Service & Operating Manual

Mud Agitator

MUD AGITATOR
TRI-FLO INTERNATIONAL introduces the TFI-FLO MUD AGITATOR, a new, more
compact unit that incorporates high efficiency, light weight, minimal maintenance
and the high torque capabilities required for maintaining a drilling / workover fluid of
uniform consistency throughout the surface mud system.
Powered by either a 1445 RPM/50 HZ or 1750 RPM/60 HZ explosion-proof electric
motor, the TRI-FLO MUD AGITATOR takes advantage of the high efficiency (94%)
gear reducer to rotate the impeller at 73 RPM or 88 RPM, depending on the input
power. The resulting flow pattern maintains an optimum turnover rate, keeping the
mud system evenly dispersed at all times. Designed to operate efficiently under
the most severe operating conditions, the TRI-FLO MUD AGITATOR is available in
all horsepower and impeller types and sizes required meeting the customers
needs.
The gear reducer utilizes a helical spiral bevel gear reduction system that produces
a highly efficient, quiet operation. Due to the minimal power loss in the reducer,
fewer horsepower is required at the input shaft in order to deliver the needed
torque. The gearbox is a cast iron, one piece, lightweight, compact unit requiring a
minimum of maintenance. A breather plug is provided to prevent surging of the
lubricant, thereby maintaining a consistent temperature within the gearbox. Both
the input and output shafts are constructed of alloy steel and the gears themselves
meet AGMA Class 10 quality.

AGITATOR SELECTION
Agitators were originally employed to supplement mud guns in keeping the
mud from gelling. Maintaining a consistent blend of the mud components
was not considered until mid of late 70s. Since then serious investigations
of agitator design have been performed by numerous manufacturers of mud
processing equipment, resulting in a better understanding of the function
and complexity of mud agitators.
Several factors must be considered in the selection of an agitator in order for
it to perform effectively:
Tank dimensions, width, length, and depth where compartmentalized
compartment dimensions.
Ratio of impeller diameter to tank width. For optimum performance
this ratio should be in the range of +/-0.3.
Mud Weight. The maximum anticipated mud weight; if unknown use
a weight of 20 PPG.
Rig Power. The voltage and frequency (HZ) to be supplied to the
agitators.

SIZING
Sizing of agitators is performed by using squares. If your tank is 8 feet
wide, you should use 8 ft. x 8 ft. squares in your calculation: if it is 12 feet
wide, use 12 ft. x 12 ft. squares. If your tank or compartment length is not
an even multiple of the tank width, use the closest dimension to a square as
possible. Example: an 8 ft. x 30 ft. tank would produce four 8 X 7.5 ft.
squares. The tank width is always used in the determination of the impeller
diameter to tank width ratio. The charts illustrated have been calculated for
both 50 HZ and 60 HZ input power, producing 73 RPM and 88 RPM
respectively. A D/W RATIO of 0.3 was used in plotting the curves for fresh
water, brine water, 14 PPG and 20 PPG mud.
To determine the horsepower required, select your tank width at the bottom
of the chart and read up to find your impeller diameter. Locate the curve
that represents the heaviest mud weight to be used. Follow the vertical
impeller Diameter line to the curve representing the mud weight and read
horizontally to the left to determine your horsepower requirement. In every
case, use the higher horsepower indicated by the intersection of the Mud
Weight curve and the vertical Impeller Diameter.

Figure No. 1

0.0

88 RPM - 60 HZ

28

32

36

40

44

48

52

10

11

12

13

14

3.0

5.0
Horsepowe

7.5

Required

10.0

50 HZ

15.0

73 RPM

20.0

25.0

30.0
Tank Width, Feet (Ancho del Tanque, Pies)
FRESH WATER (Agua Fresca) : 8.33 PPG

BRINE WATER (Agua Salada): 9.50 PPG

MUD (Lodo) : 14.0 PPG

MUD (Lodo): 20 PPG

Figure No. 2
0.0

73 RPM - 50 HZ
28

32

36

40

44

48

52

10

11

12

13

14

3.0

5.0
Horsepowe

7.5

Required

10.0

50 HZ

15.0

73 RPM

20.0

25.0

30.0
Tank Width, Feet (Ancho del Tanque, Pies)
FRESH WATER (Agua Fresca) : 8.33 PPG

BRINE WATER (Agua Salada): 9.50 PPG

MUD (Lodo) : 14.0 PPG

MUD (Lodo): 20 PPG

EXAMPLE NO. 1
Agitators are required for a tank 9 ft. wide x 30 ft. long x 7 ft. deep and an
anticipated mud weight of 14 PPG. Rig power is 60 HZ. Work in squares; in this
case three 9 ft. x 10 ft. squares. Locate the impeller diameter/tank width line for a
9-ft. wide tank; follow it up to the top of the graph to determine the impeller
diameter of 32 inches. Follow the same line down to its intersection of the 14 PPG
mud curve. Read horizontally to the left to determine the horsepower required: in
this case three 5 horsepower units with 32 inch impellers would be needed.

