Intercooler and Radiator Package Calculation CRDI

Inputs from Engine Water side

Sl. No. Parameters Formulae SI

1 Rated Power 55 KW Heat dissipated by engine He 40.43 40430
Engine Speed Heat dissipated by oil cooler Ho 8.11 8110
2 At max. Torque 1300-1400 Heat dissipapted by EGR cooler Hegr 5.06 5060
At max. Power 2000 Total heat received by water He + Ho + Hegr 53600
Heat Dissipation
3 At max. torque 30 Density of water (@ 80 deg) D 1000
At rated RPM 38.43 Specific heat of water (@80 deg) cp 4187
4 Pulley Ratio - Crank pulley to Fan pulley 1.3790 Volume flow rate v 110 0.0018333333
water pump flow rate (LPM) Initial temp of water T ow 82 355
5 At rated RPM (LPM) 110 Temperature of water at engine outlet T1 = Tow+(He / ( D x cp x v )) 87.2669518206 360.2669518206
At Max Torque RPM (LPM) 115 Delta Temp between Tow and T1 5.2669518206
6 Water pump power consumption Final temperature of water T = T +((Ho+Hegr)/(D x cp x v)) 88.9826519313
2 1
361.9826519313
7 Head of Water pump 10 m Delta Temp between T1 and T2 1.7157001107
8 Ambient Temperature to be considered 45 Total Temperature rise of water T and T
o
w
2
7.0
9 Water Inlet Temp. 82 Total heat received by air through radiator 53600
10 Temperature drop across core
11 Air Inlet Temperature Intercooler
12 Air Outlet Temperature
13 Air Velocity (Max Torque, Rated) Density of outside air D 1.1
14 Operating Pressure (water) velocity of outside air v 8
15 Thermostat opening Temperature 87 Cp of outside air cp 1007
16 Cylinder Bore 95 T2 T2 52 325
17 Cylinder Length 110 T1 T1 45 318
18 Air Flow (kg/hr) 350
19 NA/TC/TCI TCI Density of charge air Dc 0.946
20 Mechanical/CRDI Mechanical mass flow rate Mc 350 0.0972222222
21 Initial restriction allowed 30 to 40 Mbar below atmospheric T2 T2c 140 413
22 Maximum Allowable terminal restriction ~125mbar T1 T1c 65 338
23 Operating Temperature Range 0 to 45 deg ambient T2-T1 dT 75
24 Engine water jacket capacity Pressure drop dP 50 5000
25 Heat dissipated from EGR cooler (KW) 5.06 Specific heat capacity cpc 1010
26 Heat dissipated from oil cooler (KW) 8.11
27 Intercooler Details Energy transferred by temp drop Et = Mc x cpc x dT 7364.5833333333
28 Air flow (kg/hr) Energy transferred by presure drop Ep = dP x Mc / Dc 513.8595254874
29 Boost Pressure(bar) ~1000 mbar -1400mbar Total Energy transferred E 7878.4428588208
30 Charge air inlet temp (°C) 140
31 Charge air outlet temp (°C) 65 Area of intercooler reqd Ai = E / (D x v x cp x (T2 - T1)) 0.1270077454
32 Coolant air inlet temp(°C)
33 Pressure drop across intercooler(mbar) ~100 mbar
34 Outside air flow speed 8 Area of radiator covered by intercooler
.
Air inlet temperature T1 52 325
Delta Temp Increase 25
Air outlet temperature T2 77 350
cp @50 cp 1007
Density @50 D 1.1
velocity of air v 8
Free Area covered 0.1412636182
Heat dissipated 31295.5419665398

Area of radiator
Heat left to be dissipated H 22304.4580334602
Air inlet temperature T1 45 318
Delta Temp Increase 25
Air outlet temperature T2 70 343
cp @50 cp 1007
Density @50 D 1.1
velocity of air v 8
Left Free Area of radiator Ar = H / ( D x v x cp x (T2-T1)) 0.1006791461

Total Free Area of radiator A 0.2419427643

 WATER CALCULATION

Thickness t 0.002 m
Width w 0.016 m
Pitch between cores 0.002 m
Area A=txw 0.000032 m2

Density of water De 1000 kg/m3

Viscosity of water m 0.000355 Ns/m2
Renold's no. permissible Re 2150
Hydraulic diameter D 0.0035555556 m

Velocity required in each column v = Re x m / ( D x De ) 0.2146640625 m/s

Volume flow rate through each tube V=Axv 6.86925E-06 m3/s

mass fr M = V x 1000 x 60 0.412155 kg/min

No. of columns required C 266.8898836603

No. of cores c 5
No. of tubes per core T= C / c 54
Pitch p 0.008 m
Total width of radiator w= (p+t)/T 0.54

No. of spaces w-1 53

Thickness of radiator 0.088 m
Width of radiator w 0.54 m
Length of radiator l = Ar / [(w-1)*p] 0.5706197271 m
Area of radiator 0.3081346526 m

INTERCOOLER CHARGE AIR

Internal Thickness t 0.002 m

Width w 0.065 m
Area A=txw 0.00013
total thickness 0.004
Density of charge air after compression De 0.946 kg/m3
Viscosity of charge air m 0.0000189 Ns/m2
Renold's no. permissible Re 4100
Hydraulic diameter D 0.003880597 m

Velocity required in each column v = Re x m / ( D x De ) 21.1084322654 m/s

Volume flow rate through each tube V=Axv 0.0027440962 m3/s

mass fr M = V x D x 60 0.1557549 kg/min
No. of columns required C 37.4520052553
No. of cores c 1
No. of tubes per core T= C / c 38
Air gap between tubes p 0.008 m
Total height of intercooler w= (p+t)*T 0.456 m
Total width 0.4177886363 m
Total area of intercooler 0.1905116182 m2