Mud Agitator Operation, Maintenance, & Technical Manual0104.nccdn.net/1_5/318/368/021/Agitator-Manual-AM-001-Rev5.pdf · Mud Agitator Operation, Maintenance, & Technical Manual Process

Mud Agitator Operation, Maintenance, & Technical Manual Process Solutions International Rev 005 10/02/2014

Company Propriety and Confidential

7519 Prairie Oak Dr. Houston TX, 77086 281-893-4774 office 281-893-1027 fax www.psimax2000.com

Mud Agitator Operation, Maintenance, & Technical Manual

(MAX2000 Drop Bearing, Low Profile, and Vertical)

Document File: AM-001

Revision

Number

Date of

Revision Description of Revision Revision Author

DRAFT 10/3/13 Draft Daniel Vasquez

1 10/25/13 Approved copy Daniel Vasquez

2 11/22/13 Added detailed parts list Daniel Vasquez

3 05/20/14 Added CTX and Impeller installation D. Vasquez

4 7/24/14 Added Warranty information D. Vasquez

5 10/2/14 Added Bushing and Rigid Coupling Installation D. Vasquez


AM-001 Company Propriety and Confidential

Table of Contents

1.0 SAFETY

2.0 WARRANTY

3.0 INSTALLATION PROCEDURE

4.0 STARTUP PROCEDURE

5.0 ROUTINE MAINTENANCE

5.1 TROUBLE SHOOTING GUIDE

6.0 SHUTDOWN AND STORAGE

6.1 SHORT TERM SHUTDOWN 6.2 LONG TERM SHUTDOWN

7.0 TECHNICAL MANUAL CONTENTS

7.1 GENERAL DESCRIPTION 7.2 MAJOR COMPONENTS 7.3 GENERAL ARRANGEMENT DRAWING

8.0 PARTS LIST

RIGHT ANGLE - DROP BEARING GEARBOX

RIGHT ANGLE - LOW PROFILE GEARBOX

9.0 INSPECTION AND TESTS

10.0 CERTIFICATION(S)

11.0 ADDITIONAL DRAWINGS, DIAGRAMS, ETC.

12.0 CONTACT INFORMATION



1.0 Safety

General safety rules and warnings This manual contains important information concerning installation, operation, and proper maintenance of your PSI 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 PSI Mud Agitator. In addition, the safety precautions below should be followed at all times. 1. Follow your companies LOCK-OUT/TAG-OUT Procedures before performing any

maintenance.

2. Inspect equipment for damages, loose fittings, safety guards (if applicable), and proper installation.

3. Wear proper PPE based on your companies Personal Protective Equipment and

Safety procedures.

4. When lifting equipment, ensure proper lift points are used. Use properly rated slings that are capable of handling the equipment.

5. Do not use the equipment for anything but its intended use.

***NO ATTEMPT SHOULD BE MADE TO STOP A ROPE OR HOSE OR ANY

OTHER OBJECT ONCE IT HAS BEEN WRAPPED AROUND A MOVING SHAFT

AND/OR IMPELLER!!!

The gearbox on the Agitator has a pre-selected gear ratio to maximize the suspension of solids in solution. This gear ratio provides an 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 shaft or impeller as they spin.



2.0 Warranty

Warranty Terms and Conditions The MAX2000

, MAKDADDY

, and Vak

name are registered trade names of Kelbro, Inc dba

Process Solutions International (PSI). Their use is reserved by Kelbro, Inc. dba Process Solutions International (PSI) and applicable laws. It shall not be used without permission and written authorization from Kelbro, Inc. dba Process Solutions International (PSI).