EXAMPLE NO. 2
Agitators will be required for a pit 12 ft. wide x 48 ft. long x 8 ft. deep. Anticipated
mud weight is 20 PPG and the power supply is 50 HZ. Work in squares; in this
case four 12 ft. x 12-ft. squares. Following the 12-foot Tank Width line up to the
Impeller Diameter, notice that a 44-inch impeller will be required. Come back down
the Impeller Diameter line to the intersection of the 20 PPG curve to find that a total
of 20 horsepower units are needed.

SIZING VERIFICATION
The Displacement Speed is the time, in seconds, required to completely displace
the total volume of mud in the mud tanks.
A DS of 35 to 90 is within the acceptable range. The slower the Displacement
Speed (the closer to 90), the more settling that will occur in the corners and
between agitators. As the Displacement Speed increases (approaches 35),
vortexing and air entrapment can be expected.

DISPLACEMENT SPEED CALCULATION

Tank volume (Gallons) x 60 sec = Displacement Speed (Sec.) Displacement
(GPM) 1 min
(Long ft x Wide ft x Deep ft) x 7.459 Gal
x 60 sec
Speed
1 min
Displacement Gal/min
1 ft3

= Sec Displacement

Tank volume, as indicated above, must be calculated in gallons. To do so, multiply

the length of the tank (or compartment) in feet by the width in feet and the usable
depth of the tank in feet. Multiply the result by 7.459 gallons per cubic feet to
obtain the desired tank volume. The Displacement Rate for Axial configuration
impellers is shown in the table below.
Table 1
Displacement Rate (GPM)
Four Axial Flow
Impeller
Diameter
Inches

60 HZ
Blades
(GPM)

50 HZ
Blades
(GPM)

28
32
36
40
44
48
52

3832
5765
8179
10886
14974
19387
24592

3179
4783
7565
9032
12423
16084
20402

INSTALLATION & OPERATION

IMPELLER POSITIONING
To ensure optimum performance, location of the impeller is critical. An Axial type
impeller should be positioned with the centerline of the impeller body 0.7 x Impeller
Diameter above the tank floor. A Radial type impeller should be located with the
bottom of the impeller blades a maximum of 6 inches above the tank floor, or 2
inches above the bottom shaft stabilizer, if used. To determine the impeller shaft
length, assume that a bottom stabilizer will be used.

AGITATOR INSTALLATION
It is essential that the agitator mounting be sufficient to support the weight and
torque of the complete unit. The gearbox itself must be securely bolted in position
with four bolts secured with locknuts.
Remove all protective coating from the shaft and flange, using solvent if necessary.
Carefully mount coupling on shaft as close to the shaft shoulder as possible. If the
shaft and coupling are a tight fit, do not use force; DO NOT HAMMER ON SHAFT.
The shaft and impeller, with bottom stabilizer in place, are then coupled to the
gearbox with a rigid coupling. Be certain the stabilizer is properly aligned before
tightening the rigid coupling. After tightening the coupling, weld the stabilizer to the
tank bottom. Check the oil level in the gearbox. Install the breather plug in the
plughole at the top of the gearbox and REMOVE THE PIN FROM THE CENTER
OF THE PLUG.

ELECTRICAL & GENERAL

Inspect unit for damage during shipment. Verify speed, horsepower, voltage and
Hertz for conformance to power supply.
Eyebolts or lugs are provided for lifting the unit: additional weight is prohibited.
Lifting angle must not exceed 15 degrees with shank of eyebolt. Use caution when
lifting units near overhead power lines.
Agitators perform longer in a clean, well-ventilated area and should be located in a
suitable enclosure to prevent access by unauthorized personnel.
Guards should be provided for exposed rotating parts to prevent injuries. Keep
fingers and foreign objects away from ventilation and other openings. Applications
involving high inertia loads may damage this equipment due to motor overspeed
during shutdown. DO NOT force drive coupling or other equipment into shaft, as
bearing damage may result.
The power supply must agree with values on nameplate. Terminal voltage should
not vary by more than +/- 10% of nameplate voltage at rated frequency.
Unbalance line voltage, even a small amount, will cause overheating. Do not
exceed the continuous rated operating current on the nameplate. Starting controls
and overload protection should be properly sized in accordance with the National
Electrical Code and the control manufacturers recommendations.
Motor connections should be made by following instructions on connection
diagram. Determine direction of rotation before connecting driven equipment. If
direction of rotation label is supplied, operate only in specified direction. Rotation
may be reversed on three phase motors by interchanging any two-line connections.
Wiring of units, controls and grounding shall be in accordance with local and
National Electrical Code requirements. Failure to properly ground unit may cause
serious injury to personnel. Where unexpected starting could be hazardous to
personnel, do not use automatic reset starting devices.

