Running on Fumes (Or not)

MSI – Safety Alert

A number of recent events have reminded us of an all too common danger when flying the Cessna 200 series aircraft. Hopefully everyone piloting one of these aircraft (Cessna 205, 206, 207, 210) is well aware that you must be very careful to switch tanks in a very disciplined and deliberate manner, otherwise there is a great risk of running a tank dry and the engine stopping at a very inopportune time. This can be very embarrassing (or much worse!), especially if you still have plenty of fuel in the other tank that was not selected. In most cases, switching tanks and hitting the electric auxiliary boost pump switch brings the engine back to life very quickly, but there are some exceptions, which we will discuss later in the article.

However, there is a much less commonly recognized danger relating to fuel supply and

starvation in these aircraft, and that is called “unporting” of the fuel due to uncoordinated flight maneuvers. In the Cessna 200 series, the tubes “picking up” the fuel extend into the wing tanks from the inboard ribs. This is also where the fuel quantity transmitters are located in the 205, 206, and 207.

Due to the lack of much baffling inside the fuel tanks, uncoordinated flight, such as is experienced while slipping or skidding, can cause the fuel to move away from the inboard rib, and allow air to be drawn into the pickup tubes. The U206 is especially prone to this during photo shoots with the cargo door removed, as the photographer often asks for skidding right turns to allow him to get photos out of the open right side of the aircraft while keeping the right wing up with opposite aileron. If the left tank is selected while doing this, it is very possible to “unport” the pickup tubes in the left tank, even with half fuel capacity. Couple that with the typical request to be down low for good photos, and you have a disaster in the making.

Other examples of uncoordinated maneuvers that have caused unporting events are slipping in a crosswind on long final, extended cruise or descents using only rudder, climbing right turns after a low pass with low fuel in the selected tank, circling over objects on the ground, and tipping the plane to observe air drops.

What is the solution?

1. Always stay coordinated while maneuvering the aircraft. Your fuel is doing whatever the ball in the turn coordinator is doing.
2. Always have the fuller tank selected while near the ground.
3. Avoid the temptation to run your tanks down to the last 5 or 10 gallons. If you want to know why, look inside the tank next time it is that low. The fuel is barely an inch deep, and the pickup tubes are about half an inch off the bottom of the tank.
4. Finally, “just say no” to the photographer when they ask for a skidding right turn, especially close to the ground. Offer to climb to a higher altitude that will allow for gentle banking to keep the subject in sight without getting the wing in the way. Hopefully you briefed him ahead of time to bring a telephoto lens or two.

Regarding restarting the engine if unporting or fuel starvation occurs:

Testing has demonstrated that switching tanks and immediately hitting the emergency setting on the aux pump switch for a few seconds or until you see the fuel pressure or flow start to come back up brings the engine back to life the fastest. Waiting to switch tanks only delays the restart. Holding the pump switch in emergency position for longer than a few seconds can easily flood the engine, especially turbocharged ones or the newer IO550’s.

Another consideration affecting the restart has to do with maintenance. If the TCM service bulletin (SEB 96-4R1) regarding setting the resistors that control the pump speed with varying throttle positions is not followed properly, particularly in using a properly regulated voltage of 14 or 28 VDC, there is added danger of flooding the engine while attempting a restart. Some places have used the aircraft battery while setting the resistors, but that gives an incorrect setting, as the battery gives a lower voltage than the running alternator will.

As a final warning, unporting can be deadly, and has been already. Additionally, flooding the engine while attempting a restart, while not conclusively proven, is strongly suspected to have been a major factor in at least 3 recent fatal accidents in missionary aviation.

Looking for a Cessna 206

We are missionaries in Zambia, looking for a 1980’s Cessna 206.

Please contact Gordon Hanna if you have any information.
gordon@hannalink.net

Mission aviation pilots put faith in their wings

You expect commercial pilots operating in the bush to face certain occupational challenges: Unimproved airstrips. Mechanical problems encountered in remote locations. Lack of navaids and weather reports. But for one class of bush pilot, such hazards don’t always top the list of dangers.

“During the Ebola outbreak in October of ’07, we went into the hot zone two and three times a day,” said David Francis, a Cessna TU206 pilot from Memphis, Tenn., who operates out of Ndolo Airport (FZAB) in Kinshasa, the Congo. “Nobody else would fly in there. Even the UN pilots refused. They didn’t want to go into a contagious area. We just see this as firmly within our mission.”

But what kind of mission would require that kind of commitment and potential sacrifice?

“Helping relieve suffering,” Francis said. “That’s why God put us here.

The mission, simply put, is mission aviation: pilots, deeply committed to their religious beliefs, flying in support of missionary and humanitarian activities around the globe. In addition to the challenges associated with bush flying, over the years mission aviation pilots have contended with armed insurgencies, government harassment, civil unrest, natural disasters and even death at the hands of indigenous peoples they seek to help.

