Analysis For 1/3 of 36 Rafale Cost, How Upgrading 200 Su-30MKI with AL-31F 177S Engines and Virupaksha Radar Can Create Near 5th-Gen Fleet for IAF

The Indian Air Force (IAF) is at a strategic crossroads as it evaluates the most effective path to modernise its fighter jet fleet and maintain air superiority in a complex geopolitical landscape, highlighted by recent regional tensions during events such as the reported 'Operation Sindoor' in May 2025.

While acquiring more French-made Dassault Rafale jets is one option, a compelling and potentially more cost-effective alternative is gaining traction: a large-scale upgrade of its existing Sukhoi Su-30MKI fleet.

A proposal is being considered to significantly expand the IAF's current "Super-30" upgrade plan.

The initial program, approved in 2023 for ₹19,000 crore, involves modernising 84 Su-30MKI aircraft. The new, more ambitious plan would see at least 200 of the IAF's 260 Su-30MKI jets outfitted with the powerful AL-31F 177S engine and the state-of-the-art indigenous Virupaksha AESA radar.

This extensive modernisation could transform the backbone of the IAF into a near-fifth-generation fighting force, aligning with India's national self-reliance goals in defence manufacturing.

At the heart of the proposed upgrade is the Saturn AL-31F Series 3 (177S) engine, a significantly improved version of the Su-30MKI's current power plant. This advanced engine delivers 14.5 tons of thrust, a 15% increase over the 12.5 tons from the existing AL-31FP engine.

This additional power enhances the aircraft's supercruise ability, allowing it to maintain supersonic speeds without the heavy fuel consumption of afterburners.

Furthermore, the 177S engine boasts a longer service life of 4,000 hours and improved reliability, which is crucial for operations in challenging high-altitude terrains like Ladakh and for reducing long-term maintenance costs.

The second crucial component of the upgrade is the domestically developed Virupaksha Active Electronically Scanned Array (AESA) radar.

Designed by the Defence Research and Development Organisation (DRDO), this system represents a major technological leap over the Su-30MKI's current N011M Bars passive radar.

The Virupaksha radar can detect fighter-sized targets from a greater distance of approximately 250–300 kilometres and can simultaneously track up to 40 targets. Its Gallium Nitride (GaN) technology provides superior resistance to electronic jamming, a critical capability in modern warfare scenarios.

The financial case for the upgrade is highly persuasive.

Equipping 200 Su-30MKI fighters with new 177S engines is estimated to cost between ₹20,000 and ₹25,000 crore. In contrast, acquiring 36 additional Rafale jets would likely cost upwards of ₹90,000 crore, based on the 2016 agreement.

This means the IAF could modernise a fleet of 200 fighters for approximately one-third of the cost of acquiring 36 new Rafales. Such a move would also help address the IAF's declining squadron numbers, bringing it closer to the sanctioned strength of 42 squadrons from its current level of around 31.

While the Dassault Rafale possesses superior features in stealth and its integrated electronic warfare suite, a modernised Su-30MKI presents a formidable package.

The upgraded Su-30MKI would significantly close the technological gap, offering a larger payload capacity, a longer combat radius, and the advantage of a two-person crew for complex strike and air-to-air missions.

By integrating advanced indigenous systems like the Astra series of missiles and the BrahMos-NG, the upgraded fleet would provide a potent combination of numbers, performance, and strategic value, offering India a practical path to securing its skies.

 

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[emgee]

The Su-30MKI is a large aircraft with no radar cross section reducing technologies.
More powerful engines means a larger IR signature. The Su-30MKI has reached the point of diminishing returns.
Why is no one in the Indian defence establishment considering the Su-75?
You don't need a stealthy cruise missile carrier.
You need a stealthy data gathering/distribution mode.

 

[Mc Addy]

Rafael is a dud, so leave the topic as it's now in past memory of the public. Yes, but make the Su-30 MKI with TOT, make engines with TOT and put it to work. Rafael has been a total disappointment, from the deal controversy, to inside France problems, to its landing in the UAE, where Iran targeted them, and now to this fiasco in May 2025, which is unclear yet is a headache. So don't compare anything with the Rafael jet, just do what's best.