10

Using the facts in the previous examples 1 and 2, calculate the GPM to verify the
agitator requirements.
EX 1: 32 Axial impeller, 60HZ
(A)

5765 GPM (table 1, page 8) x 3 (agitators) = 17295 GPM

(B)

(9ft. x 30ft. x 7ft.) x 7.459 gal/cf. = 14098 gal, Tank Volume

(C)

DR =

14098 gal x 60 sc. = 48.9 seconds

17295 gal/min 1 min

EX 2: 44 Axial impeller, 50 HZ
(A)

12423 GPM [table 1, page 8) x 4 (agitators) = 49692 GPM

(B)

(12 ft. x 48 ft. x 8 ft.) x 7.459 gal/ cf. = 34371 gal, Tank Volume

(C)

DR = 34371 gal
49692 gal/min

x 60 sc. = 41.5 seconds

1 min

11

MAINTENANCE
To ensure safe operation and avoid problems, it is recommended that the gearbox
be visually inspected every 50 hours of operating time.
It is also recommended that the following items be checked each 5000 hours of
operating time:
Check oil level and add oil if necessary.
Make sure vent hole in the breather plug is clean.
Be sure breather plug is open before operating.
Motor for use in hazardous locations-Class I & II installations: repairs of these
motors must be made by the manufacturer or manufacturers authorized service
shop to maintain the U.L. listing. The U.L. listing applies to the electrical motor only
and not to the belt or gear transmissions or other devices that may be connected to
the motor.
NOTE: Field repair of Gearbox is not reccommended. All internal repairs
should be conducted by the manufacture.

LUBRICANT RECOMMENDATION
The TRI-FLO AGITATOR gearbox is shipped with synthetic extreme pressure oil,
SINTOGEAR 125, for ambient operating temperatures of -25 to 125 degrees F (-31
to 51 degrees C).
Synthetic oil does not require an oil change. It is, however, recommended that oil
be checked periodically for proper oil level. NEVER MIX SYNTHETIC OIL WITH
MINERAL OIL.
The gearbox manufacturer recommends the synthetic oils listed below.
Manufacturer
Lubricant Type - Synthetic Oil
COFRAN
SINTOGEAR 125
MOBIL
SHC 629

Tri-Flo Agitator Part List

12

TFI 30 AGITATOR
TFI PART No.
03-01-805
01-00-128
03-00-300
00-00-023
00-01-141
00-00-028
00-00-091
05-00-098
00-00-092
05-00-100
05-00-090
03-00-316
05-00-032

DESCRIPTION
TFI-30 Agitator (Complete) 3 HP
3 HP 230/460 Motor 3 Phase XP
2303 Gear Box
6 S Sure Flex Coupling 1-1/8
6 J Sure Flex Coupling 5/8
6 JEM Element (Coupling)
R 25 F Rigid Coupling
2517 Taper Lock Bushing 2
R 25 M Rigid coupling
2517 Taper Lock Bushing 1-1/2
3030 TAPER Lock Bushing 2
Shaft 2
Impeller 28
TFI 50 AGITATOR

TFI PART No.

05-00-029
01-00-138
03-00-299
00-00-023
00-00-084
05-00-094
05-00-098
00-00-092
00-00-091
05-00-090
03-00-316
05-00-034

DESCRIPTION
TFI-50 Agitator (Complete) 5 HP
5 HP 230/460 Motor 3 Phase XP
2403 Gear Box
6 S Sure Flex Coupling 1-1/8
6 E Sleeve (Coupling)
2517 Taper Lock Bushing 1-3/4
2517 Taper Lock Bushing 2
R 25 M Rigid coupling
R 25 F Rigid Coupling
3030 TAPER Lock Bushing 2
Shaft 2
Impeller 32

TFI 75 AGITATOR

13

TFI PART No.

03-00-308
01-00-139
03-00-301
00-00-096
00-00-023
00-00-028
00-00-379
05-00-098
00-00-092
00-00-091
05-00-090
03-00-316
05-00-033

DESCRIPTION
TFI-75 Agitator (Complete) 7-1/2 HP
7-1/2 HP 230/460 Motor 3 Phase XP
2503 Gear Box
6 S Sure Flex Coupling 1-3/8
6 S Sure Flex Coupling 1-1/8
6 JEM Element (Coupling)
2517 Taper Lock Bushing 2-3/8
2517 Taper Lock Bushing 2
R 25 M Rigid coupling
R 25 F Rigid Coupling
3030 Taper Lock Bushing 2
Shaft 2
Impeller 36
TFI 100 AGITATOR

TFI PART No.

