It happens every two months. At about noon on Friday people begin to
arrive at the little airport that serves Ada, Oklahoma, population
16,000, lying roughly 80 miles southeast of Oklahoma City. Alternately
griddle-flat prairie and gently rolling hills, Ada probably has a
little picture of a longhorn cow and an oil well next to its name on
those schoolbook maps. But the people flying in here today don't deal
in cattle or petroleum.
They come from across the nation, many of them flying their own
aircraft. Beech Bonanzas and Barons are the most numerous types out on
the parking ramp. But here's a single-engine Cessna on stork-tall
amphibious floats, its registration and little red maple leaf
indicating that it flew here all the way from Canada. These visitors
share one thing: They're pilots who fly aircraft powered by
reciprocating engines. General aviation aircraft. The little guys.
Some of them are here because they've heard that they've been
running their engines wrong all these years and they want to learn how
to do it right. Some have thousands of hours, and others are barely
starting out. Some are openly skeptical, and some may even harbor a
private urge to unmask all that is shown and said here as fraud and
sham so they can depart vindicated. Some of these people will have a
hard time accepting what they will hear because it is hard to admit
you've been doing something the wrong way for a very long time,
especially if you are a pilot.
They have come to a class with the vaguely worded title "Advanced
Pilot Seminars." The session opens on Friday evening and ends on
Sunday afternoon, and the lessons are delivered in intense doses. But
compared to how airmen and -women have been trained in the past, what
goes on here is really closer to the founding of a religion. Call it
the First Church of Combustion.
Its bishop is George Braly (pronounced BRAW-ly), an aeronautical
engineer and attorney with a Wilford Brimley mustache and a booming
voice cultivated in the courtroom. John Deakin and Walter Atkinson
have signed on as disciples since being converted in the mid-1990s,
when they were the first, aside from Braly himself, to test the tenets
of the new gospel in their own airplanes. Deakin has the wise look of
a wood owl. He retired in 2001 as a captain with Japan Air Lines, and
the Boeing 747 time in his logbook adds up to more than four years.
Atkinson's day job is dentistry, but he is also rated as an airline
transport pilot, airframe-and-powerplant mechanic, and flight
instructor. In the right light, he's a pretty good double for actor
Fred Willard.
Braly and the two disciples promise the converted a life of
airplane engine happiness, with cooler operating temperatures, fuel
savings on the order of three gallons per hour for a typical
six-cylinder engine in a Beech Bonanza, and reduced life-sapping
carbon deposits on the valves and pistons. All they ask is that the
believers ante up for precision engine monitoring systems.
The three pilots became friends while they were exploring the same
subject they are about to preach in the classroom, which has filled
with 36 students, each leafing silently through a fat three-ring
binder. On the binders' covers is the name of the course: "Engine
Management Made Easy." The $995 tuition covers all meals (except one
on Saturday night), which are taken on site to cut down on travel time
to restaurants. And the students will find that they need every minute
of classroom time they can get. Here is some of what they'll learn:
All reciprocating engines that burn gasoline are ruled by the
incontrovertible laws of chemistry and physics. They produce power by
drawing air into a cylinder, mixing it with a combustible amount of
gasoline, sealing the cylinder, compressing the mixture, and igniting
it at just the right moment with an electric spark. Most modern
engines use some method of fuel injection to mix the gas and air.
What's different about aircraft engines is that they operate at widely
varying altitudes: As the airplane climbs, the air becomes thinner.
With less air to support combustion, the amount of gasoline to be
mixed with the oxygen molecules must be reduced accordingly. Which is
why airplanes have an engine control you'll never find in a car: the
mixture control. Whether it's a knob or a lever, the mixture control
adjusts the flow of fuel to all the engine's cylinders.
Student pilots who train in general aviation aircraft have
traditionally been taught that at some altitude during the initial
climb (typically 3,000 to 5,000 feet), they should move the mixture
control from full rich, the setting for takeoff, to lean, then even
farther to lean after they pull back the throttle to the cruise-power
setting. While leaning at cruise, they learned to keep a sharp eye on
an instrument that displays the temperature of the engine exhaust gas.
The instrument, the exhaust gas temperature (EGT) gauge, sometimes
uses a graphical bar display. (Older gauges used a needle on a dial.)
