Author: Jason Deveau

  • Centrifugal and Diaphragm Pumps

    Centrifugal and Diaphragm Pumps

    Press Play to hear the audio version of this article

    Adjusting Sprayer Settings

    Operators are encouraged to adjust airblast sprayer settings to conform to the variability in canopy size, density, spacing, and weather conditions. The efficiency and accuracy of the application is improved through the regular and independent adjustment of travel speed, nozzle output, and air settings.

    Airblast design is highly variable.

    Inflexible sprayer design results in a suboptimal match between equipment and crop. For example, sprayers intended to blow across multiple rows in a single pass are promoted for their high productivity, but typically compromise either coverage uniformity or drift control. In another example, low volume mist blowers utilize high speed air to atomize spray and are promoted as a means for saving water and/or pesticide. But, for many such sprayers, moderating air speed to reduce drift potential causes undesired changes to spray quality.

    Even with geared fans, many of Ontario’s airblast sprayers are overpowered for vines, canes, bushberries and high-density orchards. I am uncomfortable with manually obstructing the air intake or adjusting fan blade pitch for safety reasons. Fan gears and travel speed are excellent means for adjusting air energy. Alternately, we have sometimes had success reducing air energy by gearing the tractor up and throttling down (GUTD), but it’s only for very specific situations.

    It has been my experience that centrifugal pumps on axial airblast sprayers can undermine adjustment efforts when spraying small to medium sized canopies (i.e. not tree nut or citrus). In the case of GUTD, slowing the fan reduces pressure at the nozzle. Modest pressure regulation may be possible, but typically the operator must swap to larger nozzles to maintain flow. Hollow cone nozzles are only available in large flow increments (average 0.5 gpm), and stepping-up often results in excessive flow. The operator may be able to increase travel speed to compensate, but this frustrates the original intention by affecting dwell time: air settings must now be reconsidered.

    Within this context, why do some Ontario airblast operators still choose airblast sprayers with centrifugal pumps? Let’s consider Ontario’s Georgian Bay area, which many manufacturers, distributors and mechanics refer to as “the last bastion of the centrifugal pump in Canada”.

    Remember as you read on, Ontario’s airblast crops are predominantly small to moderate sized canopies. Centrifugal pumps are a common and appropriate pump for large canopies like tree nut and citrus.

    Airblast Pumps (in Ontario)

    The Georgian Bay region of Ontario.

    Airblast sprayer design is highly variable, featuring a diversity of pump styles. Piston (or plunger), peristaltic, tractor-hydraulic driven centrifugal pumps are but a few. Historically, piston pumps and centrifugal pumps on John Bean and FMC sprayers were the airblast norm in Canada.

    In the 1950s, Georgian Bay was home to Swanson Sprayers (now part of DW), who manufactured airblast sprayers featuring the Myers centrifugal pump. The sprayer was a good fit for the standard apple orchards found in the region. Huge canopies required high volume applications, and the rough and craggy bark harboured mites that drove the need for drenching sprays. To achieve this, sprayers traveled at 5 km/h (3.1 mph) on 7 m (24 foot) spacing, operating at 10 bar (150 psi) to emit as much as 3,750 L/ha (400 US gal./ac). At the time, a diaphragm pump could not manage this, even traveling at 0.8 km/h (0.5 mph).

    A Swanson Sprayer (This one likely from Georgia, USA).

    By the 1970s Holland’s Kinkelder air-shear sprayer (centrifugal pump) was introduced to Ontario and promoted as a way to use less pesticide. Perhaps ahead of their time, they never really took off because orchards were still too large for their concentrated (i.e. low-volume) applications. By the 1980s a wave of Italian-made sprayers (e.g. the Good-Boy or GB) featuring diaphragm pumps were imported into the Niagara region by distributors such as Rittenhouse.

    Similar to the Kinkelder, this was one of Ontario’s last KWH air shear sprayers. RIP 2018.
    The Italian-made Good-Boy (or GB).

    There were many cases of misuse as unfamiliar operators failed to grease direct-drive diaphragm shafts, ran the throttle beyond 540 rpm or diverted flow intended for agitation to increase flow to the booms. Decreased agitation in relatively large tanks left concentrated spray mix to clog suction filters and destroy the diaphragm pumps. It was an inauspicious start, but the diaphragm pump rallied and today we estimate that 90% of Ontario’s airblast sprayers have diaphragm pumps, while the rest are mostly centrifugal. One Ontario airblast dealer claims to sell 50 diaphragms for every centrifugal, but not in Georgian Bay.

