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.

 

Analysis  After AESA Radar Upgrade, Why Tejas Mk1A Requires Full Revalidation for Astra Mk1 Missile

Sustained Operations in Manipur Lead to Arrest of 15 Militants, Seizing Explosives and Looted Service Arms

[Prem Jain]

Upgrade of SU 30 with new avionics and engines will be good. ToT of SU 57 with licensed production with full autonomy could solve our problems to some extent. Going down in the number of squadron is another worry but the quality of the assets can to some extent solve the problem.

 

[souvick27m]

Keep everything aside. Requesting our country leader to note that we are, at the end of this year will be, left with 29 or 28 squadrons, which is just 3 more than Pakistan and no where near China. We must decide and aquire fast to fill the gap, else we will not get the time to blink and we may have to pay the price for that. Country must survive first, else there will be no place for any party.

 

[Capt Mahendra]

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.

Yes IAF and government should sign up for Su 57 without wasting any more thinking Time and get a surprise from China a Pakistan with their 5th and 6th Gen fighters while our system keeps thinking at a the tortoise pace. I can't understand why the IAF and the govt are not taking the decision to get the Russian offer of Su57 which is a dream offer of Total freedom to improve upgrade and incorporate all our Technologies as the production processes and that too at may be double the cost of wasting time and money on su30 MKI upgradation. Our decision making system is sooooooo slow that by the Time it's taken the technology has moved forward and we are still lagging behind. India must learn from Pakistan in taking critical defence decisions. Like they have already ordered the 5th Gen after op Sindoor. And we are contemplating for last 3 yrs as to what aircraft to induct is very worrying.