Badger: Installation, Operation, and Maintenance Instructions For Badger 2.5" Pumps
Badger: Installation, Operation, and Maintenance Instructions For Badger 2.5" Pumps
Badger: Installation, Operation, and Maintenance Instructions For Badger 2.5" Pumps
Phone 936-890-0120
BADGER
Fax 936-890-0140
Email hylee@dishmail.net
1
Introduction
This manual contains instructions for the installation,
operation, and maintenance of the Badger pump. Be-
cause of the varying pump service conditions and speci-
fications it is not possible to cover every situation that
may arise, but it is hoped that the information included
will serve as a basic descriptive guide. Should further
questions arise, or startup problems occur it is suggested
that you contact a salesman at D&H Oilfield Equipment.
Table of Contents
Part I Installation Part IV Specifications
pg pg
Interchangeability 5 Exploded Parts View 17
Location 5 Parts List 18-19
Foundation 5 Pump & Mounting Dimensions 20
Coupling alignment 6 Pump Skid and Motor Mounting Dimensions 23
General Piping 7
Suction Piping 7
Discharge Piping 7 Part V Pump Performance
Curves
Part II Operation
3x2x13 1150 RPM 22
Initial Lubrication 8 3x2x13 1450 RPM 23
Startup Checklist 8 3x2x13 1750 RPM 24
Maximum Operating Conditions 9
Pump Records 9 4x3x13 1150 RPM 25
Bearing Lubrication 9 4x3x13 1450 RPM 26
Lip Seal Lubrication 9 4x3x13 1750 RPM 27
Packing Lubrication 9
6x5x14 1150 RPM 28
6x5x14 1450 RPM 29
Part III Maintenance 6x5x14 1750 RPM 30
2
Badger Pump
Badger Pump Specializes in the design and manufacture of premium centrifugal pumps for the oil field industry,
agriculture, and mining. All of our pumps are built of the finest materials and craftsmanship.
The 2 ½ Badger pump is an improved version of the older industry standard 2 ½ inch pumps. Its unique design
provides an improved reliability and durability, a greater rate of production and efficiency plus an extended service
life through the use of replaceable casing wear pad, grease lubricated bearings, a tungsten carbide mechanical seal,
a stainless steel or ceramic coated shaft sleeve, and more.
We have our value series our “Silver Series”, a better pump, our workhorse pump line the “Gold series”, and the
top of the line our “platinum Series”.
Stuffing Box Cast Iron Ductile Iron Hardened (Rc 65) Ductile Iron
Stuffing Box Packing seal Mechanical Carbide Seal Mechanical Carbide Seal
—shaft seal
Bearing seals Lip seals Labyrinth seals Labyrinth Seals
Case Removal Casing Jack Bolts for easy Casing Jack Bolts for easy Casing Jack Bolts for easy re-
removal removal moval
3
General Instructions
This manual will provide both general and specific recommendations for
improved Badger pump performance in both oilfield and industrial applica-
tions.
• The pump should be operated in the performance range for which it was de-
signed.
• When viewed from the coupling end, the driver MUST turn the shaft
CLOCKWISE. Reversing the rotation will severely damage the pump and
may cause personal injury.
• Never operate the pump dry. Never operate a pump with the discharge valves
closed as this can trap air in the pump causing the pump to run dry.
• The pump packing should be tightened so that a small amount of leakage will
remain for lubrication and cooling of the packing gland.
• When operating with drilling mud prevent packing leakage from clogging the
drip area and hardening around the water slinger and front seal.
Maintenance
4
Note: A detailed description of proper procedures
for mounting base and grouting base plates may be
found in the “Hydraulic Institute Standards, 13th
Edition, Pages 116-117.
Badger pumps rugged design both in its frame and
fluid end make it more tolerable to improper founda-
tions than most other pumps.
Part I Installation
• Interchangeability
The Badger horizontal centrifugal pumps out-
side envelope dimensions are the same as the
older 2 1/2 ” pumps of the same nominal size
so that the models can be interchanged without
changing the existing piping, couplings, or
bases.
• Location
The pump should be located as close as possi-
ble to the liquid source so that the suction line
can be as short and direct as possible. The
pump should also be located below the level of
the liquid to eliminate the necessity of priming
the pump.