    Is it regional history or a long memory of diaphragm “growing pains” that propagate the demand for centrifugal pumps? Perhaps considerations of maintenance, expense or ease of use play a role. Dealers claim that the centrifugal pump is cheaper, but these savings are offset by custom installation costs. Perhaps weather conditions or the crop morphology make centrifugal a better fit? Let’s consider the relative benefits and limitations of diaphragm and centrifugal pumps.

    Design

    Centrifugal Pumps

    Centrifugal Pump – Exploded View.

    Most centrifugal pumps prime by gravity feed which is why they are located at the bottom of the sprayer. While less common in Ontario, there are self-priming versions that reserve fluid in the case, or employ clever plumbing, permitting a more accessible location on the sprayer.

    Engine-driven centrifugal sprayers are artefacts in Ontario. The more common PTO-driven impeller operates at high speeds, requiring a >1:4 speed step-up mechanism (e.g. gearbox, pulley or hydraulic motor), and unlike diaphragms, they create smooth flow that does not require pulse suppression. While not technically required, most have a relief valve between the pump outlet and nozzle shut off valve to handle changes in pressure.

    Diaphragm Pumps

    Diaphragm Pump – Exploded View.

    Diaphragm pumps are self-priming and readily accessible because the shaft runs through the pump to power the fan at 540 RPM, with no need to step-up. Flow is directly proportional to pump speed which in turn depends on the tractor PTO speed. A pressure regulator is used to control bypass flow, which is convenient for making adjustments in nozzle output.

    Pump Flow and GUTD

    Centrifugal pumps are capable of higher flow at lower nozzle pressure and require more horsepower than diaphragm pumps. Note the large relative difference in flow for a centrifugal pump between the operating pressures of 90 and 100 psi (red curve shaded red) versus that of a diaphragm pump (blue curve shaded blue).

    Relative difference in flow versus PSI at constant RPM for a common Centrifugal (red) and Diaphragm (blue) pump. Shaded pressure represents 90 to 100 psi.

    Centrifugal Pumps

    The flow curve of a centrifugal pump drops off dramatically; pressure (not RPM) dictates flow. If you were to throttle back on a PTO-driven centrifugal pump, reduced flow would reduce the ability to build nozzle pressure. This means fan speed cannot be separated from nozzle pressure, and reducing air speed means re-nozzling.

    Centrifugal flow at different RPM. Shaded pressure represents 90-100 psi.

    While (unfortunately) still rare in Ontario, rate control monitors can be used (regardless of pump type) to calibrate output based on a target rate, speed and material flow using travel speed and flow sensors. Nevertheless, they cannot compensate for the aforementioned pressure loss at the nozzle if a centrifugal pump is throttled down to reduce air speed.

    In any case, throttling back on a centrifugal pump can cause a condition called suction or recirculation cavitation (aka pinging). Tiny high-pressure air bubbles form on the suction side of the impellor, explosively pitting the impellor. The damage is similar to corrosion and it causes vibration that will wear the pump prematurely.

    Any restriction on the inlet side (e.g. clogged suction strainer, collapsed/undersized line) can cause a loss of volume that can damage a centrifugal pump. “Dead-heading” (i.e. closing the outlet) is possible for a short period of time, but it quickly results in heat build-up which can cause damage.

    Diaphragm Pumps

    The flow curve of a diaphragm pump is flatter and more efficient; RPM (not pressure) dictates flow. If you slow the airblast fan by throttling the PTO below 540 rpm, flow decreases moderately, but surplus capacity allows sufficient flow to the nozzles without pressure drop. As long as the tractor does not lug, there is less noise, lower fuel consumption and therefore operator can typically adjust the air without having to change nozzles. Even if the flow changes the pressure regulator on the diaphragm pump can be used to adjust nozzle operating pressure, precluding a change in nozzle size. Convenient.

    Diaphragm flow at different RPM. Shaded pressure represents 90-100 psi.

    Diaphragm pumps are capable of high pressure, but are rarely operated above 150 psi in Ontario. Molded hollow cones (eg. TeeJet’s TXR or Albuz’s ATI) operate well in the lower psi range compared to pressure-loving disc-cores. Therefore, while regulators and springs are sized according to the pump’s maximum settings, they do not reflect the usage pattern. The relatively heavy spring is too stiff to compensate for changes in pressure (e.g. driving on hills or closing one boom) behaving more like a fixed bypass and undermining a calibration. The phenomenon is discussed more detail in this article.

    Maintenance

    Centrifugal Pumps

    A centrifugal pump with self-lubricating bearings and quality seals (e.g. carbide) that is maintained seasonally and operated in the best efficiency point of the curve will run reliably for many years.

