Waste Gas Flare Igniter Usage
ElectraSoft Cost Effective Waste Gas Flare
Ignition Control Systems are used by many industries including...
o Oil and Gas exploration and production industry for flaring off unusable gases including natural gas
mix with contaminants.
o Portable flare stacks: Dependable igniter system for portable flare stack ignition systems, that
can stand up to continuous moving from place to place, and being set up in diverse situations.
o Farming: Farm manure cover and flare off systems to reduce odors and methane gas flare stacks are
used in cattle stockyards, dairy farms and other farm livestock industries.
Smart Multi Function Flare Igniters
Not only will your ignition wire be used to deliver sparks to your spark plug electrode, but it will
also be used to set up communications between the ignition unit and your spark plug, thus allowing
for other tasks such as detecting ionization for monitoring the flame, etc. This allowed
these flare ignition control systems to work with flammable gas oxygen mixtures including LP, liquid
propane gas, NG, natural gas, acetylene, butane, acetylene, and methane ethylene ethane silane
hydrogen mixes.
Standard Flare Igniter
Standard Flare Ignition: One of the many things being
monitored on the ignition wire is whether there is a flame. This is done by checking for
flame ionization. If the
Flame Detection Option is set for [Ionization] and there is a flame on the electrode, then we will turn
off the spark.
Flame Detection
You have the option of using the spark electrode, a flame rod, or thermocouple to monitor and turn
the spark on and off. Flame detection via ionization using the spark electrode or a flame rod,
where the spark electrode, or a flame rod is immersed in the flame in order to exploit the ionizing
effect of the flame. In addition to ionization flame monitoring, you have the option of using
thermocouple flame detection instead of or in conjunction with ionization by moving a jumper.
These option can also be used to alert you if the flame is present or not.
HEI-CDI Flare Igniter
HEI-CDI
High Energy Ignition with Capacitor Discharge Flare Igniter using a
High Voltage Pulse Circuit: The flare ignition wire does additional monitoring, such as,
check for water on the spark plug and if water is found it removes it. Check for and burn
away debris. Place the spark in the best place. Increase spark voltage if necessary.
In the HEI-CDI Flare Igniters, Flame monitoring for the purpose of turning the sparking off when the
flame is present is achieved by connecting a thermocouple to the unit. These option can also be used
to alert you if the flame is present or not.
Flame Detection
You have the option of using a flame rod, or thermocouple to monitor and turn the spark on and off.
Flame detection via ionization using a flame rod, where a flame rod is immersed in the flame in
order to exploit the ionizing effect of the flame. In addition to ionization flame monitoring, you
have the option of using
thermocouple flame detection instead of or in conjunction with ionization by moving a jumper.
These option can also be used to alert you if the flame is present or not.
Monitoring the Flame
Here is how we can preform so many functions using only one ignition wire. First off, the sparks only
take up a small fraction of the overall time of a sparking cycle. The rest of the time is being used
to send inquires to the plug and receive important status data in return. We use the data to make
decisions on how to best achieve ignition.
Deliver Sparks to Your Spark Plug
This is easy as long as the system is in good repair.
Check for and Remove Water from the Plug
If water splashes on the plug, normally that means a miss-fire. We overcome this problem by sending
and receiving information about the plug. If we sense a wet plug, we send a high current across the
spark-gap and boil the water away.
Check for and Burn Away Debris
If debris forms or falls on the plug, normally that means a miss-fire. We overcome this problem by
sending and receiving information about the plug. If we sense debris in the spark gap, we send a high
current voltage across the spark-gap to burn it away.
Placing the Spark in the Best Place
About 1/1000000th of a second before sending the ignitor spark, we send a quarry asking for data on
the gas mixture. If the returned data says that the mixture is too rich at the moment, we monitor the
returning data until an ignitable mixture is present before sending the HEI-CDI igniting spark-train.
Because the mixture is moving in a constant state of flux, the mixture moving even 100th of an inch
can make the difference of igniting or not. If after a reasonable time interval we can not get a good
mixture report, we send an extra high HEI-CDI voltage at maximum current.