Terms of Sale Any terms and conditions contained in any purchase order or other form of communication from PSIs customers, which are additional to or different from these terms and conditions, shall be deemed rejected by PSI unless expressly accepted in writing by PSI. In general, no modification, amendment, waiver or other change of any of these terms and conditions or attachments hereto, or of any of PSIs right or remedies thereunder, shall be binding on PSI unless expressly accepted in writing by PSIs authorized officers. No course of dealing, usage of trade or course of performance shall be relevant to explain or supplement any of these terms and conditions. If any document issued by any party hereto is sent by facsimile or another form of electronic document transmission, the parties hereto agree that (a) the copy of any such document printed on the facsimile machine or printer of the recipient thereof is a counterpart original copy thereof and is an writing, (b) an electronically stored and reproduced copy of any such document shall be deemed to be legally sufficient evidence of the terms of such document for all purposes. Delivery; Risk of Loss All sales are F.O.B. PSIs plant or other point of shipment designated by PSI. Shipping dates are estimates only which are not guaranteed and are based upon prompt receipt from Buyer of all necessary shipping and other information. PSI reserves the right to make delivery in installments, all installments to be separately invoice and paid for by Buyer when due per invoice, without regard to subsequent deliveries. Delivery of equipment to a commercial carrier at PSIs plant or other loading pint shall constitute delivery to Buyer, and any risk of loss and further cost and responsibility thereafter for claims, delivery, loss or damage, including, if applicable, placement and storage, shall be borne by Buyer. When equipment is delivered by PSIs truck, unloading at Buyers dock shall constitute delivery to Buyer. Claims for shortages or other errors in delivery must be made in writing to PSI within ten (10) days after receipt of shipment and failure to give such notice shall constitute unqualified acceptance and a waiver of all such claims by Buyer. Claims for loss or damage to equipment in transit by common carrier must be made to the carrier and not to PSI. Freight and handling charges by PSI may not reflect actual freight charges prepaid to the carrier by PSI due to incentive discounts earned by PSI based upon PSIs aggregate volume of freight tendered to a carrier or when a carrier must be used which charges a rate which is different than the rate upon which PSIs freight and handling charges were based. When shipments are delivered in PSIs private trucks, Buyer will be charged an amount approximating the prevailing common carrier rate. Excusable Delays; Force Majeure PSI shall not be liable for any ordinary, incidental, or consequential loss or damage as a result of PSIs delay in or failure of delivery or installation due to (i) any cause beyond PSIs reasonable control, (ii) an act of God, act of the Buyer, embargo or other government act, authority, regulation or request, fire, theft, accident, strike, slowdown, or other labor disturbance, war, riot, delay in transportation, or (iii) inability to obtain necessary labor, material, components, or facilities. Should any of the aforementioned events of force majeure occur, PSI, at its option, may cancel Buyers order with respect to any undelivered equipment or extend the delivery date for a period equal to the time lost because of delay. Notice of such election shall be given promptly to Buyer. In the event PSI elects to so cancel the order, PSI shall be released of and from all liability for failure to deliver the equipment, including, but not limited to, any and all claims on behalf of Buyer for lost profits, or any other claim of any nature which Buyer might have. If shipping or progress of the work is delayed or interrupted by Buyer, directly or indirectly, Buyer shall pay PSI for all additional charges resulting therefrom.



Storage If the equipment is not shipped within fourteen (14) days after notification has been made to Buyer that it is ready for shipping, for any reason beyond PSIs control, including Buyers failure to give shipping instructions, PSI may store the equipment at Buyers risk and expense in a warehouse or on PSIs premises, and Buyer shall pay all handling, transportation and storage costs at the prevailing commercial rates promptly following PSIs submission of invoices for such costs. Warranty Period PSI warrants the products manufactured under the Kelbro register trade name mentioned above to be free from defects in materials and workmanship and to conform to PSI written specifications for a period of 12 months from the date of manufacture. Warranty Remedies If, prior to expiration of the foregoing applicable warranty period, any of such products shall be proved to PSIs satisfaction to be defective or nonconforming, PSI will repair or replace such defective equipment or components thereof, F.O.B. PSIs plant or other destination designated by PSI, or will refund or provide Buyer with a credit in the amount of the purchase price paid therefore by Buyer, at PSIs sole option. Buyers exclusive remedy and PSIs sole obligation under this warranty shall be limited to such repair or replacement, F.O.B. PSIs plant or other destination designated by PSI, or refund or credit by PSI, and shall be conditioned upon PSIs receiving written notice of any defect within a reasonable period of time (but in no event more than thirty (30) days) after it was discovered or by reasonable care should have been discovered. In no event shall PSIs liability for such defective or nonconforming products exceed the purchase price paid by Buyer therefore. Exclusions This warranty does not (i) cover shipping expenses to and from PSI factory or other destination designated by PSI for repair or replacement of defective equipment or any tax, duty, custom, inspection or testing fee, or any other charge of any nature related thereto, nor does it cover the cost of disassembling or removing defective equipment or reassembling, reinstalling, or testing repaired or replaced equipment or finishing the reinstallation thereof, (ii) apply and shall be void with respect to equipment operated in excess of rated capacity or otherwise not in accordance with installation, maintenance, or operating instructions or requirements, to equipment repaired or altered by others than PSI or PSIs authorized service agencies, or to equipment which was subjected to abuse, negligence, misuse, misapplication accident, damages by circumstances beyond PSIs control, to improper installation (if by others than PSI), operation, maintenance or storage, or to other than normal use or service, and (iii) apply to equipment or components not manufactured by or for PSI. With respect to equipment or components not manufactured by PSI, PSIs warranty obligations shall in all respects conform and be limited to the warranty actually extended to PSI by its suppliers, but in no event shall PSIs obligation be greater than those provided under PSIs warranty set forth in this section. The fore going warranties are in lieu of all other express and implied warranties (except title0, including, without limitation, the implied warranties of merchantability and fitness for a particular purpose. No employee, representative, or agent of PSI other than an officer of PSI is authorized to alter or modify any provision of this section or to make any guarantee, warranty, or representation, express or implied, orally or in writing, which is contrary to the foregoing. Any description of the equipment, whether in writing or made orally by PSI or PSIs agents, specifications, samples, models, bulletins, drawings, diagrams, engineering sheets or similar material used in connection with Buyers order are for the sole purpose of identifying the equipment and shall not be construed as an express warranty. Any suggestions by PSI or PSIs agents regarding use, application or suitability of the equipment shall not be construed as an express warranty unless confirmed to be such in writing by PSIs authorized officer. Consequential Damage Disclaimer PSIs liability with respect to equipment proved to its satisfaction to be defective within the warranty period shall be limited to repair, replacement or refund as provided hereof, and in no event shall PSIs liability exceed the purchase price of the equipment involved. Kelbro shall not be subject to any other