The global mission

Dozens of missionary aviation organizations operate around the globe. The International Association of Missionary Aviation in Worthington, Minn. (this website) counts some 50 in its membership, according to president Chuck Daly. Francis, the pilot in the Congo, flies for Mission Aviation Fellowship ( www.maf.org), based in Nampa, Idaho, one of the oldest and largest such organizations. Operating in Africa, Asia and the Americas, its 130 aircraft conducted more than 88,000 flights last year, serving some 3,000 locations, the great majority of them remote and otherwise inaccessible.

“The kind of environment we fly in is hostile, not just in the air and in the airstrips, but in the countries in which our people are based,” said John Boyd, MAF president and himself a former mission aviation pilot. “Most of the time you’re living in situations with no running water, no constant electricity, no telephone, no shops. You have none of the support you would have grown up with here in the U.S.”

MAF’s roots go back to World War II, an outgrowth of prayer meetings held by a small group of pilots operating in the Pacific theater. The gatherings gave rise to the Christian Airmen’s Missionary Fellowship, MAF’s predecessor organization, launched in 1945. The following year the organization began missionary work in Mexico with its first airplane, a 1933 Waco

Initially operations were focused solely on the ministry, such as bringing translated Bibles to remote villages and transporting missionaries to their posts. But In the decades since, the scope and scale of MAF’s operations have grown dramatically.

“Basically, you become the logistics system of the country,” said Harry Berghuis, a Papua, Indonesia-based MAF pilot from Holland. “Everything that needs to be transported has to be done by the airplane. We form a big part of that.”
“Typically in a week we’re flying a mixture of freight, medicines and parts to the interior stations, and we do the mail delivery as well to a lot of the small villages,” said Francis of his work in Africa. “And we’re flying sick people in and out of the villages to better equipped hospitals, and flying missionaries and pastors.”

MAF also transports personnel from NGOs (non-governmental organizations) such as the International Red Cross and Doctors Without Borders. But make no mistake: spiritually rewarding though it may be, there is nothing glamorous about this work.

“It’s not about just jumping in your airplane and having a jolly for a couple of hours,” Boyd said. “You’re going out of eight to ten tiny airstrips a day, loading and unloading in 110 degree heat, flying around weather and over mountain ranges.”

Candidate requirements

Because of the demands of this calling, both in the air and on the ground, prospective MAF pilots are carefully screened and evaluated. All MAF pilot/mechanics must complete a minimum of 400 hours of flight time, and hold instrument and commercial ratings. And because they are expected to maintain and repair as well as fly the airplanes, they must also have an A&P (airframe and powerplant) license. Twelve credit hours of biblical training is another requirement. MAF also evaluates prospective pilots and their spouses – who will be stationed with them, along with their children, during the two-and-a-half to three-and-a-half year terms they are expected to serve – to ensure they are psychologically fit to handle life in the field.

“It’s not for everybody,” said Brent Palmer, another Papua, Indonesia-based MAF pilot. “I’ve seen a lot of people come and go. There are people who come out with good faith and they can’t hack it. The stress, the remoteness, the difficulty in living, whatever it is, it was just not what they expected.’’

Another requirement of missionary life further filters out all but the most committed: Missionary pilots are expected to raise the money to underwrite their service, typically from their church, community, and other sponsors. MAF pilot salaries are pegged to the cost of living in the country of operation. A pilot with a family of four earns an average $2,627 per month.

All applicants accepted for consideration undergo a technical evaluation at MAF headquarters. The evaluation includes ten hours, divided between flight time in a turbocharged Cessna TU206 to check their piloting abilities, and in a simulator to test instrument flight skills. That’s followed by a practical examination of their A&P talents. Thirteen to fifteen pilots undergo technical evaluation annually, and about 10 go on to the next phase, technical standardization training.

“Attitude is everything,” said Dave Ringenberg, an MAF instructor pilot. “It’s easy to teach a skill. It’s harder to teach an attitude.”

Training

Technical standardization consists of 40 hours of ground school followed by 30 hours of flight in a C-TU206 equipped with Garmin GNS 430 IFR-certified panel-mounted GPS, a Codan HF radio (used for transmitting position reports to a base station) and STOL kits. During this training pilots learn the standard procedures MAF uses everywhere it operates, focusing on three key areas: checklists, dealing with terrain, and making stabilized, power-on approaches.
“A written checklist is used for all phases of flight and preflight for MAF operations,” said Ringenberg.

The training location takes advantage of Idaho’s wealth of challenging back-country strips, giving trainees a taste of the kind of terrain and rugged landing sites they’ll encounter in the field. These operations also hammer home why power-on approaches are a necessity for bush ops: shifting winds and up- and downdrafts require power management to negotiate while maintaining a precise approach angle and airspeed. The end result is a predictable touchdown point.
Given the training, commitment and skill required for this kind of aviating, it’s noteworthy that many who find their way into MAF were not pilots when they decided to enter this line of work.

