = 8 x 5.8 x 2.8 m

Table Size

3 x 2 m

Stroke

XYZ = 5 x 2.5 x 3.2 m

Quill Axes

700 mm

5 Axes Double Column Gantry Machining Center Colgar, Italy � X, Y & Z Axes Hydrostatic for High Accuracy

� Detachable 4+1 Head configuration

� X, Y & Z Axes Repeatability 3 µm

� C & A Axes Angular Accuracy ±4”

� Moving Cross Beam

� 15 T/m2 Load Carrying Capacity Table

� High Pressure through Spindle Coolant 70 Bar

� Auto Tool Changer

� Auto Head Changer

� Rapid Rates 20 m/min

� 5 Axes Machining of Titanium, Steel and

Aluminium Alloys

5 Axes Floor Type Machining Center PAMA, Italy � X, Y & Z Axes Hydrostatic for High Accuracy


� X, Y& Z Axes Repeatability 3 µm


� Through Spindle Retractable Quill

� NC Rotary Table adjacent to Floor Plate






Aluminium Alloys

5 Axes Horizontal Machining Center PAMA, Italy � X, Y & Z Axes Linear Roller for High Accuracy




� Through Spindle Retractable Quill

� NC Rotary Table with Auto Pallet Changer

(2 nos.)







Aluminium Alloys

Stroke

6 x 3 m

Thickness = 160 mm

Table Size

Dia 1 m

Stroke

XYZ = 1.2 x 1.2 x 1 m

5 Axes Water Jet Cutting Flow, USA � 5 Axes Drilling, Taper Correction and

Composite Cutting

� 5 Axes Bevel Head

� 55 degree chamfer

� 360 degree rotation

� Accuracy: ±0.05/500 mm

� Repeatability: ±0.015 mm

� Max Air speed 25 m/min

� Max Cutting speed 25 m/min

� Sigma Nesting Software, compatible

with 5 Axes CAM Software

Stroke

XZ = 210 x 610 mm

Y = ±60 mm

Swing over Saddle

Dia 360 mm

4 Axes Turn Mill Center DMG, Germany � X, Y & Z Axes Linear Roller for High Accuracy

� X, Y& Z Axes Repeatability 3 µm

� C Axes Angular Accuracy ±5”

� Hydro-mechanical Programmable Tailstock


� Feed Rate of 6 m/min

� Machining of Titanium, Steel, Aluminium and

Composite

5 Axes Mill Turn Center Huron, France � X, Y & Z Axes Linear Roller for High Accuracy

� High Torque 5 Axes Machining Head

� Detachable Vertical Rotary Axes on Table



� NC Rotary Table with Auto Pallet Changer

(2 Nos.)






� 5 Axes Machining of Titanium, Steel,

Aluminium and Composite

� 5 Axes CAM Software

WELDING AND HEAT TREATMENT

CAR bottom furnace with a capacity of 10 T and operating temperature of 900° is installed.

Application: Stress relieving, normalising and annealing. TIG and MIG welding facilities also exist.

LAB TESTING EQUIPMENT

The laboratory has a CMM from Zeiss, Germany with a table size of 2.25 x 1.5 x 1 m and having

an accuracy of 1 micron. There is a profile projector having 100 x magnification. Argon gas

based Spectrometer, hardness tester and fully automatic microscope with image analyzer is also

existing in the Lab.

RESEARCH DEVELOPMENT AND TEST FACILITY

Further cementing the Group’s services is PL Engineering, a full spectrum design and

engineering company providing services in Energy, Product and Infrastructure sectors.

PL Engineering also provides consulting services in e-learning and embedded systems design.

By virtue of its past experience, PL Engineering has been able to evolve proven systems and

processes for need identification, transitioning, execution and delivery in a customer centric

manner. Its global delivery model helps to support customers during execution even from

remote locations. To enhance effectiveness in the off-shore delivery model, front-end offices in

US/Canada, Europe and Middle East have been established.

� Focus on value engineering to drive optimum project cost to clients

� Punj Lloyd Group’s wide experience in EPC/AEC domain

� Experienced talent availability with PL Engineering both in engineering as well as in

setting up successful offshore design centers.

