MICRON SPRAYERS LIMITED Visit to Macedonia in Support of TCP/MCD/208 11 20 Aug 2002 1. Introduction This report summarises a visit to Macedonia by a Micron Sprayers technical representative between 11 20 August 2000 in support of the Micronair aerial spraying equipment supplied as part of TCP/MCD/208. This equipment was to be used for the application of biological insecticide for forest pest control. The objectives of the visit were: To install two 10 unit Micronair AU5000 spray systems on AN-2 aircraft. To test and calibrate the systems for the application of ULV forest insecticide (Foray). To participate in training course for Macedonian Forest Ministry, Macedonian Forest Enterprise and aircraft operator s personnel and to carry out field demonstration of the spray system. 2. Itinerary 11 Aug Travel to Skopje via Istanbul Meetings with FAO personnel 12 Aug Travel Skopje Bitola Meeting with aircraft operator 13 Aug Start installation of spray systems 14 Aug Continue installation 15 Aug Complete first aircraft Micronair presentation 16 Aug Demonstration and training at airfield Continue work on second aircraft 17 Aug Complete second aircraft 18 Aug Travel to Skopje via Orhid 19 Aug Meeting with CAA in Skopje Travel to Bitola with CAA personnel Test & calibration flights Return to Skopje 20 Aug Final meetings at FAO office Return to UK via Istanbul
3. Installation of Equipment on Aircraft FAO had issued a tender for the services of an aircraft operator to spray the area covered by the project. Two companies (the only aerial operators in Macedonia) had responded. These were: Boni Air, Based in Kumanvo near Sveti Nicola. This is the largest operator in Macedonia with about six agricultural AN-2 aircraft. Two of these had previously belonged to Vektra Prom and had been fitted with AU5000 atomisers (10 per aircraft) by Micronair during a visit in 1998. (Local personnel advised that some of these atomisers had been removed and installed on two other aircraft in the fleet, reducing the number on each aircraft to four or six.) Barni, Based in Bitola. This is a smaller company with two AN-2 aircraft purchased from Bulgaria. The owner of the company was an individualist who clearly took pride in his operation and had developed his own spray equipment (a small copy of a Micronair atomiser, a variable rate electrically driven pump for mosquito adulticide application etc). The aircraft appeared to be in better condition than the majority of AN-2s seen in E Europe and had low hours on both airframes and engines. The two pilots contracted by Barni each had several thousand hours of agricultural experience on AN-2s and had both worked with Micronair equipment in former Yugoslavia. One had been trained by Micronair when he previously worked with Vektra Prom. Barni was chosen on the basis of a lower price per ha and had also submitted a more professional bid presentation. As the choice of contractor was only made immediately prior to the departure of the Micron Representative, it was not possible to establish the exact configuration of the spray system prior to the mission. It was, therefore, necessary to hand-carry some parts and materials additional to the basic spray system to ensure compatibility with various aircraft pump and valve installations used on AN-2 aircraft. The installation of the spray system was carried out at Bitola airfield, where the operator had their main base. The work was done in conjunction with the three mechanics of the operator. Two staff from the Ministry of Agriculture, Forestry & Water Economy and one from the Public Enterprise for Macedonian Forests were also present for training and to assist with the work. A staff member from the FAO office acted as interpreter and helped with both local liaison and the work on the aircraft. The installation of each of the two spray systems involved the following: Assembly of atomisers and RPM indicator transducers Removal of existing booms from aircraft Installation of Micronair booms and boom support structure under lower wing Page 2
Installation of atomisers on booms and connection of pipework Installation of flowmeter turbine and pipework (including brazing of pipe fittings to suit pump configuration) Installation of application monitor electronic unit and application printer in cockpit and providing electrical power supply connections Installation of wiring from RPM transducers on atomisers and flowmeter turbine to application monitor The installation was started on aircraft registration Z3-BGS first and work commenced on the second aircraft (Z3-BGO) once the mechanics and trainees had gained the necessary experience with the initial installation. The installation of the spray system proceeded smoothly without any significant problems with either the spray system or the aircraft. Detailed photographs were taken throughout the installation to assist local personnel during the fitting of the equipment to other aircraft in the future. These are included on the same CD as the electronic version of this report for distribution as appropriate. 4. Ground Tests Each spray system was tested on the ground upon completion of the installation. The engine of the aircraft was run so as to provide sufficient airflow from the propeller to turn the wind-driven spray pump and to pressurise the spray system (using water as the spray liquid). The objective of the ground tests was to: Verify proper operation of the pump, valve and controls Check for leaks in the booms and pipework of the system Flush out the system to remove any debris that could block the atomisers Verify proper operation of the application monitor These tests identified a few minor leaks that were cured by tightening pipe fittings and also demonstrated the need to improve the security of pipe connections on the outlet of the aircraft spray pump (these were part of the original aircraft spray system and not items supplied as part of the contract). This work was done by staff of the aircraft operator. 5. Flight Tests & Calibration Although it had been the intention to flight test and calibrate each aircraft on completion of the installation, the work was delayed by ongoing negotiations with the Macedonian Civil Aviation Authority (see later). In view of this, it was Page 3