03-00-309
01-00-131
03-00-301
00-00-096
00-00-023
00-00-028
00-00-091
00-00-092
05-00-098
00-00-379
05-00-090
03-00-316
05-00-023

DESCRIPTION
TFI-100 Agitator (Complete) 10 HP
10 HP 230/460 Motor 3 Phase XP
2503 Gear Box
6 S Sure Flex Coupling 1-3/8
6 S Sure Flex Coupling 1-1/8
6 J M Element (Coupling)
R 25 F Rigid Coupling
R 25 M Rigid coupling
2517 Taper Lock Bushing 2
2517 Taper Lock Bushing 2-3/8
3030 Taper Lock Bushing 2
Shaft 2
Impeller 40

TFI 150 AGITATOR

TFI PART No.

DESCRIPTION

14

05-00-030
01-00-125
03-00-301
00-00-700
00-00-712
00-00-086
00-00-091
05-00-098
00-00-092
00-00-379
03-00-316
05-00-090
05-00-033

TFI-150 Agitator (Complete) 15 HP

15 HP 230/460 Motor 3 Phase XP
2503 Gear Box
8 S Sure Flex Coupling 1-5/8
8 S Sure Flex Coupling 1-1/8
8 JEM Element (Coupling)
R 25 F Rigid Coupling
2517 Taper Lock Bushing 2
R 25 M Rigid coupling
2517 Taper Lock Bushing 2-3/8
Shaft 2
3030 Taper Lock Bushing 2
Impeller 36
TFI 200 AGITATOR

TFI PART No.

03-00-305
01-00-135
03-00-302
00-00-648
00-00-475
00-00-012
00-00-090
05-00-086
00-00-089
03-00-316
05-00-090
05-00-014

DESCRIPTION
TFI-200 Agitator (Complete) 20 HP
20 HP 230/460 Motor 3 Phase XP
2603 Gear Box
9 S Sure Flex Coupling 1-5/8
9 S Sure Flex Coupling 1-3/8
9 JEM Element (Coupling)
R 30 F Rigid Coupling
3030 Taper Lock Bushing 2-7/8
R 30 M Rigid coupling
Shaft 2
3030 Taper Lock Bushing 2
Impeller 42

TFI 250 AGITATOR

TFI PART No.
03-00-311

DESCRIPTION
TFI-250 Agitator (Complete) 25 HP

15

01-00-148
03-00-302
00-00-081
00-00-475
00-00-012
00-00-090
05-00-086
00-00-089
03-00-316
05-00-090
05-00-014

25 HP 230/460 Motor 3 Phase XP

2603 Gear Box
9 S Sure Flex Coupling 1-7/8
9 S Sure Flex Coupling 1-3/8
9 JEM Element (Coupling)
R 30 F Rigid Coupling
3030 Taper Lock Bushing 2-7/8
R 30 M Rigid coupling
Shaft 2
3030 Taper Lock Bushing 2
Impeller 42

MAX2000

MUD AGITATOR
Installation, Operation and Maintenance Manual
16

Prepared for:

Safety First!
Cautions and General Safety Rules
A Division of..

This manual contains important information concerning installation, operation,

and proper maintenance of the MAX2000 Mud Agitator. To prevent injury to
personnel or equipment damage, this manual should be read by those
responsible for the installation and operation of the Mud Agitators. In addition,
the safety precautions below should be followed at all times.
Lift the agitator only at lift points detailed in this manual and use
properly rated slings capable of handling the equipment weight.
The structure on which the agitator is to be installed must be capable of
supporting both the static weight and dynamic loads listed in this manual.
TURN OFF, LOCK OUT, AND TAG OUT the electrical power supply to
the agitator before working on the agitator.
Inspect the unit regularly, and replace damaged or worn components only
with parts supplied by the original equipment manufacturer.
The gearbox on the Agitator has a pre-selected gear ratio to maximize the
suspension of solids in solution. This gear ratio provides a great increase
in torque that is transmitted to the impeller. Any object that might fall
into or be placed in the mud tank runs the risk of being caught by and
wrapped up by the agitator. *** NO ATTEMPT SHOULD BE MADE TO
STOP A ROPE OR HOSE OR ANY OTHER OBJECT ONCE IT HAS
BEEN WRAPPED AROUND A MOVING AGITATOR!!!
Before entering a mud tank for any reason, the mud agitators should be
locked out and tagged out.

Table of Contents
Foreword
Cautions & General Safety Rules 1
Table of Contents 2
List of Illustrations 3

Section 1 - Introduction
Role of Mud Agitators 5

17

Design Features 5 & 6

Sizing 7-10

Section 2 - Installation
Dimensional Data & Weight Information 9,10 &13
Lifting Information 11
Mounting Pattern 10
Prior to Motor Start-Up 12

Section 3 Operation
Starting the Agitator 14
Adjusting Impeller Height 14

Section 4 Maintenance
Lubrication 13
General Maintenance 15
Cautions 16

Section 5 Troubleshooting
Guide 16

Section 6 Spare Parts List Availability

Information 17

Section 7 Spare Parts

Bill of Materials 18

List of Illustrations
Figure No. Page #
Figure 1.1 Major Components 4
Figure 1.2 Impeller Diameters vs. Pumping Rate 8
Dimensional Data 9 & 10
Figure 2.1 Weight Data 13
Figure 4.1 Lubrication 13
Bill Of Materials 18

