REVISED MARCH 5, 2021

MUD AGITATOR
MAINTENANCE & OPERATION MANUAL
575-600VAC / 3PH / 60HZ

IMPORTANT:
Read these instructions before installing, operating, or servicing this equipment.
COPYRIGHT© Fluid Systems, Incorporated. Each duplication and official rendering, even in extracts
shall not be allowed unless expressively agreed in writing.
This documentation is subject to change without notice.
Fluid Systems, Inc.
18703 Intercontinental Crossing Dr.
Houston, TX 77073
USA

Sales: Phone USA 832-467-9898

International +1-832-467-9898

E-mail [email protected]

Service: Phone USA 832-467-9898

International +1-832-467-9898

E-mail [email protected]

Fax: USA 832-467-9898

International +1-832-467-9898

Internet: Home Page www.FluidSystems.com

If you are outside the US or Canada, please contact your local distributor.

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TABLE OF CONTENTENTS

1 NOTES FOR THE USE OF THIS TECHNICAL DOCUMENTATION 5

1.1 Who Should Know This Technical Documentation 5
1.2 What Should be Observed in Particular 5
1.3 How to Use This Manual 6
1.4 Equipment Identification 6
1.5 Receipt of Equipment 6
2 SAFETY REGULATIONS 7
3 GENERAL 8
3.1 Description of Equipment 8
3.2 General Arrangement Drawing 10
4 STORAGE 11
4.1 Definitions 11
4.2 Preferred Storage Conditions 11
4.3 Preparation for Storage 12
4.4 Storage Maintenance 12
5 EQUIPMENT INSTALLATION 13
5.1 Location 13
5.2 Installation Instructions 13
6 ELECTRICAL 16
6.1 Electric Motor 16
7 OPERATION 18
7.1 Start-Up 18
7.2 Standard Operating Conditions 21
8 MAINTENANCE 22
8.1 Gear Reducer 22
8.2 Troubleshooting 23
8.3 Lubrication 24
9 PREVENTIVE MAINTENANCE 26
10 SPARE PARTS 27
10.1 Electric Motor 27
10.2 Gear Reducer 27
10.3 Main Shaft & Keyless Bushing 28

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 10.4 Couplings 28
10.5 Impellers 28
10.6 Optional Equipment 29
11 WARRANTY 29

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1. NOTES FOR THE USE OF THIS TECHNICAL DOCUMENTATION

In order to improve the understanding and therefore the use of this technical documentation, we kindly ask
you to read the following pages.

Prior to use, installation or start-up, this technical documentation must be observed. Please follow the
general and local rules and regulations for the prevention of accidents.

1.1 Who Should Know This Technical Documentation

• All persons working in the operation area of the agitators must be aware of the safety regulations
of this technical documentation.
• Operators must be familiar with the operating instructions of this technical documentation.
• Qualified electricians must know the instructions for the electric connections.
• Service staff must know the maintenance and repair instructions.
• Each person working on the equipment must know the contents of this technical documentation.
• The user of this machine is obliged to instruct their staff accordingly.

1.2 What Should be Observed in Particular

Please note that this technical documentation:

• In general, should not be modified, only Fluid Systems is allowed to modify the technical
documentation.
• Must be located in an area close to the mud agitators. Missing pages or complete technical
documentations can be ordered at any time from Fluid Systems.
• Must be accessible for the operators at any time.
• Must be read and understood completely by the service staff for maintenance and repair works
before they work on the mud agitators.
• Corresponds to the technical status of the mud agitator at the time of the delivery. Any subsequent
modification must be documented properly and added to the technical documentation. This shall
also be applicable to all further sets of the technical documentation supplied along with this
equipment.

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1.3 How to Use This Manual

This Manual usually applies to the specification or equipment models listed on the cover. To ensure safe
operation, read the entire manual, including the chapter on safety instructions and warnings.

1.4 Equipment Identification

The unit’s identification number (model or part number), series, and serial number usually appear on a
nameplate attached to the gear box. In some cases, the nameplate may be attached to the mounting plate.

1.5 Receipt of Equipment

When you receive the equipment, check the contents very carefully against the invoice to make sure it is
complete and inspect the equipment for possible damage due to shipping. If there is damage, notify the
carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping
errors in writing to Fluid Systems, Inc. Shipping Department, 18703 Intercontinental Crossing Dr, Houston,
TX 77073, USA. Include all equipment identification numbers as described above along with a full
description of the parts in error.