• Foundation
When fabricated bases or fabricated skid bases
are being utilized, the foundation should be
sufficiently rigid and substantial to absorb any
vibration and to provide the base plate support
at all points. A concrete foundation poured on
a solid footing of adequate thickness to support
the pumping unit, will provide the most satis-
factory foundation. The base plate should be at
a level position when being installed.
5
Measuring offset misalignment of
pump shaft and motor shaft with dial
indicator gauge
Motor—Coupling—Pump alignment
Maximum service life of the pump and driver depends
upon good alignment through the flexible coupling. If the
electric motor was mounted at the factory then the pump
and motor were in alignment when shipped. To ensure
that transportation or other handling has not caused mis-
alignment of the unit, the alignment between the pump Measuring angular misalignment of
and driver should be inspected after installation. Poor pump shaft with motor shaft with a dial
alignment may cause failure of the coupling , pump, mo- indicator
tor, or bearings. Alignment must not be attempted until
the base is in position and the mounting and flange bolts
have been tightened.
The recommended procedure for coupling alignment is
with the use of a dial indicator, as illustrated in figures 1
and 2. The dial indicator is attached to one coupling half
with the indicator button resting on the O.D. of the other
coupling half to measure offset misalignment. To meas-
ure angular misalignment, the indicator is positioned so
that the indicator button rests on the other coupling half
face near the O.D. Rotate the shaft and dial indicator one Measuring offset misalignment with
revolution while the other shaft remains stationary. Note
the total indicator run out. Unless otherwise specified by
the coupling manufacture, offset misalignment should be
limited to 0.005 inches T.I.R. Adjust the alignment by
loosening the pump or driver mounting bolts and re-
tighten or shim as required.
In areas where a dial indicator arrangement is not avail-
able, an adequate job of alignment can be done with a
straightedge. This method is especially useful if the cou-
pling used contains a rubber drive element.
To check offset misalignment, lay the straightedge in line
with the shafts on the O.D.'s of the coupling halves. There
should be no gaps under the straightedge. Check two lo- Measuring angular misalignment
cations 90 degrees apart. Angular misalignment can be with a straightedge
checked by measuring the gap between the two coupling
half faces. There should be no more than 1/64 gap under
the straightedge or a 1/64 variation in the gap between the
coupling halves. (see figures 1A and 2A)
6
Piping (General)
Piping must not be connected to the pump until the
foundation grout has hardened and he pump anchor bolts
have been tightened.
Pipe should be anchored independent of the pump and as
near to it as possible. Pipe companion flanges should
line up naturally with the pump flanges without being
forced to align. Do not draw the pipe to the pump with
the flange bolts.
Piping (Suction)
Properly selected and installed suction piping is ex-
tremely important to eliminate cavitation in the pump.
Vibration can cause packing problems, mechanical seal
damage, or undue bearing loads.
The suction line should be equal to or greater than the
pump suction. The capacity of a centrifugal pump
should never be adjusted by throttling the suction line.
A positive shut-off valve that causes minimal turbulence
should be installed in the suction line to allow removal
of the pump for inspection and maintenance.
When designing the suction line, the piping should
gradually slope downwards to the supply source to
eliminate any air pockets. The suction line should also
have a straight section of pipe that run into the pump
with a length equivalent to at least two times its diame-
ter; i.e. a 4-inch suction line should have a 8-inch
straight run.
For temporary hook-up when flexible hose is used, a
non-collapsing hose is essential since the suction line
pressure is often lower than the atmospheric pressure.
Piping (Discharge)
A positive shut-off valve should be located in the dis-
charge piping to permit the closing of the line for the
removal of the pump for inspection and maintenance.
All piping should be independently supported and accu-
rately aligned. The pump must not support the weight of
the pipe or compensate for misalignment of the piping.
If operating conditions are not known with certain accu-
racy, it will be necessary to provide a throttle valve in
the discharge line to ensure that the pump operates at the
design point. If the pump is connected to a pressurized
system, it is important to install a check valve between
the pump discharge and the throttling valve . The check
valve will prevent backflow through the pump. Back-
flow may cause the impeller to become loose on the
shaft. A loose impeller will likely result in mechanical
damage and fluid leakage beneath the shaft sleeve.