    Proponents of the centrifugal pump claim they are low maintenance (compared to the diaphragm pump). This may be anecdotal, because of the pump’s out-of-sight position on the sprayer and their tolerance for neglect. A mistreated centrifugal pump fails by degrees, often forgotten until a seal leaks or a pressure drop is noticed. In the later situation, increased flow from nozzle wear can mask the problem as the sprayer continues to cover the same number of hectares. Often overlooked, worn or misaligned sheaves/belts on a centrifugal sprayer can also cause a loss of flow. Operators might notice a tail breeze that blows spray onto the belts can cause slippage and lower the nozzle pressure.

    Diaphragm Pumps

    Opinion is divided on the longevity and maintenance of diaphragm pumps. Some claim they are reliable and low maintenance as long as regular oil changes occur. Others suggest the complication of connecting rods, o-rings and valves require more upkeep than the simpler centrifugal. Unlike the centrifugal pump which merely loses pressure, failure on a positive displacement pump is complete and requires immediate repair

    Much depends on the diaphragm material and the products being sprayed. For example, corrosive materials (e.g. copper sulfate, urea, etc.) require polymer manifolds to minimize contact with metal. Metal manifolds do not weather well.

    The diaphragm pump can run dry for extended periods. This creates heat but does not often lead to failure. Failures occur from exposure to vacuum, which can happen with dirty suction filters or long and/or improperly sized suction lines, or even lack of oil support on the compression stroke (caused by over-revving).

    While three-cylinder designs may not require pulsation dampening, most require an accumulator to suppress the pulsing created by each stroke. Improper adjustment can lead to “hammering” that cracks mounts and valves, and can exacerbate rub-points on hoses. Diaphragm pumps that use direct drive shafts (i.e. carry the PTO to the fan) are subjected to the thrusting of the drive shaft during turns. It is important to keep them greased.

    Summarily, the longevity and maintenance requirements for either pump design seem about equal. They depend on the products being sprayed, the quality of pump materials, and adherence to the manufacturer’s instructions on correct usage and preventative maintenance.

    Conclusion

    Ontario’s airblast-specific crops have become smaller, closer and denser. High liquid volumes and air speeds are typically not required. Operators are encouraged to use Crop-Adapted Spraying to adjust fan speed and nozzle output to the crop and the weather. In my opinion, the diaphragm pump facilitates this, resulting in lowered input costs, reduced drift and improved coverage uniformity. I recognize that this requires skill and effort on the part of the operator, and setting-and-forgetting a centrifugal pump can be attractive, but it’s unacceptable if it leads to unnecessary environmental impact.

    In the end, the sprayer manufacturer chooses the pump, atomization and air-handling system while considering safety, effectiveness, reliability and price point. The operator must acknowledge the capabilities and limitations of the sprayer design when choosing the best fit for their operation.

    I still don’t know why regions like Georgian Bay seem to prefer one pump over another. Perhaps it’s simply herd mentality. Perhaps they know something I don’t. But consider: an airblast sprayer’s average lifespan is 30 years. That’s a long time to live with a decision.

    Choose wisely.

    Special thanks to the many dealers, manufacturers, engineers, mechanics and end-users that helped to inform this article.

  • Testing and Correcting Airblast Pressure

    Testing and Correcting Airblast Pressure

    The role of pressure is often underappreciated in spraying. Many airblast operators (still) don’t use rate controllers, so the only way to monitor sprayer pressure is using a single liquid-filled pressure gauge located near the pump… and it may not be trustworthy. An inaccurate pressure gauge may cause you to spray more or less product than you intended. That translates to wasted resources and potentially higher residue levels. Conversely, spraying less than intended may lead to reduced efficacy and the need to re-apply. Many operators use budget pressure gauges on their sprayers and have never tested or replaced them.

    Testing pressure gauges

    Here are a few clear indications that your pressure gauge should be retired:

    • Gauge has an opaque or unreadable face
    • Mineral oil leaking or mostly gone
    • Needle does not rest on zero pin when sprayer is not under pressure (it has likely spiked)

    Sometimes a gauge is not obviously in need of replacement. To test it, you need to apply a known pressure to see if it is reading accurately. One way to do this is using a commercial manometer.

    AAMS-SALVARANI Gauge tester
    AAMS-SALVARANI manometer

    These systems work well, but they can be an expensive proposition if you only use them once in a while. In a past sprayer workshop, one participant had a great suggestion for testing gauges. His idea was to use an air compressor (which most farms have) and some simple plumbing to create a homemade manometer. Be sure to vent the gauges before testing.

