O’DRILL/MCM, INC.
MUD AGITATOR
Installation,Operation
&Maintenance
Manual
O’Drill/MCM, Inc
5055 Cranswick
Houston, TX 77041
Ph: 832-782-6300, Fax: 713-460-0320
CAUTIONS AND GENERAL SAFETY
RULES
All personnel responsible for the installation, operation and
maintenance of this equipment should read the following safety
precautions to prevent injury to personnel or equipment damage
Turn off power, engage lock out, and tag out BEFORE
PERFORMING ANY MAINTENANCE TO THIS AGITATOR.
Do not perform any maintenance or service on the motor before
disconnecting the power source.
Discharge all capacitors before servicing motor.
Electrical repairs should be performed by trained and qualified
personnel only.
Serious injury could result if safe electrical procedures and
instructions are not followed.
INSPECT THE UNIT REGULARLY, AND REPLACE WORN OR
DAMAGED COMPONENTS ONLY WITH THE PARTS SUPPLIED
BY THE ORIGINAL EQUIPMENT MANUFACTURER.
Always keep hands and clothing away from moving parts.
The agitator gearbox has a designated gear ratio to maximize the
suspension of solids in solution. This gear ratio greatly increases the
torque that is transmitted to the impeller. NEVER ATTEMPT TO
STOP OR RETRIEVE ANY OBJECT THAT HAS FALLEN INTO
THE AGITATOR TANK.
Mud agitators should be locked out and tagged out before entering a
mud tank for any reason.
SECTION 1 - INTRODUCTION
A. PRINCIPLE OF MUD AGITATORS
Agitators play an important role in the surface treatment of drilling fluids. Impeller-
type mixers provide both axial and radial flow, which lowers mud costs and
improves mud properties. Impeller-type mixers are basically low-shear and low-
energy, inexpensive to operate and easy to maintain. Low-shear mixers are
used to suspend and mix mud additives minimizing particle size degradation and
polymer shear.
Mud Agitators serve three purposes:
1. Ensure mud additives are homogeneously mixed, preventing spot over
treatment of chemicals, dilution water or weighting agents.
2. Prevents the pits from “gelling” by keeping the active mud system moving
when the mud pumps are disengaged.
3. When drilling with weighted mud, properly sized agitators will keep the
weighting agents in suspension, minimizing solids from settling in corners or
dead spots of the pit.
B. DESIGN FEATURES
Design features that minimize maintenance and maximize reliability include:A
gearbox with a helical bevel gearing set that is so precisely ground that there is a
minimal amount of back lash in the gear sets, eliminating a “slamming” effect of
the gears at start up, promoting a longer life. Each helical bevel gear set is 98%
efficient. A typical worm gear set is only 85% efficient and loses most of its
efficiency through the generation of heat. Odrill/MCM’s Mud Agitator features an
ultra-tough cast iron gearbox that houses a triple-reduction helical bevel gear set,
providing one of the highest levels of efficiency available today.
MOTORS
Explosion proof motors are designed to withstand pressure washing and
exposure to corrosive fluids with no contamination. Odrill/MCM uses Nema C-
face motors that bolt directly to the gearbox housing eliminating any alignment
issues.
IMPELLERS
Axial and radial flow patterns created by the impellers provide optimal
suspension and mixing. Odrill/MCM offers a 60, 45, or a hydrofoil style impeller,
available in carbon steel and 310 series stainless.
KEYLESS SHAFT COUPLINGS
O’Drill/MCM keyless shaft couplings eliminate the need for keyways in the
agitator shaft and allow for greater impeller depth flexibility. All components
including flanges, bushings, flange screws, and bushing screws are supplied with
Dacroment anti corrosion coating (coefficient of friction = .12, so corrosion will
never be an issue.
C. SELECTING AGITATOR
To properly select the agitator’s horsepower, impeller diameter and number of
agitators required, use the information provided below.
Tank Geometry
a. Width
b. Length
c. Mud Depth
Maximum Anticipated Mud Density
a. Specific Mud Weight
b. If unknown use 20 pounds per gallon (lb/gal)
Power Requirement
a. Voltage
b. Frequency
D. LOCATING AGITATORS
A canted blade impeller creates a simultaneous radial and axial flow providing a
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. Example: 16-foot by 16-foot suction tank
would require two agitators for each 8-foot by 8-foot area. All data below is for
canted blade impellers.
E. AGITATOR SIZING
1. Calculate the volume of the sizing area using the equation
below:
V=(L) x (W) x MD) x 7.5
Where V = Volume in Gallons
L = Tank Length in Feet
W = Tank width in feet
MD = Max. Mud Depth in Feet
2. Select an impeller diameter using Table 2.2 to find an impeller that
gives a pumping rate close to the calculated
Volume V.