SECTION 1- Introduction
A. Role of Mud Agitators
Agitators or mud mixers serve an important role in the surface treatment of
drilling fluids. Using an impeller mixer that promotes both axial and radial flow
will lower mud costs and improve mud properties.
Unlike centrifugal pumps or sub-guns, impeller mixers are relatively low shear
and low energy devices making them easy to maintain and inexpensive to

18

operate. Using low shear mixers to suspend and mix mud additives minimizes
particle size degradation and polymer shear.
Properly sized agitators serve three purposes:
1. Impeller mixers ensure that mud additives are homogeneously mixed.
This prevents spot over treatment of chemicals, dilution water or
weighting agents.
2. Agitators keep the active mud system moving when the mud pumps are
disengaged and will prevent the pits from gelling.
3. When drilling with weighted mud, properly selected agitators will keep the
weighting agents in suspension and minimize any tendencies for solids to
settle in corners or dead spots.
B. Design Features
The design features of the Agitator that minimize maintenance and maximize
reliability include:
A rugged cast iron gearbox houses either a double or triple reduction helical
bevel gearing set that is so precisely ground that there is a minimal amount of
back lash in the gear sets. This feature eliminates a slamming effect of the
gears at start up, promoting longer life. Each helical bevel gear set is 98%
efficient. Therefore a double reduction box is 96% efficient and a triple
reduction box is 94% efficient. A typical worm gear set is only 85% efficient,
losing most of it efficiency through the generation of heat.
The internal gears are lubricated with oil. For ambient temperatures below 23
F 0 or above 140 F 0 a synthetic lubricant should be substituted. A unique feature
of the MAX2000 Agitator is the greased lower bearing. This lower bearing can
be maintained, greased, from the topside of the tank, eliminating the need for
in-tank inspections of the lower bearing. This design feature provides a barrier
layer of grease that can be expunged out the lower seal. Which allows the lower
bearing to be in contact with good, uncontaminated lubricant at all times. The
lower seals are arranged to accommodate the grease pocket and makes for a
four-tier layer of protection for the gearing. All four ofthese levels must be
breeched prior to the gearbox losing its oil:
1. Lower seal-drop bearing
2. Grease pocket
3. Upper seal-drop bearing
4. Lower seal in gearbox
An external oil sight glass has been provided so that the oil level can be checked
at a single glance. Vent plugs are supplied, installed in the gearbox housing, to
maintain a homeostatic internal pressure, preventing a pressure build up that

19

could blow out an oil seal.

MOTORS
Explosion proof motors are designed to withstand pressure washing and
exposure to corrosive fluids without bearing contamination. Motors are available
with either a foot mount design or a NEMA C-face input. The foot mount or T
frame motors are mounted using flexible coupling between the motor and
gearbox, for ease of alignment. The NEMA C motors bolt to the gearbox housing
and no alignment issues are seen.
IMPELLERS
Optimal suspension and mixing results from the axial and radial flow patterns
created by from impellers. Using a 60 o , 45 o , an axial or a hydrofoil impeller the
optimal situation can be created for you application. In addition to the standard
welded impeller, the MAX2000 Agitator is offered with a bolt-on design blade
in carbon steel and the 310 series stainless. On the welded impellers a QD
bushing is provided to allow for adjustment of the height of the impeller.
60 CANTED
BLADE SHOWN
QD BUSHING
KEYWAY FOR
IMPELLER HEIGHT
ADJUSTMENT
THE 3 ARROWS DENOTE THE
DIRECTION OF CORRECT
PRODUCT FLOW OR MOVEMENT

Section 1 Introduction
C. Selecting Agitator
To properly select the correct horsepower and impeller diameter needed for a
mud tank agitator, the information below is needed.
Tank Geometry
a. Width
b. Length
c. Mud Depth

20

Maximum Anticipated Mud Density

a. Specify if know
b. Otherwise use 20 pounds per gallon (lb/gal)
Power Available
a. Voltage
b. Amperage Available
c. Frequency
D. Locating Agitators
A canted blade impeller creates a combination of radial and axial flow that
provides for uniform suspension and mixing in circular or square areas. A
rectangular tank with a length to width ratio of greater than 1.5 should be
divided into sizing areas that are square (or close to square areas) with an
agitator located at the center of each. For example, two agitators would be
given the responsibility for mixing each of the two 8-foot by 8-foot area of a
16-foot by 8-foot suction tank. All data below is for canted blade impellers.
E. Sizing Agitator
1. Calculate the volume of the mud located with in the Sizing Area.
Volume (in gallons)=length X width X max mud depth X 7.5
2. Select an impeller diameter using Figure 1.2 to find an impeller that
gives a pumping rate close to the calculated volume V. (Note the
frequency of the electric motor will affect pumping rate since 50 Hz
motors turn slower than 60 Hz motors.)