    The Pressure Gauge Tester. The “true” gauge is in the elbow and can be compared to the suspect gauge in the tee. Concept from K. Voege, Ontario.
    The “Pressure Gauge Tester”. The accurate gauge is in the elbow and is compared to the suspect gauge in the tee. Concept: K. Voege, Ontario.

    This tool allows you to test your suspect gauge (set in the tee) against an accurate gauge (set in the elbow) for less than $75.00 CAD. Construct your own “Pressure Gauge Tester” using the following parts (valve optional):

    PartApprox. Price (CAD)
    ¼” by 3” Galvanized nipples (x 2)$3.50
    ¼” Galvanized 90º elbow$3.50
    ¼” Galvanized Tee$3.50
    ¼” Ball valve (threaded)$10.00
    *Plug Air Connector (A over ¼”)$4.00
    Teflon pipe tape$3.00
    †300 psi liquid-filled gauge$40.00
    *Depending on the quick-connect fitting on your compressor 
    †The range of the accurate gauge should match your existing gauge. The range of your existing gauge should be twice as much as your typical operating pressure. 

    As a public service announcement, be aware that many budget, liquid-filled gauges are inaccurate right off the shelf. A 5% variance is typical. When replacing a worn gauge, or buying the “accurate” test gauge for your homemade manometer, buy a few and save the receipt. Test them in different combinations to ensure they all agree with one another. Return the extras and let the dealer know if you discover an inaccurate gauge. I’m sure they won’t put it back on the shelf for the next person… *ahem*.

    Gauges should be rated twice as high as your average operating pressure. For example, if you typically spray at 150 psi, your should have a gauge rated up to 300 psi. That way, you can see small changes in pressure more clearly. Plus, if your needle is pointing straight up, a quick glance confirms the ideal operating pressure.

    Another way to confirm pressure gauge accuracy is to install a second in-line. They’ll keep one another honest. This may be difficult if the gauge set into a molded plastic tank, or located under the chassis next to the pump where it is not visible from the tractor.

    Two gauges keep each other honest – this GB (Italian-made Good Boy) is sporting a home-made assembly that cost ~$50 to assemble, including the second gauge. The silver spray paint on the black pipe prevents rust and makes it look pretty darn sharp.
    Two gauges keep each other honest – this GB (Italian-made Good Boy) is sporting a home-made assembly that cost ~$75 CAD to assemble. The silver spray paint on the black pipe prevents rust and makes it look pretty darn sharp. Note that they should be the same range, but are not in this photo. The one on the right is the correct range for this operating pressure.

    Measuring and Correcting for Pressure Drop

    Boom pressure can sometimes be less than the desired operating pressure (a phenomenon known as “pressure drop”) and must be accounted for. Pressure drop is affected by hose diameter, hose fittings, and the distance from the pump. You’ll find it at the far ends of boom sections on field sprayers and it’s an issue that plagues many low-pressure, tower-style sprayers. Dress appropriately because you’re going to get wet performing this diagnostic.

    1. Fill a clean sprayer about half-full with water.
    2. Install a liquid-filled test gauge in the highest nozzle position of one of the booms. The image below shows how the nozzle cap or entire nozzle body may need to be removed for this step. For Metric fittings, contact your sprayer dealer – they can be hard to find.
    3. With the tractor parked, bring up the rpms and get the lines to the desired operating pressure.
    4. Open the boom(s) and measure the pressure at the nozzle farthest from the pump. All nozzles on all booms should be open during this test. That’s why you are wearing PPE.
    5. For positive displacement pumps, adjust the main pressure regulator until the test gauge reads the desired pressure. For centrifugal pumps, it is possible to make small changes to the pressure, but more important to note any pressure differential for later considerations regarding nozzle output and spray quality.
    There are many ways to install a gauge onto a nozzle body. Here are three examples of common fittings.
    There are many ways to install a gauge onto a nozzle body. Here are three examples of common fittings.

    Switching between multi and single boom operation

    When sprayers that employ a positive-displacement pump are switched to one-sided operation (E.g., border spraying or during turns), the pressure can change considerably. Most units will experience a pressure increase, thereby increasing the boom output. This is typically an indication of a faulty relief valve, which is positioned between the pump and nozzles. It’s actuated by a spring-loaded piston or diaphragm, opening and closing in response to changes in pressure. The operator sets the desired pressure and any additional pressure forces the valve open, diverting excess flow back to the tank via a bypass.