Increase Spark Voltage if Necessary
If you have a need for higher than normal voltage and or current, you can use the HEI-CDI Train Intensity
adjustment to increase the ignition output.
HEI-CDI Plasma Flare Ignition
Why Plasma Ignition
We use HEI-CDI produced plasma to improve flare ignition spark plug performance. Plasma
ignition will ignite a flare where other systems fail.
Creating Plasma using HEI-CDI
We take into consideration the four states of matter: 1.solids, 2.liquids, 3.gases, 4.plasma.
To form the plasma, we subject the gases in the gas-air mixture atoms to high electrical
energy that ionize them into plasma. This process breaks atoms apart to form a collection
of positively and negatively charged highly reactive particles. Plasma consists of positively
charged ions with their detached electrons moving freely about in a very active manner
reacting with other atoms.
The Power of Plasma
The plasma is produced at the location where the flame is about to ignite and then acts as a
catalyst to accelerate combustion of the flare igniter. Because plasma is extremely reactive,
it ignites immediately and burns quickly. The remaining gaseous gas-air mixture is instantly
ignited by the large cloud of burning plasma affected fuel.
HEI-CDI Plasma
HEI (High Energy Ignition) combined with CDI (Capacitor Discharge Ignition) is an
important element in our achieving the power of plasma.
How Our HEI-CDI Works
Our HEI-CDI generator uses an integrated capacitor to accumulate, store, and compress electrical
energy. We then communicate with the spark gap via the ignition wire. When returning data indicates
that a spark is forming, we release a measured amount of electrical energy that we have stored in
the capacitor in a quick and powerful brief pulse equal to about 4,000,000 watts for approximately
3/10,000,000ths of a second. This high energy discharge pulse is intense enough to convert the
gas-air mixture into highly excited plasma.
HEI-CDI Train Intensity
The 4,000,000 watt pulse(s) are sent in the form of a train with about 1/100th seconds between each
pulse. The HEI-CDI Train Intensity is an adjustable option and can be set to one or more of these
pulse(s) per train.
High Intensity Plasma Pulse Benefits
HEI-CDI Instant Ignition
The HEI-CDI pulse creates a flash of heat creating the plasma that gives the gas-air
mixture a head start to achieving the temperature required to ignite. In addition,
this pulse ionizes the gaseous gas-air mixture, breaking down air components like
H² and O² into their atomic state Hydrogen and Oxygen where they are most volatile.
These highly excited elements react to the spark by igniting instantly. The result
is a cleaner burn.
HEI-CDI Quicker Burn
The high-intensity pulse breaks apart the long hydrocarbon chains found in gas-air
mixture into shorter chains that react quickly. This rapid burn keeps the spark gap
cleaner.
HEI-CDI Cleaner Burn
The portion of the fuel that contains shortened hydrocarbon chains burns faster, and
creates a larger surface area to ignite the rest of the gaseous gas-air mixture.
This allows the gas-air mixture to burn more completely ensuring a cleaner spark gap.
Fireball Shot Tube Flare Stack Pilot Ignition
Why Use a Shot-Tube Flare Stack Pilot Igniter
The benefit of using an ElectraSoft
Fireball Shot-Tube Flare Igniter, is that you do not need to
have spark plugs, ignition wires, insulators, etc, up near the searing heat of the flare stack
bonnet.
Building a Shot-Tube Flare Stack Igniter
You start anywhere from one to six foot from ground level, where you run a tube or pipe
up to the flare stack bonnet. This tube or pipe is call a shot-tube. The size of the pipe
will be determined based on variables including the height of the Flare Stack. The shot-tube
has a venturi with a gas orifice at the bottom. Part way up near the bottom there is a
spark plug. The Flare Stack Igniter Control System is connected to this spark plug via an
ignition wire. When the shot-tube is filled with gas-air mixture from the venturi, a spark is
introduced, igniting the gas in the shot-tube, resulting in a fireball that travels to the
top and ignites any fuel it encounters.