decided to extend the Micron component of the mission by two days and to carry out the test flights once permission was granted by the CAA. Both systems were tested and calibrated. Two airworthiness inspectors and one CAA test pilot travelled from Skopje to Bitola for this work. The aircraft were flown by the CAA pilot and a pilot from the operator. The Micron representative acted as observer. Both flight tests were satisfactory. The necessary data was obtained for calibration of both systems. This formed the basis of written calibration recommendations that were prepared locally and left with the FAO office in Skopje. FAO agreed to translate these into Macedonian prior to passing them to the aircraft operator. Flight test reports and the English version of the calibration recommendations are included in Appendix II. 6. Training Training was given to participants and to the staff of the aircraft operator. This consisted of both practical training during the installation of the equipment on the aircraft. Details of the training and trainees are as follows: 1. Mechanics from aircraft operator (3), representatives of Ministry of Agriculture, Forestry & Water Economy (2) and the Forest Public Enterprise (1): Assembly of AU5000 atomisers Installation of Micronair booms on AN-2 aircraft Installation of atomisers on booms Installation of Micronair Application Monitor, Printer & RPM Indicators on AN-2 Cleaning and routine maintenance of spray system Maintenance of AU5000 atomiser and flowmeter turbine 2. Mechanics from aircraft operator (3), pilots from aircraft operator (2) and representatives of Ministry of Agriculture, Forestry & Water Economy (2): Operation and calibration of Micronair Application Monitor, PRM Indicator and Printer 3. All participants (in training room at hotel). Presentation covering: Principles of ULV application Introduction to rotary atomisers & related equipment Overview of calibration and application technique This presentation used computer graphics translated into Macedonian by local FAO staff. Handouts were produced in advance and given to all participants. See copy in Appendix I. Page 4
4. All participants (at airfield). Demonstration by Micron and USFS representatives covering: Explanation of spray system on aircraft Techniques of assessment of spray deposit using sensitive cards Practical and meteorological aspects of field application It had been planned to carry out a spraying demonstration during this session. However, this was not possible as the CAA had not authorised the aircraft operator to fly. Instead, the principles of spray deposit assessment were demonstrated by spraying onto water-sensitive cards from a small hand-held sprayer. In addition to the presentation materials, the text of the front panel and display messages of the Application Monitor were translated into Macedonian. Copies were given to the aircraft operator and to the FAO office for distribution. This material is also included on the CD of the electronic version of this report. See copies in Appendix II. 7. Macedonian Civil Aviation Authority The test and calibration of the system were delayed by a disagreement between the Macedonian CAA and the aircraft operator. This seemed complex in its origins, but MCAA officials made the following claims: The operator had not given sufficient advance notice of their intention to fit the spray system. (This must be seen in the context of them only receiving notification of the contract just before installation commenced.) The MCAA had not received a British Airworthiness Approval Note for the installation of the system on an AN-2. (It was pointed out that this would be impossible as the British CAA would only issue this for a British registered aircraft and there has never been an AN-2 on the British Register. Instead, copies of British AANs were produced showing approved installations of AU5000 atomisers on other aircraft types registered in the UK.) The MCAA requested a manufacturer s release tag for the atomisers. (It was pointed out that any approval would cover the entire installation and not just the atomisers. A manufacturer s Certificate of Conformity was produced to cover the atomisers and related equipment.) The MCAA made their requests in the context of ICAO regulations relating to components with a direct influence on the airworthiness of the aircraft. (It was pointed out that the functionality of agricultural spray equipment has no airworthiness implications and that such equipment is treated by the British CAA as Agricultural Equipment and that agricultural aircraft in the United States operate under the Restricted Category.) Page 5
As the complexities of these discussions threatened to disrupt the programme, it was agreed that the Micron Representative would remain in Macedonia for two extra days for a meeting with the MCAA and to carry out the test and calibration flights if this could be agreed. Following a meeting at MCAA Headquarters, the technical issues appeared to be resolved and the aircraft was inspected by MCAA inspectors and flown with one of their pilots. An assurance was given by the MCAA that the necessary approval documents and permits to fly would be issued to the aircraft operator in due course. 8. Contact Details 8.1. Micron Representative Timothy P Y Sander Micron Sprayers Limited Bromyard Industrial Estate Bromyard Herefordshire HR7 4HS United Kingdom Telephone: +44 1983 406111 Fax: +44 1983 404461 E-mail: tsander@micronair.co.uk 8.2. USFS Representative John Ghent USDA Forest Service Forest Health Protection PO Box 2680 Asheville NC 28802 USA Telephone: +1 828 257 4328 E-mail: jghent@fs.fed.us 8.3. Aircraft Operator Barni DOOEL 7000 Bitola Macedonia Stanojeski Dragan General Manager Telephone: +389 47 231 402 Fax: +389 47 231 402 Page 6
8.4. Macedonian Civil Aviation Authority Ministry of Transport & Communications Civil Aviation Administration Dame Gruev 1 1000 Skopje Macedonia Valentin Jovanovski Head of Airworthiness Dept Nikola Trendov Airworthiness Inspector Telephone: +389 2 117298, 114046, 114298 Fax: +389 2 115708 E-mail: vjovanovski@dgca.gov.mk 9. Acknowledgement Micron Sprayers would like to acknowledge the tireless support of all FAO staff involved in the project. This extended not only to practical arrangements for the mission, but also to invaluable assistance with interpreting and translation of documents. The managerial and technical staff of the aircraft operator gave their full cooperation and practical support during the installation and test of the system. T P Y Sander 23.08.02 Page 7
APPENDIX I Micron Presentation in Macedonian Appendices\Micronair Macedonia Forestry Mac.ppt [Click on link above or print file for hard copy]
APPENDIX II Flight Test Reports & Calibration Recommendations Appendices\Macedonia AN2 Cal.xls Application Monitor Information in Macedonian Appendices\Monitor Text Macedonian.doc Appendices\Monitor Mac Text.doc Appendices\Mac Atomiser sn.doc [Click on links above or print files for hard copy]