obligations or liabilities, whether arising out of breach of contract, warranty, tort (including negligence) or other theories of law, with respect to equipment sold or services rendered by PSI, or any undertakings, act or omissions relating thereto. Without limiting the generality of the foregoing, PSI specifically disclaims any liability for property or personal injury damages, penalties, special or punitive damages, damages for lost profits or revenues, loss of use of equipment or any associated equipment, cost of capital, cost of substitute products, facilities or services, downtime, shutdown, or slowdown costs, or for any other types of economic loss, and for claims of Buyers customer for any such damages. PSI shall not be liable for and disclaims all consequential, incidental and contingent damages whatsoever. Even if the repair or replacement remedy shall be deemed to have failed of its essential purpose under section 2-719 of the uniform commercial code, PSI shall have no liability to Buyer for consequential damages, such as lost profits, lost revenue, damage to other equipment or liability or injury to a third party. Indemnification by Buyer Buyer shall indemnify, hold harmless, and defend PSI and PSIs employees and agents from and against any and all damages, liability, claims, losses and expenses (including reasonable attorneys fees, court costs, and out-of-pocket expenses) arising out of or resulting in any way from claims by customers of Buyer or third parties against PSI alleging a breach of contract or warranty by PSI to the extent that such damages, liability claims, losses and expenses which may be payable by PSI to Buyer pursuant to the and as limited by PSIs warranty and damage obligations as contained hereof so as to effectively limit Kelbros obligations to customers of Buyer or third parties to those set forth. Return of Equipment No equipment or part shall be returned to Kelbro without written authorization and shipping instructions first having been obtained from PSI under the companys Return Policy. Return Policy:

Client/Customer requests an RMA from Sales Department

Sales shall issue an RMA with an assigned number along with the Product Warranty information and a quote for replacement cost.

Client/Customer issues a Purchase Order to PSI (pending evaluation), with the RMA properly filled in.

Product is returned back to PSI at Client/Customers expense with all RMA documents for reference. If the product is warrantied, then the freight cost will be credited back.

An evaluation will be conducted to determine warranty status.

If product is not returned within 30 days of issued RMA, then an invoice will be issued regardless of warranty status.

A copy of the evaluation is available upon request.



3.0 Installation Procedure

Your companies LOCK-OUT/TAG-OUT Procedures should be followed before performing any maintenance.

Dimensional Data The weight data for all models of the Agitator is given in below. 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.

AGITATOR WEIGHT

Model No. Weight Less

Shaft & Impeller

DROP BEARING

M2A-03 (Right Angle) 428 lb [195 kg]

M2A-03 (Vertical) 488 lb [222 kg]















LOW PROFILE

LPM2A-03 (Right Angle) 381 lb [173 kg]

LPM2A-03 (Vertical) 332 lb [151 kg]

















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 shaft 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.

Before Installing the 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.

Installing the Agitator Typically, neither the shaft nor 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 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 installed.

KEEP IN MIND THAT PROPER ALIGNMENT IS NECESSARY BEFORE BOLTING THE

AGITATOR DOWN. MOTORS AND GEARBOXES MUST NOT BE FORCED INTO

ALIGNMENT USING THE BOLTS. USE SHIMS IF THERE IS A GAP, NOT DOING DO

MAY CAUSE THE EQUIPMENT TO BIND AND LEAK OIL LEAKS OR MAY CAUSE

OTHER MECHANICAL ISSUES

Using the QD bushing 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 bolt hole 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.

BE SURE TO INSTALL THE BREATHER/VENT PLUG THAT HAS BEEN PROVIDED

WITH THE EQUIPMENT. FAILURE TO DO WILL CAUSE THE GEARBOX TO BUILD

UP INTERNAL PRESSURE OVER TIME AND POSSIBLY RESULT IN A LEAK FROM

THE SEAL.



CTX Coupling Installation Check to insure that all components are available: Two half sections; one threaded & one counter bored with through drill holes, two lock rings, one key, and eight socket head cap screws. Check that the output shaft and the impeller shaft are the same diameter. Check the diameter of the coupling to ensure it matches the shafts. Coat the threads of the socket head cap screws with a lubricant for prevention of corrosion and easier removal of the fasteners later as needed. Install one lock ring on the impeller shaft and one lock ring on the output shaft of the gear box. [Rings must be oriented so that profile matches machined section on coupling.] Align the gap of the lock rings with the keyway in the shafts so a key can be inserted in both shafts. Align the keyways in the shafts so a key can be placed in the keyway. The gap between the gear box output shaft and the impeller shaft should be less than 1/8. Place the key in the aligned keyway. Place half of the key in each shaft. Place the coupling section with the keyway over the key in the shafts. The section should 50/50 between the two shafts. Place the other section on the shafts and align the holes. Install the socket head cap screws in the assembly.

Starting with the end socket head cap screws, tighten up the screws to a snug fit. Starting with the end socket head cap screws and working to the middle, tighten up the screws bringing the torque on the screws to 77 pound-feet [ 924 pound-inches].