3. Calculate the turn over rate. The TOR is the number of

seconds required for the impeller to pump the full volume
within the sizing area. Remember that a lower TOR
indicates more agitation because the tank turns
over in fewer seconds. TOR should be in the range of
35 to 90 seconds for all sizing areas. Although, for the
suction tank, it should have a TOR closer to 90 (less

21

agitation) to prevent aeration.

TOR= Volume X 60 divided by Pumping Rate
or
TOR= volume X 60
Pumping rate
4. If TOR is over 90 select a bigger impeller. If TOR is below
35 select a smaller impeller. Then recalculate the TOR
using the new impeller diameter.
5. Using Figure 1.2, look up the horsepower (Hp20)
required for 20 ppg drilling fluids.
6. Using Figure 1.2, select the minimum gearbox size for this
application.
7. Specify the shaft length using the data on page 9 & 10.
Tank depth is obtained by measuring from the top of the
structure (beams, channels, etc.) on which the agitator
base will be supported to the bottom of the tank. Shaft
length is typically sized to allow 3 inches of clearance from
the bottom of the tank to the agitator shaft.
Impeller diameter Pumping rate @ Pumping rate @ Hp 20 Required
in inches 60 Hertz 50 Hertz (20 ppg mud) Gearbox
20 974 806 1.20 3 Hp
24 1684 1303 1.44 3 Hp
28 2674 2213 1.68 3 Hp
30 3289 2722 2.16 5 Hp
32 3991 3303 2.40 5 Hp
36 5683 4703 4.80 7.5 Hp
40 7795 6451 7.19 10 Hp
42 9024 7468 9.59 15 Hp
44 10375 8587 10.55 20 Hp
48 13470 11148 17.99 25 Hp

Figure 1.2 - Pumping Rate and Gearbox Selection

MOUNTING PATTERN
DIMENSION M2A-3 M2A-5 M2A-7.5 M2A-10 M2A-15 M2A-20 M2A-25
A 28" 40.5" 41.5" 49.625" 55.5" 65.75" 65.75"
B 8.5" 11" 11" 15" 15" 18.5" 18.5"
C 15" 23.75" 24.5" 27" 27" 37.375" 37.375"
D 15" 21.5" 21.5" 26" 26" 36" 36"
E 2.25" 2.5" 2.5" 3.5" 3.5" 3" 3"

22

F 3.5" 3.25" 3.25" 3.5" 3.5" 3.375" 3.375"

G 9" 16" 16" 19" 19" 30" 30"
H 0.75" .875" .875" 1.125" 1.125" 1.31" 1.31"
I (Impeller Diameter, TYP) 24" 28" 32" 36" 40" 44" 48"
J (Impeller Height) Recommended height for canted blades is .75 X Impeller Diameter.
K (Tank Depth)* *
L (Shaft Length) K-M-3 K-M-3 K-M-3 K-M-3 K-M-3 K-M-3 K-M-3
M 0.0" 5.5" 5.5" 7.5" 7.5" 7" 7"

*Measure from bottom of agitator support to the bottom of the tank.

Section 2 Installation
A. Dimensional Data
The weight data for all models of the Agitator is given in Figure 2.1. Since the
length of the impeller shafts vary, shaft weight must be added by using the
weight per foot data.
Dimensional Data for the MAX2000 Agitator is given on page 10. Again, the
customer must specify the Tank Depth in order to properly size the agitator
shaft. Note that certified drawings, if requested or required, provided with the
equipment will take precedence over any information in this manual.
Tank Depth is obtained by measuring from the top of the structure (beams,
channels, etc.) on which the agitator base will be supported to the bottom of the
tank. Shaft length is typically sized to allow 3 inches of clearance from the
bottom of the tank to the bottom of the agitator shaft.
B. Lifting the Agitator
Lift the agitator only at the lift points provided. Use properly rated slings capable
of handling the weight of the equipment. In most cases, the impeller will be
installed after the agitator base has been lifted into the tank but before the base
has been securely mounted. If the agitator is lifted with the impeller shaft
installed, make sure that the shaft coupling has been completely tightened and
that the shaft is securely attached before lifting. It is always good practice to
remove the impeller shaft before removing an existing agitator.