7
Part II Preparation for
Operation
Initial Lubrication
All badger pumps are shipped pre-lubed with grease.
To prevent pressure build-up due to heating that occurs
during standard operation, the breather located on top of
the pump, should be kept clean. When lubrication is
required there are grease fittings located on the front and
rear bearing caps. /(see figures below)
Be sure the pump is never started dry. The mechanical
seal faces will gall in about one minute if the pump is
run dry. The back up packing will help the pump to run
with minimal leakage for a short period of time, but seal
replacement will be necessary.
Start Up Checklist
1. Pump should rotate freely by hand.
2. Ensure coupling aligned.
3. Suction valve fully open.
4. Pump and suction valve full of fluid
5. Discharge valve is slightly open, not fully open.
Fully open the discharge after the pump is running.
8
Bearing Lubrication
Grease Lubrications
The Badger pump comes direct from the factory lubri-
cated with grease. We recommend high quality lithium
grease for all bearing lubrication (BADGER Part No.
B25661). Note that many types of grease are incompati-
ble with other greases. Using two types of incompatible
greases can lead to premature bearing failure.
Part II Operation Oil lubrication
As an option, Badger offers pumps which have bearings
Maximum Operating Conditions oil lubricated from the factory to lower bearing tempera-
ture and wear. Use a quality 10W30 weight motor oil.
Note: These maximum operating conditions apply to Do not use a detergent oil as foaming may occur. There
pumps which are exposed to room temperatures without is also a plug on the side of the pump bearing frame.
external insulation. When adding oil, remove this plug. When oil runs out of
the plug hole, the oil is at the proper level. Replace the
1. Cast Iron: Maximum working pressure is 175 psig Trico Oiler. Do not overfill the oil. High levels may
at 150 degrees F or 150 psig at 250 degrees F. Inter- cause churning and overheating of the bearings. Oil
polate for pressure between 150 degrees F and 250 should be changed every 1 to 2 months or 1000 hours of
degrees F maximum. operation. Note: When oil lubrication is used the pumps
2. Steel: Maximum working pressure and test pressure must be used in a horizontal position only.
in accordance with ANSI B-1973, tables 2.1-2.23
and table three. Inboard Lip Seal Lubrication
3. When fluid is being pumped between 150 degrees F The inboard bearing cover is supplied with a zerk fitting
and 250 degrees F cooling water should be run between the 9 and 10 o’clock position. It should be
through the lantern ring. In addition, it may be nec- greased prior to wash down and at least once a week
essary to run water over the exposed shaft to pre- with general purpose grease.
vent excessive heat build up at the lip seals and (disregard for pumps with labyrinth seals)
bearings.
4. Maximum hydraulic performance is accordance (
with published performance curves.
Pump Records
Maintain data cards or pump records whenever possible.
This will provide ready access to information for order-
Lip Seals
ing spare parts, and for evaluating pump and mechanical
seal performance.
11
B Power Frame Sub-Assembly
12
C. Assembly Of The Fluid End To D. Packing the Pump
The Power Frame
1. Make sure the box is cleaned of all old packing and
1. Lubricate the inside of the frame where the stuffing the plastic lantern ring.
box cover slips in with an anti-seize compound. 2. Bend a wire and pull it down the shaft or shaft
Install stuffing box cover (3) and secure with two sleeve to ensure it is smooth for good packing life.
bolts (3A-1/2D x 1-1/4 inch). 3. Grease all five shaft packing rings (5). Insert three
2. Lubricate the shaft threads and the face of the shaft packing rings alternating the splits in the rings from
sleeve with an anti-seize compound. Wash the O- the top to the bottom starting with the split on the
ring with a clean shop solvent and pat dry with a first ring on the top.
clean cloth. Install the O-ring into the impeller (2). 4. Install the lantern ring with the split in the vertical
Thread the impeller with impeller seal O-ring onto position. The two halves of the packing gland (4)
the shaft. Tighten to approximately 160 ft./lb. of may be used to push the packing and the lantern
torque. ring together and to the bottom of the box.
3. Loosen the two through bolts (12B). 5. Insert the final three packing rings. The objective is
4. Draw the bearing housing rearward with the jam to have the last split down so that leakage will drip
bolts (12B) while rotating the impeller. Stop when down and not have to go over the shaft and possibly
the impeller just touches the stuffing box cover. in the bearings.