THREADED

CTX COUPLING

HALF

THREADED

CTX COUPLING

HALF

BORED

CTX COUPLING

HALF

SOC HEAD

CAP SCREW

KEYWAY

SHAFT GEAROX

LOCK RING

KEY

LOCK RING

KEYWAY

IMPELLER SHAFT SECTYION A-A

SECTION B-B

.13

GAP



Impeller Installation

IMPELLER INSTALLATION APPLIES TO BOTH THE

CANTED AND HYDROFOIL DESIGN IMPELLERS



Hydrofoil Installation (if applicable)



Bushing and Rigid Coupling (if applicable) Installation

TO INSTALL BUSHING: 1. Clean shaft, bore and outside of bushing, and hub bore of all oil, paint and dirt. File away any burrs. 2. Insert bushing in hub. Match the hole pattern, not threaded holes (each hole will be threaded on one side only). 3.LIGHTLY oil setscrews and thread into those half-threaded holes indicated by on above diagram. 4. Alternately torque setscrews to recommended torque setting in Table 2. 5. To increase gripping force hammer face of bushing using drift or sleeve. (Do Not Hit Bushing Directly With Hammer) Re-torque Screws After Hammering. 6. Recheck screw torque after initial run-in, and periodically thereafter. Repeat steps 4 & 5 if loose.

DO NOT USE WORN HEX KEY WRENCHES.

INSTALLATION ON SHAFT: 1. Read To Install Bushing, steps 1 thru 3. Mount the female flange on the shaft end having the least length available. This leaves the longest shaft end for the male flange which requires more room to tighten the bushing. 2. Locate large end of bushing in female flange flush with end of shaft. Tighten bushing per steps 4 thru 6 under To Install Bushing. 3. Mount male flange on the other shaft. Locate the small end of the bushing flush with the end of the shaft. Tighten bushing per steps 4 thru 6 under To Install Bushing. 4. Locate and align shafts to bring coupling halves together. Pilot diameters and flange surfaces should mate fully against each other before bolting the flanges together. 5. A gap between the mating surfaces anywhere around the flanges indicates angular misalignment. Difficulty in mating the pilot diameter indicates parallel misalignment. Shafts should be aligned with a dial indicator to eliminate misalignment. 6. Insert and tighten screws A to the recommended torque given in Table 1. The screws are supplied with the male flange assembly. It is necessary that the shafts be free to move endwise when tightening screws. Using the screw to pull the flange together or into alignment without end float may pre-load the system and cause bearing problems or damage to the coupling.

TO REMOVE BUSHING: 1. Remove all setscrews. 2. Insert setscrews in holes indicated by on Figure 2. Loosen bushing by alternately tightening setscrews. 3. To reinstall, complete all six (6) installation steps.



Stabilizer Installation (if applicable)

STEP 1: INSERT SHAFT IN THE BOTTOM STABLIZER AS SEEN BELOW

WELD TO THE TANK BOTTOM

STEP 2: CENTER BOTTOM STABILZER TO AGITATOR SHAFT AND WELD IN PLACE.



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.

Checking Motor Rotation

BEFORE STARTING OR EVEN BUMPING THE MOTOR, CHECK THE SIGHT GLASS TO

MAKE SURE THAT GEARBOX IS PROPERLY LUBRICATED AND CHECK TO SEE IF THE

BREATHER VENT PLUG IS PROPERLY INSTALLED.

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.

Checking and Filling Oil 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. If the equipment requires additional oil, use ISO 220 Gear Oil to refill at an Ambient Temperature of 4

oC-40

oC. Outside of this temperature range,

contact the factory. When mounted level, the oil level should hit the mid-point to 3/4 on the sight glass. In addition to oil level, check the drop 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, Lithium based.

Low Profiles are lubricated at the factory.



4.0 Startup Procedure

Before proceeding, check all fasteners to make sure that they are tight and that all parts are secure prior to continuing.

Once installation is complete and proper lubrication levels have been confirmed, pressing the

start button on the motor starter will 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 noise or vibration upon start

up.

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.

5.0 Routine Maintenance

Use proper lock-out/tag-out precautions when performing maintenance.

Once the unit is placed into full operation, a Preventative Maintenance Program should begin. This program should include regular inspection set up on a periodic basis.

The Preventive Maintenance Program should include a general inspection of:

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 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 maintenance check of the agitator, you take the opportunity to put 3 pumps of a grease gun into the zerk on the side of the housing.

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 discouraged to attempt any field repair. If any field attempt is made to repair the gearing section of the MAX2000 Gearbox, any warranty either implied or express is voided, IMMEDIATELY. Please advise any and all personnel to observe this important statement.



5.1 Trouble Shooting Guide

Problem Cause Action - Solution

Motor will not start -Power problem -Defective motor -Wrong or bad heaters/coil

-Check electrical supply -Replace motor -Check heaters/starters

Motor quits running -Starter tripping out -Burned out heater -Motor burned out

-Reset starter -Replace heater -Replace motor

Tripped Starter -Bad heaters -Over amp draw -Agitator undersized

-Replace heater -Check amp draw -Replace agitator

Whining noise -Check the motor bearings -Replace the motor

Random noise (gear box) -Contamination in oil -Drain and replace oil

Rhythmic noise (Gear box) -Possible bur on the 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 -Broken Weld (tank base)

-Tighten all bolts -Re-weld base to tank

6.0 Shutdown and Storage

6.1 Short Term Shutdown

Units may be deactivated and left on line for up to four months without special precautions.