May Need a Flare Stack Pilot
The Shot-Tube Flare Stack Igniter may be able to ignite the Flare Stack directly if the flare
gas is constant and of high quality gas. Lighting the Flare Stack directly is not alway practical
for a variety of reason. If the gas to be ignited varies in pressure or is present only
periodically. Or the flare-gas may be a mix of gases that make it difficult to ignite. These are
good reasons to consider using a Flare Stack Pilot Ignition Control System.
Adding a Flare Stack Pilot
To make the Shot-Tube Fireball Flare Stack Igniter into a Shot-Tube Fireball Flare
Stack Pilot Igniter you will need to add another pipe along side the shot-tube pipe,
connecting to a small pilot burner. This pilot pipe will, like the shot-tube, have a venturi
with a gas orifice at the bottom. When the shot-tube sends a fireball to the top, it ignites
the pilot burner. Now when the gases of varying quantity and quality are present, they will
have this stable and dependable flame to ignite them.
Shot-Tube Fireball Flare Stack Pilot Igniter
ElectraSoft Shot-Tube Fireball Flare Stack Pilot Igniter
The ElectraSoft Flare Igniter waits for
the shot-tube to fill with gas-air mixture. When the shot-tube is full, it ignites the fuel, sending a
fireball to the pilot or flare. Then it listens for feedback from your choice of electrode ionization,
flame-rod ionization, thermocouple, or any combination of the three. If the feedback verifies a flame,
the unit's LED turns from blue to green, sends a flame-on signal to the Alarm Terminal Connector and to
the Flame Data Logger, and shuts off further sparks as long as there is a flame detected. Every time the
Flare Igniter sparks, the LED flashes from blue to red for a short time.
Why Flame Detection
The Ignition Control System receives continues feedback, telling it many things, including letting it
know that the flare or pilot is lite. Knowing whether or not there is a flame is important so it can stop
sparking when a flame is present. When using a shot-tube with a pilot, another fireball may blow the
pilot flame out. Another reason for shutting down the spark after a flame is detected is to save on the
unit's circuitry, battery, and the spark plug gap ignition electrode.
Flare Ignition Equipment for Every Need
Production and Exploration
We have oil and gas field industry flare ignition system for production, exploration,
skid-mounted flare, well site flares, tank vent flares, portable, trailer, etc. We have flare igniters
for all your needs. If you need us to, we will custom build you a flare igniter.
Trailer Flaring Systems
We can supply you with a trailer flare ignition systems that uses a dual power source. We have systems
that have a combination solar and 12VDC or what ever else your prefer. This is handy if you need the
trailer flare for a quick blow-down and do not want to setup a solar panel. Just connect a wire from
your 12V battery to the unit, or don't bother to connect any power source but instead just turn it on
and it will run up to 10 days using the built-in Li-ion solar rechargeable batteries. Then if later
you want to set the flare up semi-permanent, connect your solar panel and leave it.
New and Existing Ignition Control Systems
ElectraSoft will provide
you with a cost effective solution for your new or existing Ignition Control Systems. If you need a
repair or an upgrade of your existing ignition system, contact us, and we will do that for you. If you
want to buy an ignition system from us and install it yourself, we will sell it to you at a very
competitive price and assist you with the installation. We can also build a custom ignites for you to
install yourself.
With our low priced high efficiency solar powered ignition systems you will not need to
supply electricity to the flaring sight. Tell us what you need and we will create it for
you.
High Performance yet Low Power Consumption
These ignition control systems can be used with any
gas flare or gas fired
equipment including low flow production gas flares. The basic unit comes complete with
Solar Panel ready
Li-ion Lithium Ion Battery Pack.
You can buy the basic unit or add any of the following options:
o Flame detection via ionization from the igniter electrode.
o Flame detection via ionization from Flame Rod.
o Flame detection via a thermocouple.
o Gas valve shut-off when flame is detected.
o Gas valve shut-off power saver for high-current high-flow valve.
o Alarm output high / low when flame is detected or not.
o Solar Li-ion Lithium Ion Battery Pack.
o Smart Solar Lithium Ion regulator.
o Programmed radio communications system for alarming.
o Gas flaring consulting and custom built tank battery flares available upon request.
Let Us Build You a Custom Flare Ignition System
Choose the power source that you have available:
o Solar Panel, 12VDC, 5 Watt or higher.
o 12VDC, 4 Watts.
o 12VAC, 4 Watts.
o 120VAC, 4 Watts.