When the gasoline-air ratio is such that combustion has used up
both fuel and oxygen, combustion occurs at the highest possible, or
peak, temperature. (This mixture is described by chemists as "stoichiometric.")
If the mixture is rich, containing an excess of fuel, or lean,
containing an excess of air, the temperature of the combustion process
drops. In managing mixture control, it is not a matter of what the
absolute temperature of combustion is but where the mixture is
relative to peak temperature, which serves only as an easily
measurable reference point. Aircraft engines are not operated at peak
EGT despite the apparent chemical perfection of combustion there.
Cooler operating temperatures are desirable; on that all agree.
"Lean the engine until the EGT needle reaches its maximum
temperature," instructors intoned, as student pilots gently pulled
knobs or moved levers, "and then move it back until you are running 50
degrees on the rich side of peak temperature." The occasional
inquisitive pup might ask why this is done. Instructors would warn of
toasted valves, burned spark plug electrodes, holed pistons, and
engine failure.
And all pilots learned through experimentation and experience that
the Continental and Lycoming engines on their airplanes began to run
rough around the point of peak EGT. They ran especially rough if one
continued to lean the mixture past peak temperature-the dreaded lean
side of peak. Roughness suggests engine failure; passengers get
wide-eyed and pilots feel their palms getting moist. No one asked why
these four- and six-cylinder air-cooled engines ran rough when leaned.
Here be dragons, said the conventional wisdom; just don't go there.
But George Braly, who bought a Beech Bonanza in 1991 and shortly
thereafter installed an instrument to measure the EGT for each
cylinder, noticed that when he pulled the knob that leans the mixture
and reduces the fuel flow, the six cylinders of his Continental IO-520
engine reached their peak temperatures at widely scattered points
across that range of motion. Why didn't they all peak together? he
wondered.
On Compuserve's online aviation forum, pilots of all stripes-and
those with none-could debate freely and anonymously the precepts of
their training. In 1991 Braly began wondering about engine mixture
management in messages to John Deakin. In an e-mail, Deakin recounts
that time: "It took Compuserve's AVSIG [AViation Special Interest
Group] to bring us all together and serve as a catalyst." Braly led
the way, Deakin recalls, "with the rest of us asking questions he
could not, at first, answer. Drove him nuts, so he began (in about
1994) the long, long trail that leads to today."
Braly says that the prevailing opinion of the time was that the
peak EGT spread he saw on his engine was attributable to the design of
Continental's induction system-that there was something wrong with the
airflow (it's actually quite good). But mechanics adjusted the fuel
injection systems on these engines on the theory that the airflow to
each cylinder was equal and perfect. Using four or six containers
(often cola bottles, resulting in the coinage "Coke bottle test") to
catch the gas and determine the volume delivered, they would carefully
tweak the system until it was metering precisely the same amount of
gasoline through each injector to its respective cylinder.
Continental engines use continuous-flow fuel injection systems: The
injector spritzes fuel in a flow as steady as a garden hose, even when
the intake valve to the cylinder has closed. Braly began to suspect
that some of the fuel that accumulated when the valve was closed was
making its way down the induction system to the adjacent cylinders. If
he was right, some cylinders were getting the wrong amounts of fuel,
and the variation would prevent all six cylinders from arriving at
peak EGT simultaneously. And if the fuel flows that brought the
cylinders to peak EGT were different enough, the power outputs from
all the cylinders would differ at leaner mixtures, where the power
falls off quickly. No wonder the engines ran rough.
Maybe fuel distribution to each cylinder shouldn't be equal. Maybe
it should be different.
By 1993, Braly had teamed up with an Ada-based parts manufacturer,
Tim Roehl, to form General Aviation Modifications, Inc. He and Roehl
began to experiment with injector nozzles calibrated to deliver fuel
at a rate precisely matched to the needs of each cylinder. They had
help from new microprocessor-based systems that displayed in
monkey-simple graphics all the important engine data: exhaust gas
temperature-not just for the engine, but for each cylinder-cylinder
head temperatures, and, for turbocharged engines, turbine inlet
temperature.