    Spraying from one boom. This operator checked to make sure the pressure didn’t increase when he closed the second boom. High pressures or sudden spikes could indicate a faulty regulator valve.
    Spraying from one boom. This operator checked to make sure the pressure didn’t increase when he closed the second boom. High pressures or sudden spikes could indicate a faulty relief valve.

    This problem can be greatly reduced by properly sizing the regulator (specifically the spring) to the typical operating pressure. Many sprayers come equipped with regulator springs matched to the maximum pressure range of the pump (often 600 – 900 psi). These springs are unable to respond to changes when operating at lower pressures (E.g., 100-200 psi, which is typical of applications to moderately-sized canopies).

    The springs are so stiff that the liquid pressure is unable to act on the spring and the valve essentially acts as a flow control (throttling) valve rather than a pressure control valve. Liquid pressure is difficult to control using a throttling valve; it is unable to compensate if the tractor engine speed drops while driving uphill and sprayer output is subsequently reduced. Further, this phenomenon can cause pressure gauges to spike.

    Valve springs and seats wear out, such as in this regulator assembly. Check yours each season.
    Valve springs and seats wear out, such as in this regulator assembly. Check yours each season. If you spray using moderate pressures, be sure your regulator spring can compensate for small changes.

    Some sprayer designs attempt to compensate for excess flow during single-boom operation. They employ an additional throttling valve to shunt the volume that would normally would be spraying out through the closed boom. The result is that the pressure should remain constant when a single boom is shut off. If your sprayer has this feature, here’s how you set the valve:

    1. With PTO at application speed and both booms open, adjust regulator to calibrated operating pressure.
    2. Close one boom.
    3. If pressure increases, open throttling valve to achieve calibrated operating pressure. If pressure decreases, close throttling valve to achieve calibrated operating pressure.
    4. Repeat process for the other boom, and find a compromise position for the valve.

    Some operators elect to remove the handle from the throttling valve once it is set so they don’t accidentally bump it later. That’s fine, but further adjustments may be required when transitioning between dilute and concentrated volumes, so don’t lose the handle.

    Here’s an oldie-but-a-goodie filmed in New Hampshire in June, 2014. It’s something to keep in mind when you’re getting your sprayer ready for spring service. Thanks to Chazzbo Media and Penn State Extension for making an unscripted and spur-of-the-moment concept into a polished video.

  • Spray and Soil Fumigant Buffer Zones in Canada

    Spray and Soil Fumigant Buffer Zones in Canada

    Spray buffer zones are no-spray areas required at the time of application between the area being treated and the closest downwind edge of a sensitive terrestrial or aquatic habitat. Spray buffer zones reduce the amount of spray drift that enters downwind, non-target areas.

    Sensitive Terrestrial Habitats

    Sensitive terrestrial habitats can include hedgerows, grasslands, shelterbelts, windbreaks, forested areas and woodlots. Crops and private properties adjacent to treated areas are not considered to be sensitive terrestrial habitats and do not require spray buffer zones. However, labelled spray buffer zones are a good indicator of potential damage to adjacent vegetation. Applicators are responsible for ensuring their spraying programs do not adversely affect neighbouring properties.

    Sensitive Aquatic Habitats

    Sensitive aquatic habitats can include lakes, rivers, streams (channelized or natural), creeks, reservoirs, marshes, wetlands and ponds. Temporary bodies of water resulting from flooding or drainage to low-lying areas are not considered sensitive aquatic habitats. Nor are aquatic drainage ditches or seasonal water courses that are dry at the time of application. Water body depth will determine the buffer zone distance, as indicated on the pesticide label. Downslope open water may also require a vegetative filter strip .

    The pesticide label will indicate when a spray buffer zone is required. The distance will depend on the product used, the method of application and the crop being sprayed. In some cases, the buffer zone may be modified using Health Canada’s Spray Buffer Zone Calculator . When provincial and label restrictions differ, or label restrictions differ between tank mix partners, use the greatest distance.

    Buffer zones or No-Spray zones physically separate the end of the spray swath for the nearest downwind sensitive area.
    Buffer zones or No-Spray zones physically separate the end of the spray swath for the nearest downwind sensitive area.

    Spray Buffer Zone Calculator

    Unless forbidden by the pesticide label, Health Canada’s Spray Buffer Zone Calculator may permit applicators to reduce the size of the spray buffer zone specified on a pesticide label. To be eligible, the product label must specify a field or aerial spray quality coarser than “Very Fine” and finer than “Very Coarse”. All airblast spray qualities are applicable.

