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Check My Math Please

07/07/2010 4:16 PM

So, I'm designing this gizmo that continually ignites oil well flares with a 30,000V spark from a HV coil. The control card (proprietary) fires the coil for 0.5 sec every 5 sec. The Card itself along with the associated circuitry draws 300ma when not firing. When firing total amperage is 3A. The entire package operates on solar power with a charge controller and battery for those pesky times when the sun goes down. Assuming 10 Hrs. of darkness I need to size the Amp/Hr capacity of the battery. So;

3*0.5/36000 + 0.3(32400)/36000 = 0.27 avg. amps

Capacity = amps * time

0.27 * 10 Hrs. = 2.7 Amp/Hrs

Did I miss much?

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#1

Re: Check My Math Please

07/07/2010 4:53 PM

Yes. Based on your math, your battery would be dead at sunrise. And the battery will lose a small amount of it's power every hour. By the 9th hour, your battery would be too low to power the charge. If you are designing a system, start with overkill, and delete when you are sure it produces no use. IMHO, I would use a group 31 battery designed for solar charging. good luck.

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#2

Re: Check My Math Please

07/07/2010 5:14 PM

Hi RR,

I approached it this way:

The draw is 3A firing 0.5s/5s or 10% of the time.

The draw is 0.3A the rest (4.5s/5s = 90%) of the time. This becomes (3)(0.1) + (0.3)(0.9) = 0.57A draw average.

So, for 10 hrs you need a 5.7 A-hr. battery. (I think).

Mike

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#3
In reply to #2

Re: Check My Math Please

07/07/2010 5:28 PM

RDGRNR,

Yes, you badly missed something. You did the average over an hour (36000 seconds) but you didn't count the total number of 3A cycles throughout the hour. You can do average ampere calculation using either an hour or 5 seconds period. Here the calculations are for both cases:

(1) Over the hour (36000 seconds) period:

Total number of 3A pulse in an hour = 36000/5= 7200

Average current = (3*0.5*7200)/36000 + (0.3*32400)/36000 = 0.3 + 0.27 = 0.57 A

(2) Over the 5 seconds period:

There will be only one 3A pulse in 5 seconds and 0.3A for rest of 4.5 seconds

Average current = (3*0.5)/5 + (0.3*4.5)/5 = 0.3 + 0.27 = 0.57 A

Ampere-Hour for 10 hours = 0.57 * 10 = 5.7 AH

For both cases, the average ampere is same. The final unit should be AH (Ampere-Hour), not Amp/Hrs. This is the AH the flare ignition system will consume during the dark time. When you select the battery capacity in AH, select at least 50% more of this requirement.

- MS

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#6
In reply to #3

Re: Check My Math Please

07/07/2010 6:09 PM

I just pulled out my calculator and it says there is 3600 seconds in an hour.

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#7
In reply to #6

Re: Check My Math Please

07/07/2010 6:51 PM

Yes, you are right. In fact, the calculation (1) has been done for 10 hours period (36000 seconds). The calculation can be done using any time interval which is multiples of 5 seconds. However, 5 seconds calculation is simpler though. The result will be same all the times.

- MS

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#11
In reply to #7

Re: Check My Math Please

07/08/2010 7:02 AM

Sorry, I was drinking and feeling really smart. Thanks for taking it easy on me.

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#4

Re: Check My Math Please

07/07/2010 5:53 PM

Also... the number of sun hours varies greatly by location. Make sure you have enough capacity for the worst case scenario... and that there will be enough sun hours to charge the batteries during the time available to do so.

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#5

Re: Check My Math Please

07/07/2010 6:00 PM

Others have worked the math.

I have an observation: "Assuming 10 Hrs. of darkness..." As my pessimistic nature kicks in, I wonder if that might be better as ten hours of usable light? Maybe less.

[edit] I see North of 60 voiced a similar opinion. Didn't mean to step on you.

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#8

Re: Check My Math Please

07/07/2010 10:52 PM

I would approach the problem more conservatively:

8 [hours] good sun
16 [hours] not enough sun
Use only 50% of battery capacity to extend life.
Assume 75% efficiency for all other conversions.

0.3 [A] x 0.90 + 3 [A] x 0.10 = 0.57 [A] average current

0.57 [A] x 16 [hours] / 0.50 = 18.2 [A-hours] battery capacity needed

Solar panels must be large enough to supply charge current AND ignitor current during sun hours.

Assuming a 12 [Volt] system...

Solar power needed to charge battery

12 [V] x 0.57 [A] x 16 [hours] / 8 [hours] / 0.75 = 18.2 [W]

Solar power needed to run ignitor

12 [V] x 0.57 [A] / 0.75 = 9.1 [W]

Average solar panel output during an 8 [hour] sunny day should be at least 30 [W].

Good Luck!

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#9

Re: Check My Math Please

07/08/2010 5:35 AM

You have had many suggestions in the maths and etc.

In all cases, when you reach a conclusion about the exact required AH for the next 14 hrs or 16 hrs of darkness, double the battery capacity (at least) and make sure that the solar panel has enough power to run the Gizmo and charge the battery to full.

You can only draw 1/2 what you put into the battery (normally).

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#10

Re: Check My Math Please

07/08/2010 6:20 AM

Mikerho has provided the easy way to look at the total current drain: it's 3A for a tenth of the time and .3 Amps for the rest of the time, about 0.6 Amps average (ignoring the sort of overlap which he has accounted for).

Lots of people have pointed out the foibles of batteries.

I'm more worried about your short estimate of night time. The best scenario from your point of view is having the equipment at the equator: 12 hours daylight, and 12 hours night. Any other part of the world you might get longer days in the summer, but, you also get shorter days/longer nights in the winter.

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#12

Re: Check My Math Please

07/08/2010 8:17 AM

Thanks for the attention! FYI; I had already chosen a 30W BP Solar, a 26 AH Powersonic sealed LA Batt. and an ASC charge contoller. Test phase underway.

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#13
In reply to #12

Re: Check My Math Please

07/08/2010 10:03 AM

Would the light from the flare produce any output from a solar panel?

Just asking,,,,,

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#14
In reply to #12

Re: Check My Math Please

07/08/2010 10:33 AM

I believe you are on the right track and some empirical testing should confirm operation at your location.

Probably too costly and not worth the effort (you have to run the numbers on your end), but what about using the waste heat and a thermoelectric generator to augment the solar panel and battery backup?

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#15

Re: Check My Math Please

07/08/2010 1:36 PM

RDGRNR,

I am very interested in your project. Are you an end user or are you designing this product for the oil and gas industry? I would be interested in speaking with you. You can reach me at ***-***-****. My name is Andy.

---

Comment edited: It's probably not wise to leave your phone number on a public forum. One of you should private message the other to obtain contact info.

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#16
In reply to #15

Re: Check My Math Please

07/08/2010 2:05 PM

Andy,

FYI, there is a private mail response option you should be able to use to contact the OP (or any other registered poster) to exchange contact information. Click on a username and look for a "Send username a Message" icon near the upper right corner of the new window.

While none of the "regulars" here would abuse the contact information you post publicly, there are many unregistered opportunistic surfers and bots which might cause you grief.

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#17
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Re: Check My Math Please

07/08/2010 3:49 PM

Great information. Thank you!

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Users who posted comments:

Andy@E&MSales (2); bob c (1); Doorman (1); kramarat (2); LAA_Lucke (1); Mikerho (1); mjb1962853 (3); msamad (2); North of 60 (1); Randall (1); RDGRNR (1); Unredundant (1)

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