1. LOCKOUT/TAGOUT ALL POWER. 2. Inspect all components for damage or wear.

6.2 Long Term Shutdown

1. Inspect all components for damage or wear. 2. Remove the breather/vent plug and place a set screw in its place. This keeps

condensation out of the gearbox. 3. If the agitator has been in operation for longer than 6 months, then drain the oil from the

gearbox and replace with fresh oil. 4. If possible keep the equipment covered to help protect against weathering. 5. Spray down any non-painted metal, such as shafts and couplings with a rust protectant.



7.0 Technical Manual Contents

7.1 General Description

Agitators or mud mixers serve an important role in the surface treatment of drilling fluids.

Using an impeller 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 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. 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.

When deciding which Impeller and Gearbox to use, the following diagram can be used.

Impeller Diameter in Inches

Pumping Rate @ 60 Hz

Pumping Rate @50 Hertz

HP 20 (20 ppg mud)

Required Gearbox

20 900 750 1.20 3 Hp

24 2000 1300 1.44 3 Hp

28 2400 1900 1.68 3 Hp

30 3000 2700 2.16 5 Hp

32 4400 3800 2.40 5 Hp

36 5850 5480 4.80 7.5 Hp

40 7200 6000 7.19 10 Hp

42 8100 7000 9.59 15 Hp

44 9900 8100 1055 20 Hp

48 12500 10200 17.99 25 Hp

Pumping Rate and Gearbox Selection



7.2 Major Components

GEARBOX 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. Vertical units are double reduction inline helical and Right angle units are triple reduction helical-bevel. This feature eliminates a slamming effect of the gears at start up, promoting longer life. Each gear set is 98% efficient. The internal gears are lubricated with oil. For ambient temperatures below 23

o F or above

140o F 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 of these 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 could blow out an oil seal.

CTX SHAFT TO SHAFT COUPLING

INLINE-HELICAL

GEARBOX

EXPLOSION PROOF MOTOR

DROP BEARING

FOUR BLADED CANTED IMPELLER

CTX SHAFT TO SHAFT

COUPLING

FOUR BLADED CANTED

IMPELLER

DROP BEARING

EXPLOSION PROOF MOTOR

RIGHT ANGLE

HELICAL GEARBOX



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 Impellers create optimal suspension and mixing results from the axial and radial flow patterns. Using a 60

0, 45

0, an axial or a hydrofoil impeller the optimal situation can be created for your 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.

PSI CANTED BLADE IMPELLER

PSI MAXFLOW HYDROFOIL IMPELLER



7.3 General Arrangement Drawing

LOW PROFILE DESIGN

DROP BEARING DESIGN

VERTICAL

RIGHT ANGLE

RIGHT ANGLE

VERTICAL



8.0 Parts List



Recommended Spare Parts for 1 year

Description Quantity

First Input Bearing 1

Second Input Bearing 1

Input Seal 1

First Output Bearing 1

Second Output Bearing 1

Output Seal 1

*Drop Bearing 1

Motor Side Coupling 1

Spider 1

**Motor 1

*Low Profiles do not use a drop bearing.