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2. SAFETY REGULATIONS
The successful and safe operation of the equipment depends upon proper handling, installation, operation,
and maintenance. Failure to follow certain fundamental installation and maintenance requirements may
lead to personal injury, failure or loss of the machine, as well as damage to other property.

Only qualified personnel should be involved in the installation, operation and maintenance procedure. All
plant safety procedures must be observed.

A qualified person is one who is familiar with the installation, maintenance and operation of industrial
equipment, and any hazards involved. In addition, the person has the following qualifications:

• Is trained and authorized to energize, de-energize, clear, ground, and tag circuits and equipment in
accordance with established safety practices.
• Is trained in the proper care and use of protective equipment such as rubber gloves, hard hat, safety
glasses or face shields, flash clothing, etc., in accordance with established safety practices.
• Is trained in rendering first aid.

To avoid serious injury and/or equipment damage, before any adjustments, servicing,
wiring, parts replacement, or any other acts requiring physical contact with the
electrical or mechanical working components of this equipment, all equipment must
be de-energized, disconnected and isolated to prevent accidental contact with live or
rotating parts.

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3. GENERAL
Mud agitators serve an important role in the surface treatment of drilling fluids. They use an impeller that
promotes both, axial and radial flow, to assist on suspension of solids and improve mud properties. Fluid
Systems (FSI) offers two types of mud agitators, vertically mounted and horizontally mounted.

3.1 Description of Equipment

Unlike centrifugal pumps or mud guns, the mud agitators are relatively low shear and low energy devices,
making them easy to maintain and inexpensive to operate. Properly sized agitators serve three purposes:

1. Agitators ensure that mud additives are homogeneously mixed. This prevents spots 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 muds, agitators will keep the weighting agents in suspension and will
minimize tendencies for solids to settle in corners or the bottom of the tank.

Figure 3.1.1 shows the main components of the mud agitator.

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Figure 3.1.1. Main components of the FSI mud agitator.

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3.2 General Arrangement Drawing
This drawing is for reference only. Please contact Fluid Systems to get the engineering drawings for your equipment.
4. STORAGE
When moving the unit, care should be taken to protect external parts from breakage or damage due to
accidental knocks or falls.

If the unit is to be stored in a hostile atmosphere or for a long period of time (2/4 months), it is important
to apply protective and waterproofing products to avoid deterioration of shafts and rubber parts.

Before starting up the unit, carry out the following checks:

• Check the data shown on the name plate of the reduction unit and/or the electric motor.
• Check for any leaks of lubricant.
• If possible, remove any traces of dirt from the shaft and from the areas around the oil seal.
• If the oil seal is not immersed in the lubricant inside the assembly during particularly long storage
periods (4/6 months) it is recommended that it should be replaced as the rubber might stick to the
shaft or even have lost the elasticity it needs to work.

4.1 Definitions
The FSI mud agitator is considered “in storage” in any of the following situations:

• While awaiting installation after delivery.

• After installation, but prior to beginning of regular operation, if regular operation does not
begin for two (2) or more months.
• During idle periods exceeding two (2) months between cycles of regular operation.

4.2 Preferred Storage Conditions

As conditions permit, FSI mud agitators should be stored indoors in a clean, dry environment, in an ambient
not less than 41 °F (5°C) with a relative humidity not more than 60%. If the mud agitator has been stored
for longer than two years, the mud agitator should be evaluated by authorized personnel to ensure that the
grease on the motor is intact, that there is no bearing damage such as brinelling and that the ground
insulation is sound and not damaged from condensation.

NOTE: Any storage outdoors in a humid, dusty or salty atmosphere is not considered normal storage. Please
refer to the instructions below.
4.3 Preparation for Storage
Normal storage

Store the mud agitator in a level position.

Storage under poor or extreme conditions

Cover the mud agitator completely by shrink wrapping, cover with tarps to protect it from the
weather.

4.4 Storage Maintenance

If stored outdoors, check the condition of the coating, and take preventative measures if rust is evident.

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5 EQUIPMENT INSTALLATION
5.1 Location
The mud agitator is designed for Explosion Proof Class I Division 1 hazardous locations.

5.2 Installation Instructions

Particular care must be taken when installing drives, as this is often the source of damage and down time.
Careful choice of the type of drive and mounting position can often avoid the need for protection of sensitive
areas, particularly underneath the unit from oil leaks, however limited they may be.