5. Bring the through bolts up finger tight 6. With the packing gland (4) in position, swing the
6. Loosen the jam bolts. gland bolts into place. Initially tighten the gland
7. Tighten the through bolts until a clearance of 0.020 hard to compress the packing. Then back off the
inch exists between the impeller back vanes and gland bolts and retighten only finger tight.
stuffing box cover (3). A hacksaw blade is approxi- Caution: Tighten the gland against the pack-
mately 0.020 inch thick and can be used as a gauge ing finger tight only. If packing is tightened
when no better tooling is available. excessively it may be burned when the pump is
8. Advance both jam bolts until they touch the frame started.
finger tight, then tighten the jam nuts (12C). Lantern ring packing
9. Now tighten the through bolts evenly. Rotate the
shaft.
The impeller should turn freely without rubbing.
10. Install the casing gasket (1A). Hold in place with
grease if necessary.
11. Apply a coat of anti-seize compound on all of the
stuffing box cover diameters.
12. Install casing (1) on the frame using studs (1C) and
nuts (1D). Put a small quantity of anti-seize com-
pound on the threads on the nut end of the studs.
Tighten the nuts to 140 ft./lb. of torque using a
criss-cross tightening pattern.
13
6.
Remove the rotating seal ring (4A of Figure 9) if it
is not glued into position and store in a safe place.
Gluing can be determined by pulling on it gently.
Coat the O.D. of the shaft sleeve (7A) and the I.D.of
the rubber bellows (Item 4B of Figure 9) with a thin
coat of oil.
7. Place the sleeve (7A) with the impeller end up on
the table. The impeller end is the end with the
smallest I.D. With the sealing face of the rotary unit
E. Mechanical Seal Assembly facing down and the rubber end up, gently ease the
Changing the B22451-1 Mechanical Seal rubber bellows over the sleeve and push it to the
bottom half of the sleeve. (see photo next page) It is
1. If the impeller and/or stuffing box are being re- not necessary to push it all the way to the bottom. If
placed, adjust the impeller clearance BEFORE in- the rotating seal ring (4A) has been removed, lightly
stalling the seal. Back the through bolts (12B) out coat the face of the bellows (Item 4B of Figure 9)
approximately 1/4 inch. Tighten the jam bolts (12B) with grease. (This is necessary to hold the rotating
until a clearance of 0.015-0.020 inch between the seal ring in place during assembly). Reinstall the
back of the impeller (2) and the stuffing box (3) is rotating seal ring into the cage assembly ( 4C of
obtained. Alternately tighten the through bolts and Figure 9).
jam bolts making sure that the clearance set above is 8. Make sure no foreign material is present on the seal
maintained. Tighten the jam nuts and recheck the faces. Make sure the shaft (7) is free of nicks and
clearance. burrs and is clean and dry. The sleeve area of the
2. Make sure the shoulder where the stationary will sit shaft, the shaft threads and the shaft face must be
and the inside of the stuffing box (3) is clean and lightly coated with anti-seize compound before in-
that the 30 degree bevel on the 3-3/8 inch I.D. is stalling the sleeve (7A). Install sleeve with a twist-
free from burrs and sharp edges. Coat the I.D. of the ing motion. As the seal faces make contact, con-
stuffing box stationary seat packet with oil. Place tinue to push the sleeve through the I.D. of the ro-
the stuffing box on a table or other flat surface with tary seal element until the gap between the sleeve
the impeller side facing up. (see photo next page) and the shaft shoulder is approximately 1/32 inch.
3. The slotted side of stationary seal must be installed 9. Install the spring retainer (Item 9 of Figure () and
away from the impeller or down when the stuffing the impeller O-ring (2A) in the groove and coat with
box is positioned as described in step 2 above. Coat anti-seize compound. Place the mechanical seal
the O.D. of the stationary seat and O-ring with a spring (Item 6 of Figure 9) over the rotary unit of
thin film of oil. (see photo next page) the seal (which is inside the stuffing box cover).