    Modifications are based on meteorological conditions, sprayer configuration and the application method at the time of application. If modified spray buffer zone distances are less than provincial or municipal distances, use the greater distance.

    Applicators that choose to use the calculator must retain a copy of the summary page for at least one year following the application to demonstrate compliance with label directions.

    Vegetative Filter Strips

    A vegetative filter strip is a permanently vegetated strip of land that sits between an agricultural field and downslope surface waters. Vegetative filter strips reduce the amount of pesticide entering surface waters from runoff by slowing runoff water and filtering out pesticides carried with the runoff.

    Pesticide labels may require a vegetative filter strip, or recommend one, as a best management practice. They must be at least 10 metres wide from edge of field to the surface water body and be composed primarily, but not exclusively, of grasses.

    Spray buffer zones do not apply to vegetative filter strips unless there is a pre-existing sensitive terrestrial habitat within them. Therefore, vegetative filter strips may overlap spray buffer zones when open water is both downslope and downwind (see illustration). In this case, the minimum 10 metres vegetative filter strip distance must be observed, but the set-back can be larger based on spray buffer zone, provincial or municipal restrictions.

    Soil Fumigant Buffer Zones

    Soil Fumigant Buffer Zones are mandatory, untreated perimeters surrounding the treated field. They limit user exposure and increase the protection of workers, bystanders and the environment. The distance will depend on the application method, product rate and field size, as indicated on the pesticide label. An Emergency Response Plan is required when residences or businesses are located within 90 metres of the buffer zone perimeter.

    Soil fumigant buffer zones have a time component. This Buffer Zone Period begins at the start of the application and ends a minimum 48 hours following the application. Respiratory protection and stop-work triggers, as specified on the pesticide label, will apply to anyone present in the buffer zone area during the buffer zone period.

    Buildings and residential areas within the soil fumigant buffer zone must be unoccupied during this period. Unless in transit, non-handlers (including field workers) must be excluded from the soil fumigant buffer zone during this period. Entry is permitted for fumigant handlers with appropriate certification, emergency personnel and local, provincial, or federal officials performing inspection, sampling, or other similar duties.

    Image from www.onspecialitycrops.ca

    Soil fumigant buffer zone signage must be posted within 24 hours prior to the application and remain posted until the buffer zone period expires. Signage must include, but is not limited to, the date and time the buffer zone period ends and the name, address, and telephone number of the applicator. Soil fumigant buffer zone signage must be located at the outer perimeter of the buffer zone, at all entrances to the field, and along likely routes where people not under the owner’s control may approach. Soil fumigant buffer zone signs are in addition to, and do not replace, fumigant application block signage .

    Applicators must develop a written Fumigation Management Plan prior to the start of any application. The plan outlines key steps to ensure a safe and effective fumigation, including site conditions, buffer zones and emergency response planning. Both the owner/operator of the fumigated area and the fumigant applicator must retain signed fumigant management plans as well as a summary of Post-Application Procedures for two years following the application.

  • Three Manageable Factors that Affect Spray Drift

    Three Manageable Factors that Affect Spray Drift

    In 2014 one of our OMAFRA summer students designed a short-and-gritty demonstration using a backpack sprayer, a variable-speed fan and some water-sensitive paper positioned downwind at 1.5 metre intervals. The intent was to illustrate how sprayer operators could reduce the potential for off-target drift by recognizing and accounting for three factors:

    • Apparent wind speed (i.e. the sum of wind speed and travel speed)
    • Boom height (i.e. release height)
    • Droplet size (i.e. nozzle spray quality)

    Apparent Wind Speed

    Spray operators know they should not spray when the air is calm or when the wind is too high, but they often forget that the nozzles experience “apparent wind speed” which means driving 10 km/h into a 10 km/h headwind is essentially spraying in a 20 km/h wind.

    The result of spraying with a Medium spray quality in 10 km/h and 15 km/h wind: water-sensitive papers indicated that there is more downwind drift in higher winds.

    Boom Height

    Spray operators raise their booms to ensure their nozzles clear the crops, but this contributes to off target drift and greatly reduces coverage – particularly when using twin-fan style tips. Dr. Tom Wolf explains how to set your boom height here, or you could watch one of our Exploding Sprayer Myths videos on the subject.

    The result of spraying with a Medium spray quality in a 10 km/h wind at 50 cm and 100 cm from the ground: water-sensitive papers indicated that downwind drift increases as the boom gets higher.

    Droplet Size

    The coarser the spray quality, the less likely the spray will drift off target. Remember, for a given volume, shifting to larger droplets means fewer droplets. Application volumes may have to increase to compensate for potentially reduced coverage.