• The gear unit must be firmly fastened in place in order to prevent any vibrations.
• Whenever possible, protect the reduction unit from direct sunlight and bad weather, especially
when it is mounted on its vertical axis.
• Make sure the air intake on the fan side is unobstructed in order to ensure that the motor is correctly
cooled.
• In the case of temperatures of < -5 °C or > +40 °C, contact Technical Assistance.
• If the motor is to be started very often under load, the use of a heat probe inserted into the motor is
recommended.
• The various machine members (pulleys, gear wheels, couplings, etc.) must be mounted on the shafts
using special threaded holes or other systems that ensure correct operation without risk of causing
damage to the bearings or the external parts of the assemblies.
• Lubricate the surfaces that come into contact in order to prevent oxidation or seizure.

Before installation of 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.

1. Locate and weld/bolt the mounting plate and stabilizer (if required) to the tank (see Fig. 5.2.1).

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 Figure 5.2.1. Bolted mounting plate on tank.

2. Place shaft in tank, and assemble impeller, bushing, and male coupling on shaft (see Fig. 3.1.1).

3. Install female coupling on gear drive shaft.

4. Install motor and gear drive assembly, and attach shaft coupling to gear drive coupling. Lift the mud
agitator only at lift points as shown in Fig. 5.2.2; 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
loads. If the mud 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

5. Connect power supply to electric motor.

6. To ensure good performance, the impeller shaft should be aligned to prevent premature wear on the gear
drive or coupling.

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Figure 5.2.2. Lifting horizontal mud agitator.

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6. ELECTRICAL
All electrical connections should be made in accordance with the Local and National Electrical Code by
qualified personnel.

Bring electric service to the agitator starter (Three phase 575VAC – 600 VAC / 3PH / 60Hz is required).

WARNING: It is the user’s responsibility to provide a fused disconnecting device in

accordance with Local and National Electrical Codes.

The service line should be equipped with a suitable and adequate main disconnecting device.

A qualified electrician should make electrical connections inside the junction box on the side of the motor.
Care should be taken to ensure the voltage and frequency of the power supply match the data on nameplate
of the reduction unit and/or the electric motor voltage and frequency. All electrical connections must be
made in accordance with the applicable national and local codes. All electrical and conduit connections
must be secured.

6.1 Electric Motor

The electrical connection should be made according to the electrical diagram (see Fig. 6.1.1).

FSI recommends U.L. approved cable gland marine shipboard sealing fittings and armored and sheathed
power cable.

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Figure 6.1.1. Wiring Diagram, 575 V @ 60 Hz (BALDOR – RELIANCE).

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7. OPERATION
7.1 Start-Up
Before start-up, it is necessary to check the oil level (see Fig. 7.1.1). 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 grease fitting and through
the grease tube down to the lower bearing.

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 (see Fig. 7.1.2).

Check for any leaks of lubricant and remove any traces of dirt from the shaft around the coupling. Check
the shaft coupling alignment and ensure all screws are secure. Check the alignment of the motor to the
gearbox and gearbox to the shaft. Also check for any unusual noise and vibration of the unit upon start up.
Remove any tools, documents, or other materials from around the equipment.

WARNING: Before starting the mud agitator, have a qualified electrician check all
connections, wiring and overload protections.

Start the machine by pressing the "START" button on the starter box.

Fluid Systems, Inc. recommends an amperage check at start-up to avoid damage to the electric motor.

CAUTION: Maintained high amperage will cause overheating and failure of the
electric motor.

If amperage continuous to be high get a qualified electrician to check power source, power cables, switches
and motor.

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Figure 7.1.1. Gear unit mounting position.

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Figure 7.1.2. Agitator impeller rotation.

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7.2 Standard Operating Conditions
During operation of the FSI mud agitator certain conditions must be met. Please be advised that failure to
adhere to the standard operation conditions listed in this section will void any warranty either implied or
express for this equipment.

• Agitators must be correctly sized based on the turnover rate (TOR). They must be large enough to
adequately mix the fluid and not so large to cause aeration of the mud.
• Avoid TOR values greater than 85 seconds, as this may will increase chances for solids settling.
• Avoid TOR values lower than 40 seconds, as this may result in formation of vortex and air
entrapment.
• Ensure that fluid or mud level is above the impeller(s). Impellers must be covered at all times during
operation.
• Stabilizers should be used when tank depth is greater than 84" (2,134 mm).
• Maintain a steady electrical power supply to the motor without exceeding the rated value as listed
on the name plate.
• Maintenance of the agitator must be scheduled and recorded as required.