C. Before Installing Agitator

Before installing the agitator, care should be taken to ensure that the structure
on which the agitator will be mounted is capable of withstanding both the static
load and the dynamic loads that will be transferred to the tank structure.
D. Installing the Agitator
Typically, the shaft but not the impeller will be installed before lifting the unit
into place. Some conditions, like limited head room above the tank, may require
that the shaft be installed after the unit has been lifted in place. Anti-seize
compound should be applied to all threaded fasteners.
Lift the unit where indicated and place in position on the mud tank using blocks

23

to provide at least 18 inches of clearance between the bottom of the shaft and
tank bottom. Before removing the blocks and fastening the base to the tank
structure, the impeller must be
Page 11.installed. Using the QD busing and the key that are attached to the
impeller,
install the key and the QD bushing first. Locate the key so that when the
impeller is installed, the distance from the bottom of the canted blades to the
tank bottom is roughly of the impeller diameter. Example, if the impeller
diameter is 36, then the distance from the bottom of the tank should be 27
when installation is complete. Do not install impeller upside down; the product
flow or direction should be downward or toward the bottom of the tank. Once
the impeller has been installed, the blocks can be removed and the agitator
should be secured to the mud tank using the mounting bolthole pattern shown
on the dimensional drawing for the unit. Alternately, the agitator base can be
welded directly to the mud tank. Check impeller height and adjust if necessary.
A. Electrical Installation
TURN OFF. LOCK OUT AND TAG OUT the electrical power supply to the
agitator before working on the agitator or opening the motor starter or junction
box on the side of the motor. A qualified electrician should make electrical
connections inside the junction box on the side of the motor. Care should be
taken to make sure that voltage and frequency of the power supply match the
motor nameplate voltage and frequency.
B. Checking Motor Rotation
BEFORE STARTING OR EVEN BUMPING THE MOTOR, MAKE SURE
THAT GEARBOX IS FILLED WITH OIL.
The electrical installation is not complete until the motor rotation has been
checked. Reversing any two legs on a three-phase power will reverse direction
of rotation if necessary.

C. Checking Oil Level

All Agitators are shipped from the factory filled with the proper type and quantity
of gear oil. Nonetheless, gear units must be checked for oil level before startup.
Oil level should be checked using the sight glass on the side of the gearbox
housing. When mounted level, the oil level should hit the mid point on the sight
glass. In addition to oil level, check the lower bearing for grease. A grease gun
can be used to pump grease into the zerk and through the grease tube down to
the lower bearing. Mobil CM-P is recommended. However, if not available, a
moly-fortified grease should be used. Other recommended grease characteristics
include: washout resistant, broad temperature range, ISO 320, NLGI Grade II,
24

Lithium based.

DATA AND CHARTS

IMPELLER MOTOR SHAFT WT. WEIGHT LESS SHAFT
MODEL # SIZE Hp (lbs/ft) (LBS) (KG)
M2A-3 24" 3 5.5 215 98
M2A-5 28" 5 12.8 420 191
M2A-7.5 32" 7.5 12.8 495 225
M2A-10 36" 10 23.0 790 359
M2A-15 40" 15 23.0 940 427
M2A-20 44" 20 31.6 1,250 567
M2A-25 48" 25 41.4 1,400 635

TABLE 2.1- WEIGHT DATA

FIGURE 4.1
TEMPERATURE RANGE (ambient) AGMA No. ISO VG Example
Fahrenheit Celsius - Mobil Product
40 below to 32 40 below to 0 - 220 SHC630
32 to 100 0 to 37.7 5 EP 220 Mobilgear 630
Over 100 Over 37 8 EP 680 Mobilgear 636
Temperature conversions
F=(1.8 X C) + 32 C=0.555(F - 32)
LUBRICANT QUANTITY FOR MAX2000
CAPACITY CAPACITY
MODEL # QUARTS LITERS
M2A-3 2.4 2.6
M2A-5 3.79 4
M2A-7.5 3.79 4
M2A-10 6.82 7.2
M2A-15 6.82 7.2
M2A-20 12.31 13
M2A-25 12.31 13
ABOVE 25 Hp CONSULT FACTORY

FIGURE 4.2

Section 3 Operation
A. Starting the Agitator
Prior to proceeding, check the alignment of the motor to gearbox coupling
alignment. If couplings are not aligned properly, you may wear out the flexible
element before an acceptable length of operating time has passed.
Once installation is complete and proper lubrication levels have been confirmed,
pressing the start button on the motor starter can start the unit. (Note that
motor starters are NOT supplied with agitators unless they have been ordered
separately.) As is good practice with all rotating equipment, check for unusual

25

noise or vibration upon start up.

B. Operation
As with centrifugal pumps, agitators will consume more horsepower as mud
weight increases. There is no adjustment of the agitator that is required to
compensate for changes in drilling conditions. During drilling operations, mud
agitators are kept running at all times.
***Aeration of the Suction Tank - Adjusting the height of the impellers in the
suction tank is very important to prevent the agitators from introducing air that
can cause mud pump problems. If air entrainment starts causing problems with
the mud pump, while drilling with acceptable mud volume, impeller height should
be lowered at the next opportunity, to minimize aeration. Temporarily increasing
mud volume, to prevent aeration, can usually solve the problem.
C. Safety
The gearbox on the Agitator has a speed reduction ratio, which greatly increases
the torque output at the impeller. Despite their relatively slow speed, a mud
agitator can be extremely dangerous. Any objects that might fall into or be
placed in the mud tanks run the risk of being caught by and wrapped up by the
agitator. Typical examples of items that pose the threat of being caught by the
agitator are: hoses, mud sample buckets, ropes, etc.