**Upon ordering, please specify motor size, voltage, and frequency

DWG # 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*

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

22 External Key



VERTICAL DROPBEARING GEARBOX



ITEM DESCRIPTION QTY 3/5HP QTY 7.5/10HP QTY 15/20HP QTY 25/30HP

6 SPACER 1 52/M2100S 1 52/M2100S 1 52/M2A30S 1 52/M2A30S

7 SHCS, M14x90 7 52/M2A0507 7 52/M2A1007 7 52/M2A2007 7 52/M2A2507

8 Lock Washer, M14 7 52/M2A0508 7 52/M2A1008 7 52/M2A2008 7 52/M2A2508

9 GREASE FITTING 1 52/M2A0509 1 52/M2A10009 1 52/M2A2009 1 52/M2A2509

10 DROP BEARING CASTING* 1 52/M2A05010-V 1 52/M2A10010-V 1 52/M2A2010-V 1 52/M2A25010-V

11 GREASE ZERK 1 52/M2A05011 1 52/M2A10011 1 52/M2A20011 1 52/M2A25011

12 LIP SEAL 1 52/M2A05012 1 52/M2A10012 1 52/M2A20012 1 52/M2A25012


14 BEARING, SPHERICAL ROLLER 1 52/M2A05014 1 52/M2A10014 1 52/M2A20014 1 52/M2A25014

15 O RING 1 52/M2A05015 1 52/M2A10015 1 52/M2A20015 1 52/M2A25015

16 GREASE - - - - - - - -

17 GREASE LINE 1 52/M2A05017 1 52/M2A10017 1 52/M2A20017 1 52/M2A25017

18 DROP BEARING END CAP 1 52/M2A05018 1 52/M2A10018 1 52/M2A20018 1 52/M2A25018

19 HHCS, 1/2-13 X 1 1/2 LG 8 52/M2A05019 8 52/M2A10019 8 52/M2A20019 8 52/M2A25019

20 LOCK WASHER, 1/2 8 52/M2A05020 8 52/M2A10020 8 52/M2A20020 8 52/M2A25020

21 COUPLING, MOTOR SIDE 1 52/2503338 1 52/2503340 1 52/2503342 1 52/2503387

22 SPIDER COUPLING 1 52/2510645 1 52/2510647 1 52/2510647 1 52/2510653

23 OIL SIGHT GLASS 1 52/2002375 1 52/2002375 1 52/2002376 1 52/2002376

24 BREATHER PLUG-VALVE KIT 1 - 1 - 1 - 1 52/3033136

25 INPUT SHAFT PLUG 1 - 1 52/2001033 1 52/2001033 1 52/2001033

26 REDUCER COUPLING 1 52/2503351 1 52/2503355 1 52/2503355 1 52/2503390

27 PINION SHAFT 1 - 1 - 1 - 1 -

28 PINION SHAFT KEY 1 - 1 52/2001593 1 - 1 52/2001593

29 RETAINING SNAP RING 1 52/2000617 1 52/2000622 1 52/2000622 1 52/2000624

30 1ST REDUCER PINION 1 52/2507845 1 52/2507847 1 52/2507893 1 52/2507893

31 1ST REDUCER GEAR 1 52/2503397 1 52/2503397 1 52/2503414 1 52/2503414

32 RETAINING RING 2 52/2000618 2 52/2000618 1 52/2000621 1 52/2000621

33 INPUT BALL BEARING 1 52/2000470 1 52/2000456 1 52/2000456 1 52/2000457

34 INPUT RETAINING RING 1 52/2000580 1 52/2000588 1 52/2000588 1 52/2000592


36 SPACER/SHIM 1 - 1 52/2002323 1 52/2002323 1 52/2002328

37 SNAP RING 1 - 1 - 1 - 1 -

38 OIL SEAL 1 52/2000836 1 52/2000918 1 52/2000918 1 52/2000961

39 GASKET 1 52/2008798 1 52/2008798 6 52/2008798 6 52/2008798

40 PLUG 1 - 5 52/2002365 5 52/2002365 5 52/2002365

41 HIGH TEMP SILICON 1 - 1 - 1 - 1 -

42 INPUT HOUSING BOLT 6 52/2001431 6 52/2001431 6 52/2001431 6 52/2001431

43 PAM FLANGE 1 52/2502034 1 52/2521158 1 52/2521158 1 52/2502037

44 HOUSING RETAINING RING 1 52/2000588 1 52/2000588 1 52/2000590 1 52/2000590

45 SPACER/ SHIM 1 - 1 - 1 52/2002335 1 52/2002335

46 TAPER ROLLER BEARING 1 52/2000267 1 52/2000267 1 52/2006342 1 52/2006342

47 OUTPUT SHAFT KEY 1 52/2001716 1 52/2001716 1 52/2001718 1 52/2001718

48 OUTPUT SHAFT 1 52/8603739 1 52/8603739 1 52/8603711 1 52/8603711

49 LOW SPEED GEAR 1 52/2503404 1 52/2503404 1 52/2503420 1 52/2503420

50 OUTPUT SHAFT SPACER 1 52/2507873 1 52/2507873 1 52/2507917 1 52/2507917