“I had a desire to be in full time ministry, the Lord just hadn’t shown me what it was going to look like yet,” said Texas-born Palmer, who before coming to MAF was a software engineer for Morristown, NJ-based Honeywell International, working on TCAS II, the airline collision avoidance device. “Right after I got married I heard about mission aviation, how they could use airplanes in ministry. I wasn’t even a pilot.”

“We asked the Lord what he wanted us to do,” said Berghuis of he and his wife, Willie. “And over and over it came to our attention there was a shortage of pilots in mission work. We thought, ‘Hey, maybe this is it,’ and decided if the Lord wanted us to do that, he’d show us how. We don’t have to worry about the details.” According to Berghuis, support just seemed to fall into place. “He provided in a miraculous way,” Berghuis said.

Even Ringenberg, the instructor pilot, heard the call of his faith before that of the sky. “I had a desire to serve God, but I didn’t know how. One day a friend encouraged me to be a missionary,” Ringenberg said. “That same friend encouraged me to look into aviation. I never thought of that before.”

Education of a missionary pilot

A number of Bible colleges offer aviation programs, enabling students to graduate with all the ratings, licenses, and religious training a mission aviation career requires. But it seems each pilot finds his own path to the left seat, and each represents a tale of persistence and faith rewarded. Palmer, after four years at Honeywell and a lot of soul searching with his wife, Melanie, and church members, enrolled in LeTourneau University in Longview, Texas, a Christian school with a mission aviation program. In three years he had his requisite licenses and a bachelor of science degree and a minor in Bible studies.

“That got me about 250 hours of flight time,” Palmer said. “MAF required 400, so I had to get another 150 hours.”

Palmer went back to work as a programmer and convinced his company to give him the cash equivalent of an airplane ticket when he had to travel on business. He used the money toward the rental of a Piper Warrior and flew himself on the trips, building up hours while he honed the pilotage navigational skills of a missionary aviator.

“I flew from east Texas to Toronto, Ontario, and I never turned on a nav radio,” Palmer said. “I flew the whole trip 1,000 feet AGL (above ground level). I had drawn exactly on the sectionals where I was going to go – you have to recognize every landmark you fly over.”

Palmer was accepted for his technical evaluation by MAF with 401.2 hours total time. He passed the flying evaluation with glowing reviews but failed the maintenance check.

“That was pretty devastating at first,” Palmer recalled. “They said to go work for a year as an aircraft mechanic and come back. But I was over 30 at that point. I had been working on this goal for many years.”

After considering his situation, the evaluation team told Palmer to get a C-206 service and parts manuals, study hard, and get some A&P work. Six months later Palmer came back and passed the maintenance exam, and then the month-long technical standardization course.

“From there they put you on a pretty well thought out regime preparing you to get overseas,” Palmer said.

Field conditions

But the novice’s training is far from over. After arriving on station, pilots often spend months before they fly. Rigorous language instruction and cultural orientation courses come first. Flying begins only after the pilot and his family are settled and integrated into the community. It commences with more training, applying the standard operating procedures learned in Idaho to the specific locations in which they fly. Typically MAF operates out of one or more main bases in a given country, from where pilots access to a network of remote locations. MAF operates both C-TU206s and the turbine powered C-208 Cessna Caravan.

The en route terrain often has no distinct features: no roads, power lines, or human settlements to help with pilotage. Everyone involved in mission aviation acknowledges that GPS with moving map displays has revolutionized the task of navigating in these remote landscapes.

“The GPS has allowed us to operate with more precision and safety, and with a lot less stress,” said Francis. “I don’t have to get down so low and look at all the individual river bends, the little-bitty landmarks they had to use in past, just to keep from being disoriented. We can get above the cloud layers.”

Francis, by the way, came to mission aviation after 17 years of designing advanced military aircraft for Lockheed Martin, the Bethesda, Md.-based defense contractor. “Be prepared to follow God’s leading – no matter what stage in life you may be in,” he said of his late start as a missionary pilot. “Don’t be surprised if that path may make some big turns along the way.”

Guidance from above notwithstanding, MAF pilots must be prepared to fly all their routes without GPS. Equipment failures have occurred in the field, and the units have to be considered as back-up gear. Pilots typically use ONC charts for navigation, and in the parts of the world where MAF operates, large swaths of the charts may be blank, accompanied by a simple printed legend noting that relief data is unavailable; the pilots are operating in uncharted territory.