***No attempt should be made to stop a rope or hose once it

has been wrapped around a moving agitator!!! Doing so can
result in a potentially life threatening situation for the
person attempting to remove the object from the agitator.

Section 4 Maintenance
A. Maintenance
The primary maintenance item for the Agitator is a weekly check of lubrication
levels. This includes the oil level coating the gearing and the grease in the lower
bearing. The oil level can be easily checked through the sight glass on the side
of the gearing section. The correct fill quantities are listed in Figure 4.2, on
page 13. The design of the grease pocket allows for the old grease to be
expunged out of the lower seal. You have the ability to add as much grease as
you wish, however, the more you add to the lower bearing, an equal amount of
grease that is pushed out. It is recommended, in a normal operating range of
mud levels, (i.e. below the output shaft of the agitator) during your weekly

26

maintenance check of the agitator, you take the opportunity to put 8-10 pumps
of a grease gun into the zerk on the side of the housing.
In the event you find a component of the Agitator Assembly that needs to be
repaired, consult the Drawing labeled Internal Components, page 18, for which
items can be replaced in the field. At no time, should anyone other than a
FACTORY TRAINED individual attempt any repair on the gearing section. The
gears sets are so exactly positioned that without the proper tools and presses, it
is emphatically discouraged to attempt any field repair. If any field attempt is
made to repair the gearing section of the MAX2000 Gearbox, any warrantee
either implied or express is voided, IMMEDIATELY. Please advise any and all
personnel to observe this important statement.
B. Periodic Oil Changes
During the course of normal operation, the oil in the gearbox should be changed
every three months. The use of a high quality lubricant, as listed in Figure 4.2
on page 13, will assist in the removal of any particles that might foul out the
gearing, and provide trouble free operation of the MAX2000 Agitator.
***It is very important to monitor the ambient temperature around the
MAX2000 Agitator. There are two (2) critical points at which an oils lubrication
property must be altered. Extended periods of the ambient temperature below
32 o F and above 100 o F require changing the ISO grade of the oil to
accommodate these temperature ranges.

C. Cautions
The MAX2000 Agitator is a very rugged product, however through the abuse
and misuse of any piece of equipment, the operational life of the unit can be
greatly diminished. When in a cold environment, 8 o F and below, CAST IRON
becomes fragile and must be prevented from receiving impacts, as this can crack
the housings and cause oil leakage. Whenever possible, check the impeller shaft
stabilizer for wear, excessive wearing can cause high angles of shaft deflection,
wearing out the lower bearing.

Troubleshooting Guide
Problem Cause Action -Solution

Motor Will Not Start -Power problem -Check electrical supply

27

-Defective motor -Replace motor

-Wrong or bad heaters/coil -check heaters/starter
Motor Quits Running -Starter tripped out -Reset starter
-Burned out heater -Replace heater
-Motor burned out -Replace motor
Tripped Starter -Bad heaters -Replace heaters
-Over amp draw -check amp draw
-Agitator undersized -Replace Agitator
Whining Noise -Check motor bearings -Replace motor
Random Noise
(Gearbox) -Contamination in oil -Drain and replace oil
Rhythmic noise
(Gearbox) -Possible bur on gear set -See next line
A bur on a gear set has a tendency to correct itself over time. In the event that the noise is
overly obtrusive, remove gearbox and return to factory for evaluation.
Vibration -Assembly loose -Tighten all bolts
-Broken weld (base to tank) -Re-weld base to tank

Parts List
Replacement parts for the MAX2000 Agitators can be ordered from Process
Solutions International or any of their agents, worldwide. The Drawing labeled
Internal Parts, page 18, gives you a drawing number for the parts you can
order. A list of drawing numbers and description for the drawing numbers is
located on page 19. When ordering, provide the drawing number and
description of the part you need. Please include the horsepower of the Agitator
you are repairing. If you desire a parts list with exact catalog numbers of
replacement parts, contact Process Solutions International using the information
listed below.
To order parts, schedule field service or to receive technical support, contact
Process Solutions International using the information listed below.

Parts Numbers and Descriptions

DRAWING NUMBER DESCRIPTION
1 Gearbox
2 Output Shaft
3 Internal Keys
4 Retaining Ring
5 Cover
6 Socket Head Cap Screw
7 Lock Washer
8 Socket Head Cap Screw
9 Hose Connector
10 Drop Bearing Housing

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11 Grease Zerk
12 Upper Seal, Drop Bearing
13 Lower Seal, Drop Bearing
14 Spherical Roller Bearing
15 O-Ring
16 Grease Envelope
17 Grease Tube
18 End Cap
19 Hex Head Cap Screw
20 Lock Washer
21 Hose Connector
External Key

NOTES

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30