Braly started looking for an expert to help with the process of
getting a Supplementary Type Certificate from the FAA for GAMI's new
injector. Someone recommended a Texan named Carl Goulet. "I had no
idea at that time that he was the former head of engineering at
Teledyne Continental Motors," Braly recounts. "We had a very short and
very remarkable conversation. I was considerably his junior, and he
said, 'Now young man, tell me what you plan to do.' I told him, and
these were his exact words: 'Hot damn! Somebody's finally gonna fix
this problem!' "
GAMI applied for an STC in 1996, and the FAA approved it in the
same year. At Goulet's suggestion, Braly submitted a proposal to
Teledyne Continental Motors offering to supply fuel injectors and
provide customer support. Hearing nothing, GAMI began to market the
modification to pilots. Deakin and Atkinson were among the first to
install the new injectors in their engines.
Atkinson remembers that after getting the injectors installed and
heading home in his airplane, he leaned the mixture by ear, the way
he'd been used to. Ignoring the EGT gauge, he liked to pull the
leanerator until the engine ran rough, telling him he was just lean of
peak, then adjust the mixture from there. "Except this time it
wouldn't run rough," he recalls. "I kept pulling it back and it just
kept running smoothly."
George Braly had been reading Internet postings by veteran airline
pilots from the propeller days saying that they used to run their big
radial piston engines on the lean side of peak EGT. Deakin had loads
of Pratt & Whitney R-2800 time and could affirm to Braly that the
names of instruments and methods may have differed, but leaning was
leaning, and airline crews had been ordered by their companies to run
their engines lean in order to reduce fuel consumption. But in the
bargain they got cleaner spark plugs, valves, and cylinders, and
perhaps the most important bonus of all-cooler operating
temperatures-all as pure gravy. Braly couldn't understand why what
worked in one piston engine wouldn't work in any piston engine. Born
with enough tenacity for two people, he kept talking, asking
questions, and reading.
That fall, a veteran pilot on the AVSIG forum told Braly that he
had an old American Airlines book on how to operate the Wright R-3350.
You might find it interesting, said the old vet. Perhaps the most
complex powerplant ever to propel an airliner, the mighty -3350
squeezed every ounce of energy from the combustion process, in one
version even using the exiting exhaust gas, already stripped of most
of its energy by the turbo-supercharger, to turn a set of turbines
that were geared back to the propeller shaft in order to capture the
last twistlet of torque.
As soon as Braly got the old operating manual and read about the
American pilots' lean-of-peak technique, he grabbed the factory graphs
and charts for his Continental engine and calculated where his engine
would be on the power curve if it were running under the same settings
the -3350s were run at. The point corresponded to a power and fuel
flow setting at exactly 50 degrees Fahrenheit lean of peak EGT. "It
was the eureka moment," he recalls. By the summer of 1997, Braly,
Deakin, and Atkinson were routinely flying with their engines running
on the lean side of peak EGT and were ready to tell the world.
For a couple of years they hosted flying clubs at GAMI's hangar at
Ada on Saturday mornings. In 2001, Atkinson put together a slide show
to make the whole thing clearer.
Braly still wasn't satisfied with the data he was getting from the
sensors and instruments. In 1998 Goulet had urged him to probe deeper,
telling him that he needed to develop the means for measuring
real-time cylinder pressure events. Goulet said he himself had spent a
lot of time looking at combustion pressure data and that Braly would
never really understand the engines until he understood the combustion
events. "Within 60 days after that, I was flying with the first
prototype combustion pressure sensors," Braly says. Now he could
record the rise in pressure within the cylinder as the mixture began
to ignite. On the first flight, Braly compared lean and rich
combustion events at the same horsepower and found that the lean event
produced significantly lower cylinder pressures and lower cylinder
head temperatures. It was the second eureka moment.
Braly began to imagine a facility where he could study engines all
day every day without having to go flying. He wanted to be able to
change conditions like ignition timing, fuel octane, intra-cylinder
pressure, and air inlet temperature-in short, to build a laboratory
around an off-the-shelf, six-cylinder aircraft engine that he could
poke and prod and see what happened. In 1999, GAMI built just such a
lab around a six-cylinder Lycoming TIO-540. "We probably know more
about the Lycoming TIO-540 than any other engine, and we probably know
more about it than anyone else in the world," Braly says. Later that
year, when Carl Goulet died, the lab was named for him.
