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      How to calibrate a chemical pump for the first time

      A step-by-step guide on calibrating a chemical pump linked to a WellAware Connect using the Field App.

      Last Updated: November 2nd, 2021

      WellAware makes it easy to calibrate different types of chemical pumps linked to a WellAware Connect with a Pump Monitoring & Control (PMC) or On Demand Chemical (ODC) subscription.

      This article will show you how to calibrate a chemical pump for the first time using the simple Pump Calibration Wizard featured in the Pump Application on the WellAware Field App.

      Note: The initial pump calibration process is only required if the WellAware Connect does not have a calibration already stored, or if the calibration must be cleared due to a problem. If the WellAware Connect already has a pump calibration stored, see this article on how to fine-tune chemical pump calibrations using the Field App >

      Navigate to the Pump Application home screen

      After pairing to the WellAware Connect in the Field App, select the Pump Application tile on the Device Home Screen.

      Don’t see the Pump Application tile? Your WellAware subscription on this device may not include pump monitoring and/or control. Contact WellAware Client Success for more info.

      Check for a stored calibration

      If the WellAware Connect already has a stored calibration, you'll need to clear the calibration prior to performing a new calibration. You can check to see if the Connect already has a stored calibration on the Pump Application home screen.

      In the Pump Settings below the pump graphic, look at the value for "Max Pump Output". A non-zero value indicates the Connect already has a stored calibration, in which case you'll need to clear the existing calibration. 

       

      If the Max Pump Output equals 0.00, then the Connect does not yet have a calibration and you can proceed to calibrate the pump.

      Clearing the calibration (if necessary)

      To clear the calibration from the Pump Application home screen, tap "Advanced Settings" then tap "Clear Calibration". Be sure you want to clear the calibration, then tap "Yes". Return to the Pump Application home screen.

      Caution: Be careful when clearing the calibration, as this will require you to complete all of the remaining steps in this article. If the pump only requires a fine-tuning, then DO NOT clear the calibration, and follow these steps instead.

      Calibrate the pump

      To calibrate the chemical pump from the Pump Application home screen, tap "Calibrate Pump" and follow the simple steps in the Pump Calibration Wizard in the Field App.

      Step 1 - Select Pump Type/Mode and Units

      The WellAware Connect can control both timer-based chemical pumps that use an on/off duty cycle, as well as pumps with variable speed drive (VSD) DC motors modulated using a 0-5V analog output.

      Select the appropriate pump type based on the chemical pump linked to the WellAware Connect. 

      You may also select the flow rate units for managing pump setpoints and calibrations locally. The flow rate unit options are:

      • Gallons/Day (GPD)
      • Quarts/Day (QPD)
      • Barrels/Day (BPD)
      • Gallons/Hour (GPH)
      • Quarts/Hour (QPH)

      By default, the pump flow rate units are set to Gallons/Day (GPD).

      Tip: We recommend you leave the default units settings unless you are sure you want to change the units.

       

      For reference, here is a list of common makes and models of pumps by their type:

      Timed Pumps VSD Pumps
      • Advantage Pumps Series B
      • Checkpoint Model S
      • Graco G-Chem
      • Graco Wolverine
      • Helios 2500S
      • Helios 5000S
      • LMI XRD
      • LMI B121
      • LMI B921
      • LMI OF-H-SS
      • MG&G SSE Solar DC
      • Prominent CNPA
      • Sidewinder AC160
      • SunPumper 113
      • SumPumper 880
      • SunPumper 800XP
      • Timberline 4000
      • Timervline 40001
      • TXAM HBT1
      • TXAM HBT2
      • TXAM HBT3
      • TXAM HWP100
      • Wellmark EIP
      • WellAware EXP
      • Checkpoint FXS
      • Graco G-Chem Variable Speed
      • Graco Wolverine Variable Speed
      • Helios Brushless Integra
      • LMI Series P

      Once the correct pump type and units are selected, tap "Next"

      Step 2 - Isolate the sight glass

      To perform the calibration, you'll be using the sight glass connected to the chemical tank. To isolate the sight glass, follow these steps:

      • Open the valve to the sight glass to allow chemical to fill the sight glass.
      • Close the valve between the tank discharge and the sight glass. This will force the pump to draw fluid from the sight glass.
      • When the sight glass is isolated, tap "Next"

      The Pump Calibration Wizard includes a helpful diagram to indicate the correct valve positions, shown below.

      Step 3 - Start the calibration

      With the sight glass isolated, you can begin the calibration. 

      • Note the starting level of the chemical in the sight glass prior to starting the calibration. Use the sliders on the sight glass itself, or write the numbered graduation down on a notepad.
      • Tap "Start Calibration". This will turn on the pump at its maximum output.
      • When the chemical level is nearing the bottom of the site glass, tap "Stop Calibration"
      • Note the ending level of the chemical in the sight glass.
      • Tap "Next".

      Tip: Don't worry about performing a standard "60-second" drawdown test, instead focus on drawing the sight glass down as much as possible before it becomes empty. The WellAware Pump Calibration algorithm will handle the math to account for time differences.

      Step 4 - Enter the observed drawdown

      Once the pump has stopped and the level in the sight glass has stabilized, enter the observed drawdown.

      • Calculate the difference between the starting and ending level in the sight glass. For instance, if the starting level was at 45 QPD and the ending level was at 5 QPD, the Observed Value is 40 QPD.
      • Enter the Observed Value and the Sight Glass Units into the calibration wizard.
      • Tap "Next".


      Tip: Most sight glass units are in QPD, but double-check the sight glass to be sure.

      Step 5 - Confirm the maximum output

      After the Observed Value and Sight Glass Units are entered, the calibrated Max Pump Output will display in the configured flow rate units. Confirm the validity of this measurement as a function of the pump configuration and then tap "Next".

      Tip: To check the actual theoretical maximum output of the pump, refer to the pump manual.

      However, we put together this handy Theoretical Chemical Pump Max Output Calculator that you can use to confirm the calibrated max pump output if you know the plunger diameter, stroke length, and motor RPM. 

      Note: The calibrated maximum output should be less than the theoretical output due to backpressure and efficiency loss. 

      Step 6 - Revert the pump inlet back to the tank

      After confirming the calibrated max pump output, return the valves to their operational position by opening the tank valve and closing the sight glass valve, as shown in the diagram on Step 6 of the Pump Calibration Wizard.

      After the valves are properly positioned, tap "Next".

      Step 7 - Set the pump setpoint

      Once the valves are returned back to their operational setting, set the desired pump injection rate setpoint. Tap "Next".

      The calibration is now complete!

      Note: You may wish to perform a classic "60-second drawdown" test to confirm the pump hits the target setpoint.