    The result of spraying with a Medium spray quality versus spraying with an Extremely Coarse spray quality: water-sensitive papers indicated that there is more downwind drift from smaller droplets.

    Take-Home

    This demo used percent coverage as a metric, which is convenient but greatly underestimates drift. So even when the spray window is small and the spray has to go on, take a moment to drop the boom, use a coarser droplet size and if it’s too windy, just don’t spray.

    WUR Drift Calculator

    There are many drift calculators available for home use. Some require more expertise than others to get a reliable result. This free downloadable calculator from Wageningen University & Research was made available in 2021. It can quantify spray drift deposits onto surface waters and non-target terrestrial areas near a sprayed field or orchard

    The calculator uses statistically obtained regression curves to calculate spray deposition next to the sprayed field. The spray drift curves are based on the latest experimental data for field crops, fruit orchards and avenue tree nurseries.

    Download your copy here.

     

  • Spraying Ginseng with Arag Microjets

    Spraying Ginseng with Arag Microjets

    In June 2013 we ran a ginseng spraying workshop and we learned as much as the growers did. Ginseng is notoriously difficult to spray:

    • It is highly susceptible to pathogens given the high humidity and still conditions generally found under the shade structure.
    • It forms a solid ceiling of leaves that resist spray penetrating to the stem and crown below and makes under-leaf coverage very difficult to achieve.

    Many growers have (wisely) walked away from the old Casotti sprayers, which have been shown to give erratic coverage at best. They have adopted the Arag Microjet system with it’s characteristic orange shields. The >$80.00 CAD price tag for each nozzle is due to the brass mixing valve and swivel joint, as well as import costs from Italy. Contrary to popular belief, it does not use air-assist, or air-induction – it is strictly hydraulic. It does tend to create a ‘wake’ of air movement at high pressure. This phenomenon is called air entrainment and it is caused by large droplets travelling at high speed.

    Classic Arag microjet nozzles.
    Classic Arag microjet nozzles.

    This nozzle is essentially the business-end of a spray gun. The way it is used in ginseng it works more-or-less like a hollow cone disc-core assembly. This begs the question “Why not use the cheaper and more readily available ceramic disc-core?” We set out to compare the two options using water sensitive paper set within the canopy. These yellow, paper targets turn blue when sprayed, clearly showing spray coverage.

    Location of water-sensitive papers in the ginseng canopy.
    Location of water sensitive papers in the ginseng canopy.

    Determining rates

    The first step was to determine the output rate for each nozzle. Generally, nozzle manufacturers provide rate tables showing how much volume a nozzle emits by time (e.g. US gallons per minute) at a given pressure. Finding these tables for the 1.5 millimetre Arag Microjet proved difficult. When we finally found one, it was discovered the rates were established for 200 to 850 pounds per square inch. This is excessively high pressure for a typical boom sprayer, so tables had to be developed for lower pressures.

    Classic Arag microjets have a mixing valve that opens the spray up into a hollow cone, or collapses it into a tight stream. This also changes the rate. It can never be shut off completely, and it's hard to adjust consistently.
    Classic Arag microjets have a mixing valve that opens the spray up into a hollow cone (valve handle left or right), or collapses it into a tight stream (valve handle middle). The valve position also changes the rate. It can never be shut off completely, and it’s hard to adjust consistently.
    Determining nozzle rate using the Innoquest Spot-On SC-4.
    Determining nozzle rate using the Innoquest Spot-On SC-4.

    Further, given the odd design of the mixing valve, it was determined that moving the handle ~10 degrees left of centre, or ~10 degrees right of centre, gave a difference of as much as 60%. The table below  shows the outputs for a 1.5 millimetre nozzle with the handle in both positions and the two graphs show the results… well… graphically. Outputs were determined using the Innoquest Spot-On SC-4, but the frothing effect created by the nozzles may have created minor errors. Each rate is the average of a minimum of three samples.