4. Carefully install the stationary seat into the stuffing 10. Thread the impeller (2) onto the shaft (7). Be sure
box. Be sure the groove of the stationary fits prop- the spring engages in the retainer on the impeller.
erly over the drive pin. Be sure the stationary seats Tighten to approximately 60 ft./lb. of torque.
evenly against the stuffing box shoulder. Hint: 11. Install the casing gasket (1A). Hold it in place with
Wrap the end of a wooden hammer handle, or grease if necessary. Apply a light coat of anti-seize
something similar, with a rag. Press firmly on the compound on the 14-1/8 inch diameter of the stuff-
face of the stationary. Do not strike, the tungsten ing box cover. Install the casing on the frame using
carbide can shatter. Push gently on one side, alter- studs (1C) and the nuts (1B). Put small quantity of
nating sides until the stationary is completely anti-seize compound on the threads on the nut ends
down. Coat the stationary face with light oil, and of the studs. Tighten the nuts to 140 ft./lb. of torque
then wipe off the majority of the oil with a clean using a criss-cross tightening pattern.
cloth, leaving only a light film. 12. The three shaft packing rings (5) are for emergency
5. Lubricate the inside of the frame (9) where the back up until the mechanical seal can be replaced.
stuffing box (3) slips in with an anti-seize com- When they are installed, first grease them. Insert all
pound. Install the stuffing box and secure with bolts packing rings alternating the splits from top to bot-
(3A-1/2D x 1 1/4 inch). Care should be taken to tom starting with the split on the first ring at the
prevent bumping of the stationary seal on the shaft bottom.
end.
14
Mechanical seal retaining pin
15
Packing Leakage And Rapid Packing Wear
(Most early packing failures are caused by over-
tightening or poor installation.)
Packing Appearance
If the packing being removed is hard and brittle, it has
been run dry for some time in its life. This is often done
in the first hour of service. The packing has more ability
to grow with heat during its early life. Even if the pack-
ing is adjusted right before starting the pump, in the first
few minutes of operation the packing will grow with
heat and become over-tight. It will then run drop-tight
and the packing will burn. Once the packing is
burned it will never seal properly again. Let new
packing leak more in the first few hours and then adjust
it to 10-12 drops per minute.
Bearing Failures
(Except for cavitation problems, bearing failure is the
greatest cause of increased pump operating cost.)
If you continue to run a pump when bearing failures
occur, there is an excellent chance the entire pump will
be destroyed. Therefore it is very important to change
the bearings when failure starts. If you wait for complete
failure other fluid end parts will be damaged. Bearing
failure is more often caused by inadequate or improper
lubrication than by normal wear.
16
BADGER PUMP
EXPLODED VIEW
17
BADGER 2.5 CENTRIFUGAL PUMP
PARTS LIST
18
BADGER 2.5 CENTRIFUGAL PUMP
PARTS LIST
19
BADGER PUMP
MOUNTING
20
BADGER PUMP
MOUNTING
21
3X2 BADGER PUMP
1150 RPM
8 to 13 Inch Impellers
100
90
13" Calculating
Horsepower
80 BHP=Gpm X Ft Head X SG
3960 X Effeciency
12"
Calculating
70 Effeciency
11" Eff. = Gpm X Ft Head X SG
3960 X BHP
60
10 BHP
10"
