Custom Fuel & Air curves for LOP and ROP fuel management

William Pete Hodges

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I have been working on this idea for quite a long time, and I finally have a set of Fuel and Air curves that are easy to set up for your airplane and easy use in flight.

If you have studied ROP and LOP operations, then you may be familiar with the Red Box and the Red Fin concepts. The Red Box, and the area under the Red Fin, is defined as an area of higher engine stress to be avoided if possible. It occurred to me some time ago that not only can the Red Fin be graphed but so can curves of constant fuel flow and curves of constant air flow be superimposed on the same graph. I was able to graph the curves for my 1964 Mooney M20E and I have been using them to set my mixture since 2019. In 2020 I expanded the graph to give me more information for use during light cruising at reduced power and speed. I use this graph every time I fly, to make sure I am getting the best economy out of the fuel I am using. It is easy to use and with my bird having a Fuel Flow Meter, Manifold Pressure Gauge and Tachometer it makes setting up the engine for LOP operations a snap.

I have finally figured out how to make this set of curves applicable to any airplane equipped with any engine. All you need is your POH, and calculator and a pencil. Start by printing a color copy of "Red Fin Fuel Air Curves Scales" This is a blank set of curves with some instructions underneath. Start by following instruction 1. Determine LOP fuel GPH values using FORMULA: ( Rated HP / 15 ) x ( % / 100) = GPH -50℉ LOP for each % of load calculated. Calculate the LOP GPH values and fill in the blank lines over 75%, 71.25%, 67.5%, 63.75%, 60%, 56.25%, 52.5%, 48.75%, and 45%. Now fill in those values to the corresponding fuel curve above. Notice the BLACK Fuel Curves are vertical at 75%, 60% and 45% on the graph. Notice the bottom of each fuel curve is displaced to the right at the bottom end. The value for each Fuel Flow curve should be directly below the bottom end of each curve, and that location should be directly above the blanks you just filled up with data. Once you have these values in, you can extrapolate the remaining values and label each fuel curve as applicable. To get an idea what this looks like, look at some of the other samples provided.

Now follow instruction 2. Determine ROP fuel burn from POH at % load shown. Plot known ROP Burns on graph. This may take a bit of extrapolation because your POH may not show the fuel burn for exactly 75%, 70%, 65%, 60%, 55%, 50%, and 45%. You may need to average two or three of them together to get the numbers you need. This is a "Nice to have" step not necessarily a "Need to have" step. Once you have the values from your POH, plot them on the graph with a dot placed on the % power line and the correct GPH curve. This will give you an idea what the designers were thinking when they wrote your POH.

Now follow instruction 3. Using your POH find the RPM and MP for a specific power setting. Calculate the MR number that goes along with it and label the Air Flow Curves accordingly. If your POH is written for a fixed pitch prop, there might not be any Manifold Pressures at all. Use the other samples to determine how they should be labeled.

Once all of the values have been filled in, fold the paper in half and you have a graph ready to use. I hope you find this chart useful. I use my chart on every flight.
 

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Once all of the values have been filled in, fold the paper in half and you have a graph ready to use. I hope you find this chart useful. I use my chart on every flight.
So, how exactly do you use this chart to set your mixture?

I just use EGT. :dunno:

Also, I'm not sure I understand where you're getting the numbers you put on the left side of the graph or their meaning?
 
The numbers on the bottom and up the left side of the graph are all GPH, and are lined up with the end of each fuel flow curve. Every 4th fuel flow curve is back, the other fuel flow curves are all blue, alternating thick and thin. All the fuel flow curves are the same distance apart in GPH. So if the black curves at 45%, 60%, and 75% are labeled 6, 8, and 10 respectively across the bottom, then the next two black curves are 12 and 14 labeled up the left side. Or 6+2 = 8, 8+2 =10, 10+2 =12, and 12+2 = 14. This can be seen in the sample M20E 200HP provided.