    Valve SettingPressure (psi)Avg Output (gpm)Pressure (bar)Avg Output (L/min)
    10 degrees left401.022.763.86
    10 degrees left501.13.454.16
    10 degrees left601.254.144.73
    10 degrees left701.254.834.73
    10 degrees left801.385.525.22
    10 degrees left901.46.215.3
    10 degrees left1001.456.895.49
    10 degrees left1101.67.586.06
    10 degrees left1201.758.276.62
    10 degrees left1501.8710.347.08
    10 degrees left2002.213.798.33
    10 degrees right400.652.762.46
    10 degrees right500.73.452.65
    10 degrees right600.84.143.03
    10 degrees right700.854.833.22
    10 degrees right800.95.523.41
    10 degrees right900.96.213.41
    10 degrees right10016.893.79
    10 degrees right1101.077.584.05
    10 degrees right1201.18.274.16
    10 degrees right1501.2510.344.73
    10 degrees right2001.3713.795.19
    Average 1.5 mm ARAG Microjet output at a range of pressures and two valve settings in US Imperial units.
    Average 1.5 mm ARAG Microjet output at a range of pressures and two valve settings in US Imperial units.
    Average 1.5 mm ARAG Microjet output at a range of pressures and two valve settings in Metric units.
    Average 1.5 mm ARAG Microjet output at a range of pressures and two valve settings in Metric units.

    Comparing nozzles

    Using the grower’s typical ground speed of 5 km/h (~3 mph) and operating pressure of 6.9 bar (100 psi), we found four TeeJet disc-core combinations that emitted a hollow cone pattern and approximately the same output as the Arag Microjets. The five nozzles sets tested were:

    1. ARAG Microjet® 1.5 mm = ~0.95 US g/min avg at 100 psi
    2. TeeJet® D8-DC25= 0.97 US g/min at 100 psi= ~97° cone
    3. TeeJet®D7-DC45= 0.97 US g/min at 100 psi= ~81° cone
    4. TeeJet®D4-DC46= 0.88 US g/min at 100 psi= ~33° cone
    5. TeeJet®D6-DC45= 0.93 US g/min at 100 psi= ~81° cone

    We did not use nozzle drop hoses (aka drop arms or hose drops) because it has already been firmly established that they are absolutely required to achieve under leaf coverage See OMAFRA factsheet 10-079 and this article.

    Observations

    While there were some complications with setting up the papers for the demo, we observed the following:

    1. The output of each Microjet nozzle can be as much as 50% more or less than expected without being visually detectable and output for each nozzle must be confirmed before spraying. Therefore, outputs should be confirmed before every application.
    2. Microjets at 100 psi emitting ~890 L/ha (~95 US gallons per acre) gave satisfactory coverage on all upward facing targets, but unsatisfactory under-leaf coverage. This has been demonstrated many times before.
    3. The TeeJet D7-DC45 combination emitting a similar rate gave satisfactory coverage on all upward facing targets, but unsatisfactory under-leaf coverage. They may be a viable alternative to the Microjets.
    4. Nozzle drops are advised to achieve under-leaf coverage.

    The demo also raised some questions:

    1. Did the TeeJet disc-core push the canopy apart as much as the Microjet? The audience noticed there was some leaf-shadowing where the cards did not get complete coverage using disc-core. This might have been coincidence, or it may not have. This question will be addressed in a research trial next season, but for now, the D7-DC45 appeared to give similar coverage to the Microjet.
    2. Can nozzle drops be avoided if pressure is raised to 27.5 bar (400 psi)? Thanks to one grower trying this experiment in his garden after the demo, we saw some under-leaf coverage is possible at such high pressures, but this occurred at the cost of a lot of noise, diesel fuel and considerable wear on the ceramic Microjet discs. The grower tested these tips and discovered they needed replacement after only two years of use. Nozzle drops are cheaper, easier and result in considerably more spray in the under leaf positions.
    3. We saw what minimal and excessive foliar coverage looked like, and determined how much variability there was from one nozzle to another. A significant question was “How much spray can be saved when using a more accurate application?” and the answer is yet to be determined, but could be well in excess of 10% of the typical spray volume. Given that this crop can be sprayed more than 100 times over it’s 3 or four years before harvest, this represents significant savings in pesticides and refill time.

    Additional – Newer ARAG Microjet Design

    Since this work was performed, growers have been exploring a newer option from ARAG.

    They are an improvement over the older version insofar as they are more easily calibrated and held at a given rate thanks to a lock nut. They still employ a 1.5 mm diameter ceramic disc, but this can be changed for a 1.0 or 1.2 quite easily. They are still somewhat finicky when trying to set a consistent spray quality and rate from nozzle to nozzle, but are better than the mixing-valve option.

    Learn more in this article.

    Custom-made ginseng sprayer. A standard design.
    Custom-made ginseng sprayer. A standard design with newer, cheaper and easier-to-use ARAG microjets.

    Special thanks to Syngenta Canada for providing lunch, to C&R Atkinson Farms Ltd. for hosting, to TeeJet for supplying the disc-cores and water-sensitive papers, and to Dr. Sean Westerveld, Dr. Melanie Filotas and OMAFRA summer student Megan Leedham for contributing to the workshop.