The airstrips are typically hacked out of jungle, sometimes on mountainsides. Cleared areas can be little more than 1,000 feet in length, and sloped 20 degrees or more. Rain can render them unusable with no visual indication. Swirling gusts created by orographic lifting can routinely render strips unusable after midmorning. Some are tucked into valleys so steep and narrow that a mile out on final the pilot is committed to landing; there’s not enough lateral room for a 180 degree turn, and the terrain ahead rises too steeply to outclimb.

“You take a pilot who hasn’t been exposed (to such conditions) into those strips, he’ll be blown away,” said Berghuis. “We can do it because of our training. And even more important is the proper decision-making. You have to be able to decide, ‘Is it safe to land?’”

Keeping the faith

Truly the dedication and sacrifice mission pilots routinely make is a testament to their tremendous conviction. Yet some might contend all pilots are creatures of faith. How can one not believe in the miraculous if he is willing to bet his life time and again that a hunk of metal weighing more than a ton can move through the sky, seemingly impervious to gravity’s pull? And most aviators regard the cockpit as a sanctuary, and flight as a spiritual experience. How else to explain the aviator’s axiom, “God is my co-pilot”?

Boyd chuckles when asked for comment about that phrase, and whether it carries increased weight for mission aviation pilots.

“We tend to believe that very openly at MAF,” Boyd said. “I have been a pilot and have been in situations where I can honestly testify I know God was with me. Certain things happened and otherwise I would not have survived. And there are many instances daily where we can truthfully testify that is a distinct feeling, call it what you will. (But) you try not be flippant about it. (MAF) pilots have lost their lives.”

And not just in accidents. In 1956, missionary pilot Nate Saint and four colleagues were killed in Ecuador by the Auca Indians they had come to help. News of the tragedy spread worldwide, drawing attention to missionary aviation and bringing more volunteers and supporters. (Seven of the nine Indians who attacked the missionaries and many of the tribe members subsequently converted to Christianity.) No MAF pilot has been lost in more than a decade, but overall, 18 have died in accidents.

“And the question is,” Boyd continued, “‘Where was God then?’ As Christians we have to say that is part of God’s plan.”

However one regards the plans and designs of the divine, MAF and its brethren organizations are witnessing an increase in mission aviation. And that is a blessing for the multitudes who depend on the aerial lifeline they provide.
“We think that missionary aviation is going to be around for a long time,” said Ringenberg. “There will always be people in need in remote locations around the world, and people who want to serve God by serving people.”

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By James Wynbrandt
Reprinted with permission of Pilot Magazine.

Iama Spotlight: LeTourneau University

LeTourneau University’s School of Aeronautical Science offers a broad degree in aviation from a Christian perspective in five majors and 14 total degree concentrations, including mission aviation.

We offer a study of aviation that includes all the elements from design, electronics, air traffic control, computer science, mechanics, technology and flight.

Our solid, hands-on degree concentrations teach the skills and knowledge students need to be successful in the aviation industry. Our state-of-the-art airplanes and labs use the very latest technology: electronics, composite materials, computer software and jet engines. LETU’s aviation program is primarily designed for those who wish to become experts and leaders in the aviation industry.

MAF Caravan-A floating workhorse

From Aviation News Magazine

Unique operational environments need unique solutions. In Bangladesh, the use of an amphibious aircraft for humanitarian work is answering such a need.

After just a 30-min inspection for Customs approval and only three hours for final import documentation to be approved, Mission Aviation Fellowship’s (MAF) new amphibious Cessna Caravan, S2-AEC, arrived in Bangladesh in August 2005 to begin work from its base at Dhaka. The smart new aircraft, purchased through generous donations from individuals, churches and charitable trusts, replaces a long-serving but ageing de Havilland Canada Beaver floatplane.

MAF, a Christian-based organisation established just after the Second World War by some former pilots, has been operating in Bangladesh since 1997 and anyone visiting this Asian country soon realises that it is one of the world’s poorest, most densely populated and least developed nations. Development is severely hindered by its geography and climate. With 75% of the total area covered in water and only 12 airstrips, it takes a special type of aircraft to operate there. One third of its 138 million people live below the poverty line, but the countless rivers and the huge Ganges Delta make traveling to receive vital help extremely difficult if not impossible. Water-borne diseases are common, yet medical care and support is limited due to the inaccessibility of many communities. However, with an amphibious aircraft, stretches of water no longer pose a barrier for those in need of help. Landing at over 200 sites, MAF reaches the least accessible areas, bringing life-changing and life-saving support and hope.

The organization’s role in Bangladesh is to show God’s love through providing transport to gain medical assistance by air for the needy and disadvantaged. The Beaver was frequently in need of repairs and out of service so a replacement was clearly required if MAF was to continue its work. The new Caravan was a logical successor with its ability to fly more passengers, carry between 80 and 160% more payload and reach its destination quicker. The organization already operated 21 Caravans around the world in countries as diverse as Angola, Chad, Mongolia, Sumatra, Brazil, Papua and South Africa, so it was well aware of the capability of the type.