 

[R. Singh]

Su-30MKI must attain Mac 2.5 speed and we should also make 105+ Su-57 tech based PMF fighter jet to take the tally of Sukhoi's to 15 squadrons ! R-37M & Astra-II will make it enemy fighter jet killer !

 

[sanket]

Yes, lakhs of times I have said the Super Sukhoi upgrade without the 117S is incomplete. Furthermore, heavier weapons would be carried, and the Super Sukhoi is going to remain until 2060. The current AL-31, which has about 123 kN of thrust, is insufficient with the GaN-based AESA radar with 2,400 to 2,700 TRMs, various sensors and features, and heavy weapons like the BrahMos-2K hypersonic missile and DEW on the Super Sukhoi.

With HAL expected to develop a triple pylon, close to 20 more A2A missiles can be carried. That's why the IAF should consider a 145 kN thrust engine with better technology and close to 6,000 hours.

 

[op gupta]

The Indian Air Force (IAF) has never set its priorities right. It always creates more challenges rather than solutions.

 

[Anonymus]

Kindly buy a few planes, at least 5 squadrons. We are down to 29.

 

[Alok Gupta]

The writer of this article is ignoring the fact that IAF is short on number of planes to adequately fight and dominate in a 2-front war with Pakistan and China. Yes, the Super Sukhoi will be a great addition, but that does not replace the extra squadrons that are required to fight a war. The extra planes are required. They were required yesterday, but they are still not available. Upgrading the existing planes will only increase their capabilities, but it still will not increase the number of planes.

 

[Akshat Panghal]

Prioritizing Su-30MKI upgrades with 177S engines and the Virupaksha radar isn’t just feasible—it’s a strategic imperative. It avoids the massive cost and logistical baggage of new Rafale inductions while delivering a dramatic performance boost on a platform the IAF already operates and supports. The 177S engine offers higher thrust, superior fuel efficiency, and nearly 3x the service life of the AL-31FP, all while being plug-and-play compatible—no airframe changes, no redesigns, no delays. Its modular construction cuts maintenance time and lifecycle costs, enhancing readiness across the fleet. Even more crucially, the 177S shares architecture with the AL-41F, and with over 80% tech transfer on offer, it gives India direct access to core technologies needed to fast-track the Kaveri and AMCA engine programs. Rafales offer none of these strategic, industrial, or economic returns.

And yet—bafflingly—the IAF and MoD have excluded the 177S engine from the so-called “Super Sukhoi” upgrade. That decision completely undermines the point of modernization. Worse, it squanders a golden opportunity to indigenize critical engine tech India has been chasing for decades. This isn’t just short-sighted—it’s strategically negligent.

Why on earth is our government ignoring this? If we’re serious about Atmanirbharta and next-gen capability, the Su-30MKI upgrade must include the 177S engine. No more excuses. No more piecemeal thinking. It's time for bold, informed action.

 

[Sentoki]

From the conflicts all around the world, including Op. Sindhoor, the lesson learned is that it is more important to have air assets that you can continuously develop and evolve as the nature of warfare changes, instead of having the shiniest new toy that you cannot upgrade in 5 years.

The pace of obsolescence in air conflict is such now. In 2018, when we did the G2G deal, the Rafale was perhaps the best 4.5G aircraft money could buy. By the time it had arrived and now in 2025, it is no longer the best 4.5 gen fighter as others have caught up and some have even surpassed it.

Ultimately, at Op. Sindhoor it was all the air assets that we had some control on development and upgrade that helped us, be it the S400, L70, Akash, SU-30MKI with Brahmos, the Brahmos itself, etc.

If the government and IAF understand this lesson properly, they will double down on a serious upgrade of the SU-30MKI instead of chasing the MRFA deal with the French, unless the French will give the same level of autonomy on the Rafale as the Russians have given us with the SU-30MKI. I doubt that the French will ever give that to us.

The Chinese have been strategic about upgrading their Sukhoi clones such as the J16D, where they have replaced metal panels with composites, used S-ducts for air intakes for engine blade radar and IR signature suppression, etc. along with upgraded avionics, radar, and missiles.

