Su-30MKI: News and Discussion - 24 July 2021

[Manish_Sharma]

https://x.com/bheemmz/status/2021631044873793872?s=20

Raj Malhotra @bheemmz :
A new Airframe is just 10% of the cost, so why not just build new Su-30MKIs and keep old ones in storage. For just 10% more cost we get 25 yrs extra airframe life

[drnayar]

https://x.com/bheemmz/status/2021631044873793872?s=20

Raj Malhotra @bheemmz :
A new Airframe is just 10% of the cost, so why not just build new Su-30MKIs and keep old ones in storage. For just 10% more cost we get 25 yrs extra airframe life

Not sure if this gent knows that every modern fighter is an unique example of high tech, some even say a sort of finger print code runs through every example identifying each and every fighter. Of course they can be rebuilt but not at 10 % ! It's not exactly car manufacturing !

[Manish_Sharma]

https://x.com/bheemmz/status/2021631044873793872?s=20

Not sure if this gent knows that every modern fighter is an unique example of high tech, some even say a sort of finger print code runs through every example identifying each and every fighter. Of course they can be rebuilt but not at 10 % ! It's not exactly car manufacturing !

What is your take? If not 10% then how much?

[drnayar]

Not sure if this gent knows that every modern fighter is an unique example of high tech, some even say a sort of finger print code runs through every example identifying each and every fighter. Of course they can be rebuilt but not at 10 % ! It's not exactly car manufacturing !

What is your take? If not 10% then how much?

I guess I would contradict myself but depends on damage Vs normal wear and tear ( upto 50 to 70% for damaged fighters)

In the military aviation world, a "fresh rebuild" for an aircraft that isn't damaged but has reached the end of its structural life is called a Service Life Extension Program (SLEP) or a Service Life Modification (SLM).
If the jet is just "worn out" from thousands of flight hours, a comprehensive rebuild generally costs between 3% and 15% of a new aircraft's price, depending on the generation of the jet and the depth of the upgrade.

1. Rebuild Cost Benchmarks
Unlike the 50–75% threshold for damage repair, a planned rebuild for wear and tear is much more economical because the "fingerprint" (the main fuselage and wings) is still basically sound, even if it needs reinforcement.
F-16 Fighting Falcon: A standard SLEP to add 2,000 extra flight hours costs roughly $2.4 million to $3.5 million per aircraft. Compared to a new F-16 Block 70 (approx. $60M–$70M), this is roughly 4–5% of the new unit cost.
F/A-18 Super Hornet: The Navy's SLM program, which extends life from 6,000 to 10,000 hours, was initially budgeted at about $5.5 million per jet. For a $70M aircraft, this is about 8% of the replacement cost.
Engine Overhaul: A "rebuild" of just the engine is a different story. If an overhaul costs more than 80% of a new engine, the military typically swaps it for a fresh unit.

2. What a "Fresh Rebuild" Actually Includes
When a jet goes in for a total overhaul (Depot-Level Maintenance), it isn't just cleaned; it is literally taken apart:
Structural Beef-up: Technicians replace "life-limited" parts like wing attachment points or bulkheads that have developed microscopic fatigue cracks.
Skin & Coating: For stealth jets like the F-35, the radar-absorbent skin is stripped and reapplied.
The "Mid-Life Update" (MLU): Usually, a rebuild for wear is combined with a tech upgrade (new radar, computers, or Link-16 communication systems). This is where the cost creeps up from 5% to 15% or more.

3. The Efficiency of Rebuilding
The reason air forces love these programs is the "ROI" (Return on Investment). For a few million dollars, they get another 10–15 years of service.
Turnaround Time: A full SLEP typically takes about 9 months of "hangar time" per aircraft.
Strategic Bridge: These rebuilds are often used as a "bridge" to keep a fleet flying while waiting for next-generation fighters like the F-35 to be delivered.

Summary Table: Rebuild vs. New
Jet Type Rebuild (SLEP/SLM) Cost Est. New Unit Cost Rebuild %
F-16 ~$2.4M - $3.5M ~$65M ~4-5%
F/A-18 ~$5.5M - $15M* ~$70M ~8-20%

So there might indeed be a case for rebuilding fighters much like Super Sukhoi program.

The Service Life Extension Program (SLEP) for the Indian Air Force (IAF) Su-30MKI, often referred to as the "Super Sukhoi" upgrade, is expected to cost approximately $94–$95 million (approx. ₹700–800 crore) per aircraft. This program aims to upgrade around 84 to 150+ aircraft, with total project costs estimated between $2.4 billion and $7.8 billion (around ₹66,829 crore).

Key Details of the Su-30MKI Upgrade/SLEP:

Objective: The upgrade extends the service life of the Su-30MKI fleet until 2055, providing a 20-year life extension and upgrading them to 4.5+ generation capability.

Upgrades Included:
Radar: Replacement of the current PESA radar with the indigenous Virupaksha AESA radar.
Avionics & EW: Advanced mission computers, electronic warfare suites, and new cockpit displays.
Weapons: Integration of BrahMos-A missiles and Rudram-II anti-radiation missiles.
Engine: While initially focused on avionics, the project is part of a wider effort to maintain the fleet, including a separate, massive 240+ engine procurement contract.
Implementation: The upgrade is to be carried out locally by Hindustan Aeronautics Limited (HAL).

Related Costs:
New Aircraft Acquisition: In December 2024, India signed a contract for 12 new Su-30MKI aircraft at a cost of roughly ₹13,500 crore, or approximately $127 million per aircraft.
Total "New" Unit Cost: With the upgrade, a new, upgraded Su-30MKI is estimated to cost around $222 million.

As you see it is not just a matter of swapping skins but also tech upgrades as required.

[Manish_Sharma]

Thank you for such detailed reply, wow such a comprehensive eye opening answer!

[A_Gupta]

^^^ thanks!

[V_Raman]

that is a great detailed reply!

is it a simple addition of 127+95 -> the cost of the parts in that 95 million will be saved from the 127 mil cost right? if the new aircraft is 30% more - isnt that better than upgrade?

This seems to be the logic that led to M2K upgrade which at this point seems like a waste and we could have bought Rafales with that money!

[drnayar]

that is a great detailed reply!

is it a simple addition of 127+95 -> the cost of the parts in that 95 million will be saved from the 127 mil cost right? if the new aircraft is 30% more - isnt that better than upgrade?

This seems to be the logic that led to M2K upgrade which at this point seems like a waste and we could have bought Rafales with that money!

again consider lead times for procurement of materials , labour machinery and financial aspects for new., if the requirement is now , stick to what is available right away., its usually what you have now ., in case of high tech products.

but indian procurement process is not known to consider "time" in their procurement , High tech "evolves" or matures with time ., then it becomes a reliable one. The armed forces often want the end result without going through that often painful process .. its called "disease of plenty of options"

If the RM was a tech person things might have evolved differently , just a thought

[bala]

Engines also don't last long. They are replaced more often depending on usage.