3. The Turnover Rate (TOR) is defined as the number of seconds
required for the impeller to pump the full mud volume within the sizing
area. TOR should be in the range of 40 to 90 seconds for all sizing
areas, with the exception of the suction tank, which is closer to 90
(less agitation) preventing aeration of mud pumps. Use the following
equation to calculate the TOR.
TOR = (V) x (60) / (PR)
Where V = Volume in Gallons
PR = Pumping Rate in GPM
Please note: The lower the TOR the more agitation, as the tank will
turn over in fewer seconds.
4. Use table 1.1 to identify the horsepower and gearbox
required for 20 ppg drilling fluids/
5. The “tank depth” is measured from the top of the structure (beams,
etc…) on which the agitator will be mounted to the bottom of the tank.
TABLE 1.1 - GEARBOX / IMPELLER SELECTION AND PUMPING RATE
IMPELLER PUMPING PUMPING Hp
Required
DIAMETER RATE 60 RATE 50 (20ppg
Gearbox
(inches) HERTZ HERTZ Mud)
20 900 750 1.2 MA-3GB
24 1600 1300 1.4 MA-3G
28 2400 1900 1.7 MA-3G
30 3000 2500 2.2 MA-5G
32 3700 3100 2.4 MA-5G
36 5400 4500 4.8 MA-7.5G
40 7200 6000 7.2 MA-10G
42 8100 7000 9.6 MA-15G
44 9900 8100 10.6 MA-20G
48 12500 10200 18 MA-25G
SECTION 2 - INSTALLATION
A. LIFTING THE AGITATOR
Lift the agitator only at the lift points. Use properly rated slings capable of
handling the weight of the equipment. The impeller should be installed after the
agitator base has been lifted into the tank, but before the base has been securely
mounted if possible. When lifting with the impeller shaft installed, make sure the
shaft couplings have been completely tightened and that the shaft is securely
attached before lifting.
B. INSTALLING THE AGITATOR
Prior to installing the agitator necessary precaution should be taken to ensure
that the structure on which the agitator will be mounted is capable of withstanding
both the static and dynamic loads that will be transferred to the tank structure.
As a rule, the shaft should be installed before lifting the unit into place. Some
conditions, such as limited headroom above may require that the shaft be
installed after the unit has been lifted in place.
Lift the unit where indicated and place in position on the mud tank using blocks to
provide at least 12 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. 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 ¾ of the impeller diameter. Example, if the
impeller diameter is 36, then the distance from the bottom of the tank should be
27 inches 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, 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.
C. WEIGHT AND DIMENSIONAL DATA
Weight and dimension Data for all eight models of the Agitator is given in Figure
2.1. Note, that impeller diameters and shaft lengths will vary depending on the
volume of the mud tank and the maximum mud density, per section 1.E Agitator
Sizing.
Note that certified drawings, if requested or required provided with the equipment
will take precedence over any information in this manual.
TABLE 2.1 -
AGITATOR
WEIGHTS (lbs)
MOTOR SHAFT GEARBOX/
IMPELLER SHAFT
MODEL NO HP WT. COUPLINGS/
(dia/wt) DIA.
WT (lbs/ft) BASE
24''
OD-03-MAG 111 12.8 2-3/16 223
50
28"
OD-05-MAG 126 12.8 2-3/16 223
53
32"
OD-7.5-MAG 170 12.8 2-3/16 243
64
36"
OD-10-MAG 232 23 2-15/16 277
60
40"
OD-15-MAG 333 23 2-15/16 427
67
44"
OD-20-MAG 356 23 2-15/16 451
72
48"
OD-25-MAG 516 23 2-15/16 614
77
D. 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 explosion proof 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.
E. CHECKING MOTOR ROTATION
BEFORE STARTING OR EVEN “BUMPING” THE MOTOR, MAKE
SURE THAT THE GEARBOX IS FILLED WITH THE PROPER OIL.
The proper direction of rotation for all O’Drill/MCM’s Agitators is clockwise when
viewed from above. The electrical installation is not complete until the motor
rotation has been checked. Reversing any two legs on a three phase motor will
reverse direction of rotation if necessary.
F. START - UP
1. Ensure that switches, alarms, heaters, coolers and other safety and
protection devices are installed and operational for their intended
purposes.
2. Verify that the installed mounting position is the same as the nametag
mounting position. If not, adjust the oil level accordingly and relocate the
vent plug, fill plug and drain plug according to the mounting position. See
following.
AUTOVENT PLUG
The autovent plug is brass in color and will be located at the highest point on the
gearbox. It operates like a check-valve to allow the reducer to relieve internal
pressure while preventing lubricant contamination during cooling. A spring
presses a ball or plunger against a machined orifice until pressure exceeds 2 psi.