Let me know exactly how you want me to customize your unit for you. In
most cases to customize your unit and do the final point-to-point quality
control check will take somewhere from 1 hour to 4 days.
Send me a message, and I will call or email you back.
With our low priced high efficiency solar powered flare stack ignition systems
you will not need to supply electricity to the flaring sight. Tell us what you
need and we will create it for you.
We supply the spark module control box that you can connect to your
igniter system.
These ignition control systems can be used with any gas flare or gas fired
equipment including low flow production gas flares. You buy the basic unit
and we add any of the following options:
o Fixed Smart Intelligence (highly recommended) or Embedded Computerized.
o Solar Li-ion Lithium Ion Battery Pack.
o Smart Solar Lithium Ion regulator.
o 12VDC power supply instead of solar.
o 12VAC power supply instead of solar.
o 120VAC power supply instead of solar.
o Controls and connections are placed where you want them.
o Flame detection via ionization from the flame immersed igniter electrode.
o Flame detection via ionization from a Flame Rod.
o Flame detection via a thermocouple.
o Gas valve shut-off when flame is detected.
o Gas valve shut-off power saver for high-current high-flow valve.
o Alarm output high / low when flame is or is not detected.
o IO for your radio communications system for alarming.
o Consulting available upon request.
The solar unit version has 2 power switches inside of the control box.
If you need an external switch it is optional:
o We can add an external switch in addition to the 2 internal switches.
The units have an LED indicator. When the unit is in ignite mode the LED is blue. When
the unit sparks every 3 seconds the blue light flashes red then back to blue.
On units with flame detection: When the unit is in ignite mode the LED is blue and the
[alarm logic terminal] goes high (TRUE). When a flame is detected the LED indicator
goes green and the [alarm logic terminal] goes low (FALSE).
On the basic unit, this LED indicator is normally inside of the control box.
If you need the LED on the outside of the control box, let us know:
o We can put the LED indicator on the outside of the control box.
Basic Units Fabrication
For our Basic units we use a BUD Industries
NBF-32018 Plastic ABS NEMA Economy Box with Solid Door, 11-51/64" Length x 7-55/64" Width x 6-9/32"
Height, Light Gray Finish. The back plate is a BUD Industries NBX-32916-PL ABS Plastic Internal Panel,
10-1/2" Length x 6-11/16" Width x 1/8" Thick, made for the NBF Series Boxes, or our own custom
fiberglass backplate.
Type 4X Units Fabrication
For our Type 4X units we use a
Allied Moulded Products 12" x 10" x 6" JIC Size enclosure. It is molded with
Ultraguard fiberglass reinforced polyester material and has a matching flat cover secured with
300 series stainless steel latches. Designed to insulate and protect controls and components in
both indoor and outdoor applications. Especially well suited for high temperature or corrosive
environments. Protects from dirt, dust, oil and water. Allied Moulded enclosures provide excellent
protection for applications such as agriculture, food processing, car washes, chemical plants,
machine and motor controls, oil and gas, marine, mining, pump controls, security systems, telecom,
wireless systems, transportation, utilities, water distribution and wastewater systems. Includes
300 series stainless steel mounting feet with 10-32 stainless steel screws. Meets UL Types 1, 2,
3, 4, 4X, 12 and 13. Meets NEMA and CSA Types 1, 2, 3, 3R, 4, 4X, 12 and 13. Meets IEC 60259 Type IP66.
Compliant with RoHS directive (Restriction of Hazardous Substances). We use our own custom
fiberglass backplate.
These Ignition Control Systems are designed and built by
Jon Krahmer
at ElectraSoft
near Houston TX.
Who Uses ElectraSoft Products
ElectraSoft products are used by many
well known establishments including military, government, education, medical, business, and
individuals. Some users of
ElectraSoft products include, United States
Armed Forces, United States Senate, University of Utah, Central Iowa Health Care System, San Diego Health
Department, IBM, and millions of small businesses and individuals.
ElectraSoft Home Page:
www.ElectraSoft.com
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