The thick blue curves are half way between the black curves, so 6+8 = 14 / 2 =7, and they become 7, 9, 11 across the bottom and 13, 15 up the left side. The thin blue curves are half way between all the other blue or black curves. So 6+7 = 13 / 2 = 6.5, 7+8 =15 / 2 =7.5, and they become 6.5, 7.5, 8.5, 9.5, 10.5, 11.5 across the bottom. The thin blue curve on the bottom left is partly outside the graph area and is cut into two segments, so the first thin blue curve up the left side is also 11.5, then 12.5, 13.5, and 14.5 up the left side. I didn't label these on the M20E 200HP curves, but that is what they are.

If you have used the formula to calculate 45%, 60% and 75%, all of the remaining GPH values can be derived from them.
 
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So, how exactly do you use this chart to set your mixture?

I just use EGT. :dunno:
You can use EGT, and that requires you to lean from full rich to peak EGT, then continue leaning though to a lower EGT that is now LOP. That requires you to stay in the Red Box for a period of time as you lean. If you use this chart you could lean very quickly to your LOP setting by crossing the Red Box in just 2 seconds, and know exactly where you are and how much power you are producing.

Let's say you are in my 200HP Mooney at the top of the climb at 10,000 feet, 2600 RPM and wide open throttle at 20.5 manifold pressure. 26 + 20.5 = MR 46.5 We are ROP at max power on the rich side and are burning about 12.5 GPH. Find the MR = 46.5 green curve at the top if the chart, follow it down to the blue 12.5 GPH curve. Looking at the graph you are above the Red Fin, so you are outside of the Red Box, at about 175 degrees ROP. If you leave the throttle and prop alone, the MR value remains unchanged as you lean. Engine performance will follow the green 46.5 MR curve down as you lean. If you follow the curve down to 8.5 GPH you will be below the Red fin, at about 64% power, and about 40 degrees LOP. Now just pull the mixture down to 8.5 GPH. You're done!!

Let's say you are cruising LOP at 2500 RPM WOT at 22" Man pressure and you notice your CHT hotter than you want. Your fuel burn is about 9.0 GPH and you look at the chart. At 47 MR and 9 GPH your engine is producing 67.5% power at 15 degrees LOP. You can increase MR without changing fuel burn by increasing RPM to 2600. You are still making 67.5% power but at 2600 RPM, and now you are 48 MR and 45 degrees LOP. Now your CHT drops to where you want.

Let's say you out to exercise your plane by boring a few holes in the sky. You've set the throttle for 21 Manifold Pressure and 2050 RPM. That's an MR of 41.5. Best fuel economy at that setting is about 6.5 GPH. So set the mixture there and have fun. You are out of the Red Box, about 48% power, and about 40 degrees LOP.

This chart is designed to give you quick insight as to how your engine is set up and running. It is difficult to calculate the values and label the chart, but once that is done for your engine in your airplane it is really easy to use and interpret the data in the cockpit while you fly.

I hope you find this chart as useful as I have.
 
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These are two charts I use all the time. They are 8.5 x 5.5 and are taped and laminated back to back. I use the RFFA chart to set engine power and mixture, and I use the TAS table to set cruise speed. I use them both all the time.

If you are having difficulty interpreting your POH and filling out the numbers on the chart. IM me and I will assist. Any charts I modify will be posted here.
 

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Ah, I see!

I like the thought and effort that went into this... But, let me describe what I do and maybe you all can tell me if I'm missing something?

I go with the "you can't hurt anything at 65%" theory, and I run LOP. My engine is 280hp. 280hp * 0.65 = 182hp / 14.9 = 12.2 gph. So if I'm LOP and at or below 12.2 gph I should be good, right?

I have vernier engine controls in the Mooney, and I have my Insight G3 set up so that when I start pulling the mixture, each cylinder gets a box over its bar when it peaks, and at 10 LOP it fills in. I just quickly twist the mixture back from climb (maintained by EGT) until I get 6 boxes, stopping there generally puts the richest cylinder about 25ºF LOP. With the damping lag on the fuel flow, I doubt I could do it significantly faster with fuel flow.