Above 2 psi the air is allowed to escape depressurizing the gearcase. When
internal pressure drops below 2 psi, the autovent re-seals closing the unit to the
outside environment. After shutdown, the reducer cools along with the air inside
the reducer. The unit will temporarily maintain a slight vacuum until
normalization occurs. The autovent is a standard feature for all O’Drill Agitators.
FILL LEVEL AND DRAIN PLUGS
The drain plugs are metric socket head cap screws. They will be located at the
lowest part of the gearbox for ease of draining. The fill level plug is a hex head
cap screw. It will be located between the Autovent and drain plug. Both types of
plugs will have gaskets to prevent oil from leaking.
G. CHECKING OIL LEVEL
All gearboxes are shipped from the factory properly filled with lubricant and all
plugs are installed according to the mounting position given on the nametag.
Acceptable oil fill level is within ½ inch of the bottom of the fill plug threads.
SECTION 3 – OPERATION
A. STARTING THE AGITATOR
Prior to proceeding, Make sure that the coupling from the input adaptor and the
motor are securely engaged. Once installation is complete and proper lubrication
levels have been confirmed, press the start button on the motor starter to start
the unit. (Note that motor starters are not supplied with agitators and need to be
ordered separately) Good practice dictates that all rotating equipment be
checked for any unusual noise or vibration upon startup.
B. OPERATION
Agitators will consume more horsepower as mud weight increases with no
adjustments required to compensate for changes in drilling conditions. During
drilling operations, mud agitators are kept running at all times.
Aeration of the Suction Tank To prevent air in the suction tank that can cause
mud pump problems, adjusting the height of the impellers or temporarily
increasing mud volume will usually solve the problem.
C. SAFETY
The agitator gearbox has a designated gear ratio to maximize the suspension of
solids in solution. This gear ratio greatly increases the torque that is transmitted
to 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. NEVER
ATTEMPT TO STOP OR RETRIEVE ANY OBJECT THAT HAS FALLEN INTO
THE AGITATOR TANK. DOING SO CAN RESULT IN A POTENTIALLY LIFE
THREATENING SITUATION FOR THE PERON ATTEMPTING TO REMOVE
THE OBJECT FROM THE TANK.
D. OPERATION AND MAINTENANCE CHECKLIST
1. Operate the equipment as it was intended to be operated.
2. Do not overload.
3. Run at correct speed
4. Maintain lubricant in good condition and at proper level.
5. Dispose of used lubricant in accordance with applicable laws and
regulations.
6. Apply proper maintenance to attached equipment at prescribed intervals
recommended by the manufacturer.
Perform periodic maintenance of the gear drive as recommended.
SECTION 4 - MAINTENANCE
A. MAINTENANCE
The only regularly scheduled maintenance needed for the O’Drill/MCM Agitator is
a weekly check of oil level and an oil change every 3 months. All O’Drill/MCM
Agitators have vent plug, fill plug, and drain plug
STANDARD OIL – ISO VG220
Origin of
Oil
Gearbox
Manufacturer
Ambient Temperature Formulation Oil Brand Name Assembly
20 to 104 F (-5 to 40 C) Mineral Texaco Meropa 220 NORD USA
20 to 104 F (-5 to 40 C) Mineral Shell Omala EP 220 NORD Canada
OPTIONAL LUBRICANTS
Origin of
Oil Gearbox
Ambient Temperature Formulation Manufacturer Oil Brand Name Assembly
14 to 176 F (-10 to 80c) Synthetic Texaco Pinnacle EP 680 NORD USA
14 to 176 F (-10 to 80c) Synthetic Shell Omala HD 2680 NORD Canada
-35 to 140 F (-25 to 60c) Synthetic Texaco Pinnacle EP 220 NORD USA
-35 to 140 F (-25 to 60c) Synthetic Shell Omala HD 220 NORD Canada