53 KEY 1 52/2001700 1 52/2001700 1 52/2001706 1 52/2001706

54 LOW SPEED PINION 1 52/2507865 1 52/2507865 1 52/2507909 1 52/2507909


56 SPACER/SHIM 1 52/2505996 1 52/2505996 1 52/2506094 1 52/2506094

57 SNAP RING 1 52/2000582 1 52/2000582 1 52/2000585 1 52/2000585

58 SEAL PLUG 1 52/2001042 1 52/2001042 1 52/2001044 1 52/2001044

59 INSPECTION CASING COVER 1 52/2510652 1 52/2510652 1 52/2510655 1 52/2510655

60 CASING COVER SCREW 10 52/2001223 10 52/2001223 12 52/2001223 12 52/2001223

61 GEARBOX HOUSING 1 52/2513495 1 52/2513495 1 52/2513503 1 52/2513503

62 OIL SEAL 2 52/2000978 2 52/2000978 2 52/2001011 2 52/2001011



RIGHT ANGLE - DROP BEARING GEARBOX




6 SPACER - - - - - - - -

7 SHCS, M14x90 7 52/M2A0507 7 52/M2A1007 7 52/M2A2007 7 52/M2A2507

8 Lock Washer, M14 7 52/M2A0508 7 52/M2A1008 7 52/M2A2008 7 52/M2A2508

9 GREASE FITTING 1 52/M2A0509 1 52/M2A10009 1 52/M2A2009 1 52/M2A2509

10 DROP BEARING CASTING* 1 52/M2A05010-V 1 52/M2A10010-V 1 52/M2A2010-V 1 52/M2A25010-V

11 GREASE ZERK 1 52/M2A05011 1 52/M2A10011 1 52/M2A20011 1 52/M2A25011



14 BEARING, SPHERICAL ROLLER 1 52/M2A05014 1 52/M2A10014 1 52/M2A20014 1 52/M2A25014

15 O RING 1 52/M2A05015 1 52/M2A10015 1 52/M2A20015 1 52/M2A25015

16 GREASE - - - - - - - -

17 GREASE LINE 1 52/M2A05017 1 52/M2A10017 1 52/M2A20017 1 52/M2A25017

18 DROP BEARING END CAP 1 52/M2A05018 1 52/M2A10018 1 52/M2A20018 1 52/M2A25018

19 HHCS, 1/2-13 X 1 1/2 LG 8 52/M2A05019 8 52/M2A10019 8 52/M2A20019 8 52/M2A25019

20 LOCK WASHER, 1/2 8 52/M2A05020 8 52/M2A10020 8 52/M2A20020 8 52/M2A25020


22 SPIDER COUPLING 1 52/2510645 1 52/2510647 1 52/2510647 1 52/2510653

23 OIL SIGHT GLASS 1 52/2002375 1 52/2002375 1 52/2002376 1 52/2002376


25 INPUT SHAFT PLUG 1 - 1 52/2001033 1 52/2001033 1 52/2001033


27 PINION SHAFT 1 - 1 - 1 - 1 -

28 PINION SHAFT KEY 1 - 1 52/2001593 1 - 1 52/2001593



31 1ST REDUCER GEAR 1 52/2503397 1 52/2503397 1 52/2503414 1 52/2503414

32 RETAINING RING 2 52/2000618 2 52/2000618 1 52/2000621 1 52/2000621




36 SPACER/SHIM 1 - 1 52/2002323 1 52/2002323 1 52/2002328

37 SNAP RING 1 - 1 - 1 - 1 -

38 OIL SEAL 1 52/2000836 1 52/2000918 1 52/2000918 1 52/2000961

39 GASKET 1 52/2008798 1 52/2008798 6 52/2008798 6 52/2008798

40 PLUG 1 - 5 52/2002365 5 52/2002365 5 52/2002365



43 PAM FLANGE 1 52/2502034 1 52/2521158 1 52/2521158 1 52/2502037


45 SPACER/ SHIM 1 - 1 - 1 52/2002335 1 52/2002335


47 OUTPUT SHAFT KEY 1 52/2001716 1 52/2001716 1 52/2001718 1 52/2001718

48 OUTPUT SHAFT 1 52/8603739 1 52/8603739 1 52/8603711 1 52/8603711

49 LOW SPEED GEAR 1 52/2503404 1 52/2503404 1 52/2503420 1 52/2503420




53 KEY 1 52/2001700 1 52/2001700 1 52/2001706 1 52/2001706

54 LOW SPEED PINION 1 52/2507865 1 52/2507865 1 52/2507909 1 52/2507909


56 SPACER/SHIM 1 52/2505996 1 52/2505996 1 52/2506094 1 52/2506094

57 SNAP RING 1 52/2000582 1 52/2000582 1 52/2000585 1 52/2000585

58 SEAL PLUG 1 52/2001042 1 52/2001042 1 52/2001044 1 52/2001044



61 GEARBOX HOUSING 1 52/2513495 1 52/2513495 1 52/2513503 1 52/2513503

62 OIL SEAL 2 52/2000978 2 52/2000978 2 52/2001011 2 52/2001011



VERTICAL LOW PROFILE GEARBOX

19

Lo

w P

rofile

Ou

tpu

t Sh

aft

(Op

tion

) 2

0

Lo

w P

rofile

Ou

tpu

t Flan

ge

(Op

tion

)