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8. MAINTENANCE
The FSI mud agitators are designed for continuous duty.

Note: A preventive maintenance program should also include an inspection of the

mounting plate and fasteners for tightness.

All gear reducers are repairable. They may be returned to Fluid Systems, Inc. for repair. Replacement
bearings are available; however, field replacement is not recommended.

8.1 Gear Reducer Maintenance

The high degree of finish of the internal parts ensures that the unit will work correctly with only a minimum
amount of servicing.

Generally speaking, the following rules should be followed:

• periodically check that the exterior of the assembly is clean, especially in the cooling areas;
• periodically check to see if there are any leaks, especially in the areas around the oil seals.

Assemblies that are lubricated for life and thus do not have any oil plugs do not require any special
maintenance except as stated above.

For other assemblies, low maintenance is required with an oil change at 8/10,000 hours of use. The change
of oil naturally depends on the type of environment and use to which the unit is set.

Apart from the normal maintenance rules given above, make sure the breather hole in the plug is clean and,
using the oil window, periodically check that there is sufficient lubricant.

Should it be necessary to top up with lubricant, use the same type that is already in the reducer or one that
is compatible with it.

In case of doubtful incompatibility between lubricants, we recommend you empty out the oil from the
gearbox completely and, before refilling with new oil, wash out the unit to remove any residue.

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8.2 Troubleshooting
If any problems should arise when starting the unit or during its first few hours of operation, contact Fluid
Systems, Inc. The following guide shows a series of problems with a description of possible remedies. It
should be kept in mind however that the information given is for reference only. Please note that tampering
with the motor/gearbox assembly without prior authorization from Fluid Systems immediately invalidates
the warranty and often makes it impossible to ascertain the causes of a defect or malfunction.

Problems Causes Action / Solution

The motor does not start Problems with power supply. Check power supply.
Defective motor. Replace electric motor
Wrong size of motor
Current absorbed by the Wrong size of motor Check the application.
motor is greater than shown Replace the electric motor and, if
on the data plate necessary, the reduction unit
Temperature of the motor Defective motor. Check the application.
housing is very high Wrong size of motor. Replace the electric motor and, if
Incorrect mounting of motor necessary, the reduction unit
Temperature of the motor Wrong size of reduction unit. Check the application.
housing and reduction unit Mounting position does not Correct the working conditions:
housing are high comply with the order. mounting position and/or lubricant
Incorrect mounting of motor level
Incorrect rotation speed of the Incorrect reduction ratio. Incorrect Check reduction ratio.
main reducer unit shaft polarity of motor Check polarity of motor.
Replace reduction unit and/or
electric motor
Oil leak from oil seal Defective oil seal. Replace the oil seal.
Oil seal damaged during shipment. Repair motor shaft (if possible).
Defective motor shaft Replace the part or return the
assembly to FSI
Oil leak from joint Flat gasket or O-ring damaged Replace damaged gasket or O-ring.
Return the assembly to FSI
The main shaft rotates the Incorrect connection of the electric Swap two phases of the motor
wrong way motor supply

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Intermittent noise from the Dents in the gear wheels No practical problem if the noise
gears has no effect on the application.
Return the assembly to FSI if there
is
significant noise when loaded
No intermittent noise from Dirty inside the gearbox No practical problem if the noise
the gears has no effect on the application.
Return the assembly to FSI if there
is
significant noise when loaded
Noise (whine) from the drive Bearings incorrectly adjusted. Check correct quantity of
assembly Gears with mesh errors. lubricant.
Insufficient lubricant Return the assembly to FSI
Electric motor vibrates Measurement of the assembly Check geometric tolerance of
coupling flange on electric motor.
Check tolerance and geometry of
key on motor shaft.
Replace electric motor.

8.3 Lubrication
Table 8.3.1 lists the recommended lubricants for the FSI standard units. In cases of ambient temperatures
not envisaged in the table, call our Technical Service.

In the case of temperatures under -30°C or over 60°C it is necessary to use oil seals with special properties.

For operating ranges with temperatures under 0°C it is necessary to consider the following:

1. The motors need to be suitable for operation at the envisaged ambient temperature.
2. The power of the electric motor needs to be adequate for exceeding the higher starting torques
required.
3. In the case of reduction units with a cast-iron case, pay attention to impact loads since cast iron
may have problems of fragility at temperatures under -15°C.
4. During the early stages of service, problems of lubrication may arise due to the high level of
viscosity taken on by the oil and so it is wise to have a few minutes of rotation under no load.