I do operate richer mixtures up high to maintain power. Above about 13,000 I want best power mixture, but being normally aspirated I can't do any more than 65% above 11,000 so I should be good anyway right?
 
Ah, I see!

I like the thought and effort that went into this... But, let me describe what I do and maybe you all can tell me if I'm missing something?

I go with the "you can't hurt anything at 65%" theory, and I run LOP. My engine is 280hp. 280hp * 0.65 = 182hp / 14.9 = 12.2 gph. So if I'm LOP and at or below 12.2 gph I should be good, right?
It is my understanding the "can't hurt anything" number is 60%, not 65%, but the idea that you following is sound. Also, at 65% the red box goes from about 80F ROP to 5F LOP. So if you are running at 25F LOP you should be safe, unless CHT says otherwise.
I have vernier engine controls in the Mooney, and I have my Insight G3 set up so that when I start pulling the mixture, each cylinder gets a box over its bar when it peaks, and at 10 LOP it fills in. I just quickly twist the mixture back from climb (maintained by EGT) until I get 6 boxes, stopping there generally puts the richest cylinder about 25ºF LOP. With the damping lag on the fuel flow, I doubt I could do it significantly faster with fuel flow.
You are correct when you consider your engine monitor is doing the interpretation for you, thus speeding up the process. I have a question for you. How close are your cylinders to peaking at the same level? Flat sixes sometimes have poorer fuel distribution than Flat fours. My engine is so well balanced I get no vibration or misfires all the way to lean cut-off.
 
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I do operate richer mixtures up high to maintain power. Above about 13,000 I want best power mixture, but being normally aspirated I can't do any more than 65% above 11,000 so I should be good anyway right?
Your methodology is correct. Under these circumstances you have to go richer to maintain power and airspeed. Me? I would take the loss of power and slightly lower cruise speed for better fuel economy and longer range. 65% x .94 = 61.1% LOP. Not a very big drop in the big picture.

To answer your question, you ARE good anyway. Just run rich enough to stay out of the Red Box. At 65% engine damage usually doesn't occur on the LOP side, but on the ROP side when inside the Red Box. At 65% load you need to be above 80F ROP unless CHT indicates otherwise.

Hope this helps.
 
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It is my understanding the "can't hurt anything" number is 60%, not 65%, but the idea that you following is sound. Also, at 65% the red box goes from about 80F ROP to 5F LOP. So if you are running at 25F LOP you should be safe, unless CHT says otherwise.
Nope, CHTs are usually in the low 300s. If anything, my engine gets too cool more often than too hot.
You are correct when you consider your engine monitor is doing the interpretation for you, thus speeding up the process. I have a question for you. How close are your cylinders to peaking at the same level? Flat sixes sometimes have poorer fuel distribution than Flat fours. My engine is so well balanced I get no vibration or misfires all the way to lean cut-off.
The IO-550-G in the M20R has a balanced induction, so my "GAMI spread" is usually 0.5-0.7 gph even with stock factory injectors. It's a great engine, I've been very happy with it. It runs smoothly right up until it doesn't run at all.
 
It sounds like you are doing everything perfectly and you are not missing anything. Enjoy your flying!
Excellent! I'm still going to set up these charts, there are instances where they could be useful especially at lower altitudes, I may do the Airventure Cup race one of these years which would probably be at a higher power setting. Thanks for putting them together!
 
Hello everyone

Between message #1 and message #5 I have posted a blank set of curves and six different examples of how to apply them to different aircraft. Mooney M20C 180 hp, M20E 200 hp, Cessna 172E 145 hp, Cherokee 140 150 hp, 180E 180 hp, and Bonanza A36 285 hp. There are lots more possibilities.

Has anyone got one to share? Does anyone need any help applying the curves to your aircraft? IM me. I'll be around.
 
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