19 Low Profile Output Shaft 1 52/LPM2A05002 1 52/LPM2A10002 1 52/LPM2A20002 1 52/LPM2A20002

20 Low Profile Output Flange 1 52/PB1230P350 1 52/PB1230P350 1 52/2502057 1 52/2502057


22 SPIDER COUPLING 1 52/2510645 1 52/2510647 1 52/2510647 1 52/2510653

23 OIL SIGHT GLASS 1 52/2002375 1 52/2002375 1 52/2002376 1 52/2002376


25 INPUT SHAFT PLUG 1 - 1 52/2001033 1 52/2001033 1 52/2001033


27 PINION SHAFT 1 - 1 - 1 - 1 -

28 PINION SHAFT KEY 1 - 1 52/2001593 1 - 1 52/2001593



31 1ST REDUCER GEAR 1 52/2503397 1 52/2503397 1 52/2503414 1 52/2503414

32 RETAINING RING 2 52/2000618 2 52/2000618 1 52/2000621 1 52/2000621




36 SPACER/SHIM 1 - 1 52/2002323 1 52/2002323 1 52/2002328

37 SNAP RING 1 - 1 - 1 - 1 -

38 OIL SEAL 1 52/2000836 1 52/2000918 1 52/2000918 1 52/2000961

39 GASKET 1 52/2008798 1 52/2008798 6 52/2008798 6 52/2008798

40 PLUG 1 - 5 52/2002365 5 52/2002365 5 52/2002365



43 PAM FLANGE 1 52/2502034 1 52/2521158 1 52/2521158 1 52/2502037


45 SPACER/ SHIM 1 - 1 - 1 52/2002335 1 52/2002335


47 OUTPUT SHAFT KEY 1 52/2001716 1 52/2001716 1 52/2001718 1 52/2001718

48 OUTPUT SHAFT 1 - 1 - 1 - 1 -

49 LOW SPEED GEAR 1 52/2503404 1 52/2503404 1 52/2503420 1 52/2503420




53 KEY 1 52/2001700 1 52/2001700 1 52/2001706 1 52/2001706

54 LOW SPEED PINION 1 52/2507865 1 52/2507865 1 52/2507909 1 52/2507909


56 SPACER/SHIM 1 52/2505996 1 52/2505996 1 52/2506094 1 52/2506094

57 SNAP RING 1 52/2000582 1 52/2000582 1 52/2000585 1 52/2000585

58 SEAL PLUG 1 52/2001042 1 52/2001042 1 52/2001044 1 52/2001044



61 GEARBOX HOUSING 1 52/2513495 1 52/2513495 1 52/2513503 1 52/2513503

62 OIL SEAL 2 52/2000978 2 52/2000978 2 52/2001011 2 52/2001011



RIGHT ANGLE - LOW PROFILE GEARBOX

19

Lo

w P

rofile

Ou

tpu

t Sh

aft

(Op

tion

)

20

Lo

w P

rofile

Ou

tpu

t Flan

ge

(Op

tion

)




19 Low Profile Output Shaft 1 52/LPM2A05002 1 52/LPM2A10002 1 52/LPM2A20002 1 52/LPM2A20002

20 Low Profile Output Flange 1 52/PB1230P350 1 52/PB1230P350 1 52/2502057 1 52/2502057


22 SPIDER COUPLING 1 52/2510645 1 52/2510647 1 52/2510647 1 52/2510653

23 OIL SIGHT GLASS 1 52/2002375 1 52/2002375 1 52/2002376 1 52/2002376


25 INPUT SHAFT PLUG 1 - 1 52/2001033 1 52/2001033 1 52/2001033


27 PINION SHAFT 1 - 1 - 1 - 1 -

28 PINION SHAFT KEY 1 - 1 52/2001593 1 - 1 52/2001593



31 1ST REDUCER GEAR 1 52/2503397 1 52/2503397 1 52/2503414 1 52/2503414

32 RETAINING RING 2 52/2000618 2 52/2000618 1 52/2000621 1 52/2000621




36 SPACER/SHIM 1 - 1 52/2002323 1 52/2002323 1 52/2002328

37 SNAP RING 1 - 1 - 1 - 1 -

38 OIL SEAL 1 52/2000836 1 52/2000918 1 52/2000918 1 52/2000961

39 GASKET 1 52/2008798 1 52/2008798 6 52/2008798 6 52/2008798

40 PLUG 1 - 5 52/2002365 5 52/2002365 5 52/2002365



43 PAM FLANGE 1 52/2502034 1 52/2521158 1 52/2521158 1 52/2502037


45 SPACER/ SHIM 1 - 1 - 1 52/2002335 1 52/2002335


47 OUTPUT SHAFT KEY 1 52/2001716 1 52/2001716 1 52/2001718 1 52/2001718

48 OUTPUT SHAFT 1 - 1 - 1 - 1 -

49 LOW SPEED GEAR 1 52/2503404 1 52/2503404 1 52/2503420 1 52/2503420




53 KEY 1 52/2001700 1 52/2001700 1 52/2001706 1 52/2001706

54 LOW SPEED PINION 1 52/2507865 1 52/2507865 1 52/2507909 1 52/2507909


56 SPACER/SHIM 1 52/2505996 1 52/2505996 1 52/2506094 1 52/2506094

57 SNAP RING 1 52/2000582 1 52/2000582 1 52/2000585 1 52/2000585

58 SEAL PLUG 1 52/2001042 1 52/2001042 1 52/2001044 1 52/2001044



61 GEARBOX HOUSING 1 52/2513495 1 52/2513495 1 52/2513503 1 52/2513503

62 OIL SEAL 2 52/2000978 2 52/2000978 2 52/2001011 2 52/2001011



9.0 Inspection and Tests

SEE ATTACHED (if applicable)

10.0 Certification(s)


11.0 Additional drawings, diagrams, etc.


12.0 Contact Information

Replacement parts for PSI SUPPLIED equipment can be ordered from Process Solutions International or any of their agents, worldwide. Please include the model number if possible. To order parts or to receive technical support via telephone, contact Process Solutions International using the information listed below.

Process Solutions International

A Division of Kelbro, Inc.

7519 Prairie Oak Drive

Houston, TX 77086

(281) 893-4774; FAX (281) 893-1027

Documents

Mud Agitator Operation, Maintenance, & Technical Manual0104.nccdn.net/1_5/318/368/021/Agitator-Manual-AM-001-Rev5.pdf · Mud Agitator Operation, Maintenance, & Technical Manual Process