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The oil needs to be changed after approximately 10,000 hours. This period depends on the type of service
and the environment where the reduction unit works.

For units supplied without oil plugs, lubrication is permanent and so they need no servicing.

Table 8.3.1 Recommended lubricants for FSI Mud Agitators.

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9. PREVENTIVE MAINTENANCE
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.
• At no time, should anyone other than a FACTORY TRAINED individual attempt any repair on the
gearing section.

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10. SPARE PARTS
Use only original spare parts from Fluid Systems, Inc. To ensure the supply of the correct spare parts, these
must be identified precisely in consultation with this manual and the spare parts list to avoid unnecessary
delays in time, incorrect deliveries and questions.

When placing the order please indicate the following:

• Mud agitator serial number. This information is engraved in the nameplate.

• Part Number (if available) in the spare parts list.
• The name of the part in the spare parts list.

10.1 Electric Motor

Part No. Description Qty

5 HP XP Electric Motor, 575/600VAC / 3Ph / 60Hz 1
7.5 HP XP Electric Motor, 575/600VAC / 3Ph / 60Hz 1
10 HP XP Electric Motor, 575/600VAC / 3Ph / 60Hz 1
15 HP XP Electric Motor, 575/600VAC / 3Ph / 60Hz 1
20 HP XP Electric Motor, 575/600VAC / 3Ph / 60Hz 1
25 HP XP Electric Motor, 575/600VAC / 3Ph / 60Hz 1
30 HP XP Electric Motor, 575/600VAC / 3Ph / 60Hz 1

10.2 Gear Reducer

Part No. Description Qty

5 HP PB103SS-FB-30.55-N180TC-2.00”-B6/B7 1
7.5 HP PB103SS-FB-30.55-N210TC-2.00”-B6/B7 1
10 HP PB123SS-FB-30.79-N210TC-2.375”-B6/B7 1
15 HP PB123SS-FB-30.79-N250TC-2.375”-B6/B7 1
20 HP PB143US-FB-30.05-N250TC-2.875”-B6/B7 1
25 HP PB143US-FB-30.05-N280TC-2.875”-B6/B7 1
30 HP PB153US-FB-30.35-N320TC-3.625”-B6/B7 1

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10.3 Main Shaft & Keyless Bushing

Part No. Description Qty

TB06082-206 2 3/8" KEYLESS BUSHING 1
TB06082-215 2 15/16" KEYLESS BUSHING 1

10.4 Couplings

Part No. Description Qty

5 HP Rigid Couplings, Bushings & Weld Hubs set 1
7.5 HP Rigid Couplings, Bushings & Weld Hubs set 1
10 HP Rigid Couplings, Bushings & Weld Hubs set 1
15 HP Rigid Couplings, Bushings & Weld Hubs set 1
20 HP Rigid Couplings, Bushings & Weld Hubs set 1
25 HP Rigid Couplings, Bushings & Weld Hubs set 1
30 HP Rigid Couplings, Bushings & Weld Hubs set 1

10.5 Impellers

Part No. Description Qty

Impeller, 20” – 22” Dia. Canted Blade 1
Impeller, 24” – 30” Dia. Canted Blade 1
Impeller, 32” – 40” Dia. Canted Blade 1
Impeller, 42” – 48” Dia. Canted Blade 1

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10.6 Optional Equipment

Part No. Description Qty

Mounting Plate 1
5 HP XP Starter, 575/600VAC / 3Ph / 60Hz 1
7.5 HP XP Starter, 575/600VAC / 3Ph / 60Hz 1
10 HP XP Starter, 575/600VAC / 3Ph / 60Hz 1
15 HP XP Starter, 575/600VAC / 3Ph / 60Hz 1
20 HP XP Starter, 575/600VAC / 3Ph / 60Hz 1
25 HP XP Starter, 575/600VAC / 3Ph / 60Hz 1
30 HP XP Starter, 575/600VAC / 3Ph / 60Hz 1
Starter Bracket 1
2 3/8" Main Shaft, Stabilizer 1
2 15/16" Main Shaft, Stabilizer 1

11. WARRANTY
Fluid Systems provides a warranty for 12 months from the date of initial start-up or 18 months from the
date of shipment, whichever occurs first provided that the customer will follow Fluid Systems storage
procedures. This warranty is on workmanship only and excludes abrasion, corrosion, or chemical attack.

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