� Adoption of proven process and people management practices

� Experience to work in global work share environment

� Focus on value engineering to drive optimum project cost to clients

� High quality project execution with off shore cost benefit

� Global presence in India, Asia Pacific, Europe

and Middle East

� Experience in understanding diverse cultures

while evolving

relationships

with clients

Design

� Layout, Modeling & Detailing (3D & 2D)

� Design Modifications

� Engineering Change Management

� Reverse Engineering

� Value Engineering

Specialised Services

� Welding Design

� Electrical Wire Harness

� Electronic HW Design

� PCB design, Digital, Analog and RF designs

� Microcontroller board designs

Analysis & Simulation

� Meshing & FE Modeling

� Modal Analysis

� Strength Analysis

� Dynamic Analysis

� Design Calculations

� Thermal Analysis

� CFD

� PCB Concept design,

Modeling & Simulation

Manufacturing & Testing

� Process Sheets for

� Components

� Assembly

� NC Code Generation

� Prototype Development

� Low Cost Sourcing

� Test Rig Design & Development

� DOE and FMEAs

PL Engineering offers Engineering and Design services for all disciplines under one roof. The company caters to Plant, Product &

Infrastructure sectors and has experience of working throughout the EPC, PLM & AEC life cycles.

A matrix organisation structure where each discipline is a center of excellence allows fostering of domain expertise, engineering

talent and practice development. The project teams are responsible for resource mapping, planning & control, financial

management and customer interface.

The company has capabilities to provide services during all the stages of the product life-cycle starting from concept design,

analysis and simulation, design and detailing, manufacturing upto after sales support. For defence related products and projects,

PL Engineering offers the following services:

Plant Design and Engineering Services

� Front End and Basic

Engineering

� Detailed Design and

Engineering

� 3D Plant Engineering

and Analysis

� CAD/IT Services

Product Design and Engineering Services

� Design Support

� Engineering Animations

� Analysis Support

� Manufacturing

Support

� Miscellaneous

Services

PL ENGINEERING

Technical Publication

� Electronic Spare Parts Catalogue

� Product Sales Kit

� Maintenance, Repair and Overhaul

Manual (MRO)

� e-Learning modules & Training Video

Development

� Product Assembly Sequence and

Process Manual

Miscellaneous

� Customised application development

� Configuration Management (PDM)

� Product Life Cycle Management (PLM)

� Customisation and Automation

� Template Creation and Part Libraries

Intelligent Airfield/Runway Surveillance and FOD (Foreign Object and Debris) Detection System

Punj Lloyd Ltd has a strategic tie up with Stratech

Systems Limited of Singapore for the iFERRET system.

iFerret is the world’s first intelligent Vision based

Foreign Object & Debris (FOD) Detection System

that provides real-time, automated FOD detection,

location and recording, at commercial airports and

military airbases.

Automated Surveillance for FOD

� Wide area scanning of FOD using

remotely placed electro-optic sensors

� Continuous surveillance of runway

� Automated, 24x7 all-weather

operations

� Operational at night without assisted

illumination

� Built-in redundancy for continuous

detection

iFERRET is more than FOD detection

� Only system that monitors beyond

the Runway

� Night Vision Capability

� Airside security and safety

Surveillance

� Airfield pavement condition

monitoring

� Runway wildlife Incursion

Monitoring

� Battle Damage Assessment (BDA)

Punj Lloyd Ltd will commission,

maintain and upgrade the system

and shall be the single point of contact

for the iFERRET system in India.

iFERRET, THE FUTURE OF AIRFIELD SAFETY AND SURVEILLANCE

Punj Lloyd Ltd Manufacturing & Systems Integration Division L-1, Malanpur Industrial Area, Ghirongi, District Bhind Madhya Pradesh 477 117, India

Punj Lloyd LtdCorporate Office I, 78 Institutional Area, Sector 32, Gurgaon 122 001, IndiaT +91 124 262 0123 F +91 124 262 0111

www.punjlloydgroup.com

Punj Lloyd in Defence Brochure 2013... · Conversion of civilian aircraft into aircraft for defence...

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