With the lab up and running, Braly could gather data and translate
it into operating knowledge any pilot could use. He expresses it in a
graph showing the impact on an engine of the fuel mixture (opposite);
this set of curves forms the new orthodoxy of engine operation. The
horizontal axis can be thought of as the movement of the mixture
control from full rich on the left to lean on the right. The topmost
curve indicates that EGT peaks at a certain value and forms the
reference point (dotted line) for managing the engine's operation. The
second curve plots cylinder head temperature across the range of fuel
flow, showing that a pilot can expect CHT to max out at a point
slightly to the rich side of peak EGT. Almost perfectly parallel to
CHT is the internal cylinder pressure curve. Just beneath it, the
horsepower plot reveals that maximum power is reached in an even
richer area of the fuel flow range. A curve of computed points, at the
very bottom of the group, plots horsepower per pound of fuel burned
per hour-a way of expressing fuel efficiency.
Braly's work showed-and the seminar teaches-that once the fuel
injection systems of Lycoming and Continental engines have been
adjusted to deliver the proper quantities of fuel to each cylinder,
pilots can operate their engines over on the right side of that set of
curves. (And way over on the left too, with rich mixtures at high
power. It's the range in the middle students will learn to avoid.)
Pilots in the classroom learn that cylinder head temperature-a
critical measure of engine health-rises because of rising
intra-cylinder pressure. Operate on the right side of the curve with a
lean mixture and CHT drops off nicely.
But over on the right side of the curves, the horsepower falls off
too. How did the airlines recover the power lost when they ordered
their crews to lean the mixture? The old books and the veteran pilots
revealed the simple answer: They moved the throttle back up from its
reduced cruise-power setting until they got the horsepower back to no
more than about 65 percent of rated power. And when they did that,
they found themselves with an engine that was operating at the peak of
the last curve-max fuel efficiency. In effect the First Church of
Combustion is preaching the gospel of using both fuel and air, rather
than just fuel, to manage engine power.
(For a more detailed explanation of the Wright Aeronautical
Division-WAD-Leaning Procedure, read Braly's narrative at www.gami.com;
click on "Future Series." Turbocharged engines offer a more complex
picture.)
In June 2002 about 35 pilots from the Dallas chapter of the
Experimental Aircraft Association flew to Ada to hear about the new
way to operate their engines. They departed converted, and that visit
led to the first formal seminar in Ada in September 2002 for paying
customers.
It's hard to overcome the orthodoxy of the operating manuals and
the notion that if engines were meant to be run this way, the aircraft
and engine manufacturers would revise the manual. Four years ago,
Textron Lycoming issued an advisory to its customers explaining the
company's operating recommendations. "Operating an engine 'on the
edge' is possible," the advisory states, "provided the pilot is
extremely precise, has good instrumentation, and monitors the engine
condition full time. For 98% of the pilots, it is an invitation to
potential trouble."
Some people depart the weekend in Ada unmoved and cling to the old
ways. But to date, Braly and his disciples have converted several
hundred pilots, who return to their homes merrily pulling the mixture
controls on their engines with abandon. Pull the mixture, all ye
souls! Fly lean of peak and be free! Until you have done it yourself,
some of them say, you have not tasted of the fruit.
Fred Scott, a farmer and Beech Baron owner from southern Virginia,
recalls his first experience: "A friend and I had climbed to 11,000
feet on the way back home from the school. And we pulled it back
through the peak [EGT]. 'Engine's gonna melt,' they used to tell us.
We're thinking, Well, we gotta believe. And sure enough, the head
temperatures went down and it was like a book opening, a complete
revelation to see the science you learned in the school made sense.
All of a sudden it was all true. We were like two little kids."
Students at the seminar are surprised when they don't hear the
bad-mouthing of Continental or Lycoming engines that's common among
pilots-"Lyconentals," they call them, a derisive term that
encapsulates the notion that both engines are old technology and
essentially interchangeable. All three teachers certainly have the
chops to criticize, but they're very complimentary of the durability
and efficiency of both manufacturers' engines.
As for Braly, he and the GAMI crew are now working on an electronic
spark ignition system that monitors intra-cylinder pressure and
adjusts the spark timing automatically to manage the pressure
generated by combustion and eliminate detonation ("engine knock," in
car talk), a condition in which combustion occurs too early, raising
intra-cylinder pressure and ultimately destroying the engine. Each
seminar class watches as the big TIO-540, running on 100-octane
low-lead aviation gasoline, is switched to rotgut unleaded auto gas
without missing a beat. Braly can't give a firm date by which FAA
certification will be complete. Pray it's soon.