Yet for the so-called "Super Sukhoi" upgrade we are doing none of that, just avionics, radar, and weapons. And by the time it arrives, it will be the 2025 Rafale situation all over again where all of the Super Sukhoi upgrades will be commonplace already and even Pakistan will have it, let alone the Chinese. The time for the Virupaksha radar upgrade is now, not 5-7 years from now.

In a 5-7 years timeframe, our Sukhoi 30s need to be an all composite airframe with S-ducts, a near 5th gen engine (177s), and MUMT.

This must be the lesson learned on the 5th gen fighter procurement as well. The SU57 may be far from perfect today, but so long as we get the same autonomy with its development as the SU-30MKI, we can evolve it into a much better aircraft for our needs than the F35 ever will be for us.

 

[Anjali Mary]

But the squadron's strength won't increase.

 

[Somnath Sinhababu]

Both are different. The IAF needs more jets; just upgrading the SU-30 will not solve the problem. Why, then, did you buy even 36 Rafales? You could have purchased extra SU-30s with upgraded versions.

You bought 36 Rafales for 7-8 billion dollars and are ordering 26 more Rafale Ms, making all the necessary changes for Indian conditions. If India doesn't go for additional Rafales and manufacture them domestically, all that previous investment will be considered a disaster.

That's why the IAF has to do three deals: 1. A Super Sukhoi with modern engines and avionics; 2. 5-6 squadrons of Rafales made in India; and 3. 4-5 squadrons of SU-57s. If the government goes for 2-3 squadrons of S-500s, that will be a bonus. Remember, all of our indigenous programmes will have to go side by side.

 

[Chinese eater]

Upgrade the existing Su-30, but how will the numbers of sq. match? Does this article mean to buy additional upgraded Su-30?

Indian planners should also get the Nobel Prize for self-killing and complexity development in a project.

 

[Chinese eater]

CDS Rawat had already told to buy Rafale in a staggered manner, then again and again there was thinking and spoiling the system's planned procurement, thereby causing cost overruns.

Now Rafale is almost impossible to buy and not needed actually. Rafale is very, very expensive, not worth it.

It's better to buy Su-57 parts and assemble them in India with a new name to avoid sanctions.

 

[Saurabh Jindal]

This is the most imp. and most critical defence upgrade required currently. Being delayed due to failure of completion of indigenisation of avionics needed in Super 30 currently.

This has led to a great fighter machine becoming obsolete now; it's not fit anymore for the air superiority role it was supposed to perform when acquired as the PAF successfully locked its communication, which led to pilot disorientation.

Now it is only left for different missile testings and firing stand-off munitions from long distances as we lack any other platform for these capabilities.

 

[Muks]

Just a few practical questions for everyone who is really invested in this dream of a Super Sukhoi with Virupaksha Radar and 177S engine being a universal panacea. Some people assume an upgrade to be just replacement plug and play. Sorry but it is almost akin to creating a new ac minus the air frame design phase. Let's look at a few questions, assuming that the upgrade will turn out great and that the process will be without a hitch.

1. Is the Virupaksha even fully ready for experimental ground testing?? How long before it is fully ground tested, integrated with the ac and thereafter fully tested and integrated in the air?

2. To the best of my knowledge, the 177S engine is not yet certified in Russia, let alone fully tested or in production. So when do we expect it to be ready and in production and ready for integration and testing on the Su-30MKI.

3. Integration of the Virupaksha would include integration with all other avionics systems of the Su-30MKI, whether upgraded or legacy. There would also be a need to re-test and certify every single weapon currently cleared with the SU-30MKI and future weapons like the Gandiva etc.

My simple question is this. What is the timeline at which this new super ac be ready for full scale upgrade and what would be the time line for the fleet to be upgraded?? My guess is 12-15 years for the last ac to be upgraded. Assuming HAL is able to keep to schedule.

In the meantime, what does the IAF do about the numbers?? Inducing the MRFA, or MRFA+Gen 5 mix is not a financial bean counting game anymore. It is now a strategic imperative. Thus let the upgrade to Super Sukhoi continue in parallel but also buy and urgently. Find the money which ever way the Govt can.

My apologies for being a party proper but a reality check is necessary.