22
50
9"
7.5 BHP
40
8"
10
Curve # 8641750
0
0 50 100 150 200 250 300 350 400
FLOW (gal/min)
3X2 BADGER PUMP
1450 RPM
8 to 13 Inch Impellers
140 13"
Calculating
Horsepower
BHP=Gpm X Ft Head X SG
120 3960 X Effeciency
12"
Calculating
Effeciency
11"
100 Eff. = Gpm X Ft Head X SG
`15 BHP
3960 X BHP
10"
80
23
9"
10 BHP
8"
60
BADGER PUMP
Curve # 8641750
0
0 25 50 75 100 125 150 175 200 225 250 275 300 325
FLOW (gal/min)
3X2 BADGER PUMP
1750 RPM
8 to 13 Inch Impellers
250
Calculating
Horsepower
200 13" BHP=Gpm X Ft Head X SG
3960 X Effeciency
Calculating
Effeciency
12" Eff. = Gpm X Ft Head X SG
3960 X BHP
150
30 BHP
11"
24
10" 25 BHP
5 BHP
Curve # 8641750
0
0 50 100 150 200 250 300 350 400 450 500
FLOW (gal/min)
4X3 BADGER PUMP
1150 RPM
8 to 13 Inch Impellers
100
13"
90
Calculating
Horsepower
80 BHP=Gpm X Ft Head X SG
12" 3960 X Effeciency
Calculating
70 Effeciency
11"
Eff. = Gpm X Ft Head X SG
3960 X BHP
60
10" `15 BHP
25
50 10 BHP
9"
40
7.5 BHP
8"
10
Curve # 8641750
0
0 100 200 300 400 500 600 700 800
FLOW (gal/min)
4X3 BADGER PUMP
1450 RPM
8 to 13 Inch Impellers
160
25 BHP
10"
26
80
9" 20 BHP
60 8"
Curve # 8641750
0
0 100 200 300 400 500 600 700 800
FLOW (gal/min)
4X3 BADGER PUMP
1750 RPM
8 to 13 Inch Impellers
250
Calculating
13" Horsepower
200 BHP=Gpm X Ft Head X SG
3960 X Effeciency
Calculating
12" 50 BHP
Effeciency
Eff. = Gpm X Ft Head X SG
11" 3960 X BHP
150 40 BHP
10"
27
30 BHP
100 9"
25 BHP
Ph 936-890-0120
50 `15 BHP Fax 936-890-0140
7.5 BHP
5 BHP 10 BHP
Curve # 8641750
0
0 100 200 300 400 500 600 700 800
FLOW (gal/min)
6X5 BADGER PUMP
1150 RPM
10 to 14 Inch Impellers
120
14"
Calculating
Horsepower
100
BHP=Gpm X Ft Head X SG
3960 X Effeciency
13" Calculating
Effeciency
80
Eff. = Gpm X Ft Head X SG
12" 3960 X BHP
35 BHP
11"
28
60
30 BHP
10"
Curve # 8641750
0
0 200 400 600 800 1000 1200 1400 1600
FLOW (gal/m in)
6X5 BADGER PUMP
1450 RPM
10 to 14 Inch Impellers
200
Calculating
Horsepower
14" BHP=Gpm X Ft Head X SG
3960 X Effeciency
150
Calculating
13" Effeciency
Eff. = Gpm X Ft Head X SG
3960 X BHP
12" 60 BHP
29
100 50 BHP
11"
10" 40 BHP
Curve # 8641750
0
0 200 400 600 800 1000 1200 1400 1600
FLOW (gal/m in)
6X5 BADGER PUMP
1750 RPM
10 to 14 Inch Impellers
250
14"
Calculating
13" Horsepower
200 BHP=Gpm X Ft Head X SG
3960 X Effeciency
30
60 BHP
10"
100 50 BHP
Curve # 8641750
0
0 200 400 600 800 1000 1200 1400 1600
FLOW (gal/m in)
8X6 BADGER PUMP
1150 RPM
10 to 14 Inch Impellers
120
Calculating
Horsepower
100 14"
BHP=Gpm X Ft Head X SG
3960 X Effeciency
Calculating
13"
Effeciency
80
Eff. = Gpm X Ft Head X SG
3960 X BHP
12" 50 BHP
31
60
11" 40 BHP
10"
Curve # 8641750
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400
FLOW (gal/min)
8X6 BADGER PUMP
1450 RPM
10 to 14 Inch Impellers
180
160 Calculating
14" Horsepower
BHP=Gpm X Ft Head X SG
140 3960 X Effeciency
13"
Calculating
70 BHP Effeciency
120
12" Eff. = Gpm X Ft Head X SG
3960 X BHP
100 60 BHP
32
11" 50 BHP
80
10"
20 BHP
20
Curve # 8641750
0
0 200 400 600 800 1000 1200 1400 1600 1800
FLOW (gal/min)
8X6 BADGER PUMP
1750 RPM
10 to 14 Inch Impellers
250
14" Calculating
Horsepower
200 BHP=Gpm X Ft Head X SG
3960 X Effeciency
13"
Calculating
Effeciency
Eff. = Gpm X Ft Head X SG
12" 125 BHP 3960 X BHP
150
11"
33
100 BHP
100 10"
40 BHP
Curve # 8641750
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
FLOW (gal/min)