Mailing List flyrotary@lancaironline.net Message #58869
From: Ed Anderson <eanderson@carolina.rr.com>
Subject: Spreadsheet Cooling Section
Date: Fri, 24 Aug 2012 09:06:59 -0400
To: Rotary motors in aircraft <flyrotary@lancaironline.net>
Regarding the cooling section of the spreadsheet. 
 
Calculations do compensate for the effects of less air density at altitude which for the same airspeed  results in less air mass cooling flow at altitude compared to sea level.  However, changes in Air Temperature at altitude are not automatically compensated for - you need to ensure that your engine intake air temperature is adjusted for altitude - if you are that into it. 
 
The cooling section also includes a factor that adjusts cooling flow rate based on engine rpm - higher engine rpm = higher coolant flow rate.   
 
Concept:
 
Basically the cooling section uses air mass flow and cooling mass flow to calculate heat transfer.  Air mass flow primarily dependent on:
1.  Airflow velocity in duct  for climb configuration = 0.3*airspeed
2. Air Mass flow which factors air density, frontal area of heat exchangers and the velocity of the air in the duct
3. Air density compensation for altitude and temperature
4.  Specific heat of air = 0.25 cp
 
Cooling mass flow is dependent on:
1. A  0.7 cp compared to pure water of 1.0 Cp - this compensates for the typical anitfreeze dilution of the specific heat of water. 
2. Mass flow of coolant dependent primarily on engine/pump rpm
 
There are some other factors which get a bit esoteric, but play a lesser role.  So the results are a bit conservative - for example if you don't use antifreeze then theoretically you would pick up a 30% improvement in cooling capacity due to the higher specific heat value for pure water.
 
So these factors are used to calculate how many BTU/min the cooling system can reject for the selected operational values.  Then this is compared to the BTU of waste heat the engine needs to reject based on the power it is producing.  The radiator and oil cooler can compensate to some degree for a deficiency in capacity in each.  So if the oil cooler for example is showing overheating by 1% and the radiator shows a  + 10% excess cooling capacity - it will reject some of the heat not being rejected by the oil.  So as long as the overall capacity is adequate you are probably OK. 
 
Again, this is just a 1st order SWAG at cooling and its has only been compared to tractor installations.  It fairly accurately predicts my cooling capacity at Sea level and altitude.
 
So if your cooling results were adequate for the power setting/temperature at sea level and all you do in the cooling spreadsheet is change the altitude, your cooling may no longer be adequate due to the less air mass flow at altitude due to the lessen air density.  But, since you will probably be traveling at a higher airspeed which would increase your air mass flow, the two factors in real life would tend to offset each other to some degree.  If you also increase your airspeed (as would probably happen at cruise) along with the altitude increase then you would likely find you cooling is back to adequate.
 
But, as stated before the cooling section is on less solid ground due to the fact that installation variables play such a large role in cooling and they are not taken into consideration.  But, you can play with it to see the effects of changing several variables on cooling.
 
Ed
 
 
Edward L. Anderson
Anderson Electronic Enterprises LLC
305 Reefton Road
Weddington, NC 28104
http://www.andersonee.com
http://www.eicommander.com
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