-40 to 50 F (-40 to 10c) Synthetic Texaco Pinnacle EP 32 NORD USA
-20 to 104 F (-5 to 40c) Synthetic Shell Omala HD 32 NORD Canada
-40 to 50 F (-40 to 10c) Food Grade Chevron FM ISO 220 NORD USA
-40 to 50 F (-40 to 10c) Synthetic Food Grade OilJAX Magnaplate 85W140-FG NORD Canada
5 to 125 F (-20 to 50c) Fluid Grease Mobile Mobilux EP023 NORD USA
-30 to 140 F (-35 to 60c) Synthetic Fluid Grease Mobile Mobilux SHC 007 NORD USA
30 to 140 F (-35to 60c) Synthetic Fluid Grease Shell Tivela compound A NORD Canada
STANDARD BEARING – NLGI-2EP lithium
Oil Origin of Gearbox
Ambient Temperature Formulation Manufacturer Oil Brand Name Assembly
‘-20 to 140 F (-30 to 60 C) Mineral Texaco Multifak 220 NORD USA
‘-20 to 140 F (-30 to 60 C) Mineral Texaco Cypermia RA/C3 NORD Canada
OPTIONAL BEARING GRASE
Oil Origin of Gearbox
Ambient Temperature Formulation Manufacturer Oil Brand Name Assembly
‘-58 to 230 F (-50 to 110 C) Synthetic Texaco Starfak 2202 NORD USA
‘-20 to 140 F (-30 to 60 C) Food Grade Lubriplate SIF 1 NORD USA
SECTION 5 – TROUBLESHOOTING
TROUBLESHOOTING GUIDE
Problem Cause Solution
Motor Will Not Start Power Problem Check electrical supply
Defective Motor Replace motor
Wrong or bad heaters/coil Check heaters/starter
Motor Stops Running Starter tripped Reset starter
Burned out starter Replace heater
Over- amped Check amp draw
Tripped Starter Bad heaters Replace starters
Over amped Check amp draw
Agitator undersized Replace agitator
Whining Noise Check motor bearings Replace motor
Random Noise
(Gearbox) Contamination in oil Drain and replace oil
Vibration Assembly loose Tighten all bolts
Broken weld (base to tank) Re-weld base to tank
SECTION 6 – SPARE PARTS
ONE-YEAR RECOMMENDED SPARE PARTS
SPARE PARTS FOR 3HP (180TC2) INPUT
ADAPTER
PART NUMBER DESCRIPTION QTY
24630820 INPUT ADAPTER BALL BEARING 1
27205500 SNAP RING 1
24621140 INPUT ADAPTER BALL BEARING 1
27310000 SNAP RING 1
51483380 BOWEX COUPLING (M38) 1-3/8" HUB 1
51483400 BOWEX COUPLING (M38) SLEEVE 1
SPARE PARTS FOR 3HP (SK9032) GEARBOX
PART NUMBER DESCRIPTION QTY
25070020 OIL SEAL, DOUBLE LIP 2
25070070 OIL SEAL, SINGLE LIP 2
22012005 AUTO VENT 1
SPARE PARTS FOR 5HP (180TC2) INPUT
ADAPTER
PART NUMBER DESCRIPTION QTY
24630820 INPUT ADAPTER BALL BEARING 1
27205500 SNAP RING 1
24621140 INPUT ADAPTER BALL BEARING 1
27310000 SNAP RING 1
51483380 BOWEX COUPLING (M38) 1-3/8" HUB 1
51483400 BOWEX COUPLING (M38) SLEEVE 1
SPARE PARTS FOR 3HP (SK9032) GEARBOX
PART NUMBER DESCRIPTION QTY
25070020 OIL SEAL, DOUBLE LIP 2
25070070 OIL SEAL, SINGLE LIP 2
22012005 AUTO VENT 1
SPARE PARTS FOR 7.5HP (210TC) INPUT
ADAPTER
PART NUMBER DESCRIPTION QTY
24630810 INPUT ADAPTER BALL BEARING 1
27205500 SNAP RING 1
24621140 INPUT ADAPTER BALL BEARING 1
27310000 SNAP RING 1
51483380 BOWEX COUPLING (M38) 1-3/8" HUB 1
51483400 BOWEX COUPLING (M38) SLEEVE 1
SPARE PARTS FOR 7.5HP (SK9032) GEARBOX
PART NUMBER DESCRIPTION QTY
25070020 OIL SEAL, DOUBLE LIP 2
25070070 OIL SEAL, SINGLE LIP 2
22012005 AUTO VENT 1
SPARE PARTS FOR 10HP (210TC) INPUT
ADAPTER
PART NUMBER DESCRIPTION QTY
24631010 INPUT ADAPTER BALL BEARING 1
27205500 SNAP RING 1
24631140 INPUT ADAPTER BALL BEARING 1
27312000 SNAP RING 1
51483390 BOWEX COUPLING (M38) 1-3/8" HUB 1
51483400 BOWEX COUPLING (M38) SLEEVE 1
SPARE PARTS FOR 10HP (SK9042) GEARBOX
PART NUMBER DESCRIPTION QTY
25080120 OIL SEAL, DOUBLE LIP 2
25080110 OIL SEAL, SINGLE LIP 2
22012005 AUTO VENT 1
SECTION 6 – SPARE PARTS
ONE-YEAR RECOMMENDED SPARE PARTS
SPARE PARTS FOR 15 (250TC) INPUT
ADAPTER
PART NUMBER DESCRIPTION QTY
25055100 INPUT ADAPTER OIL SEAL 1
24631110 INPUT ADAPTER BALL BEARING 1
27206000 SNAP RING 1
24631240 INPUT ADAPTER BALL BEARING 1
27313000 SNAP RING 1
52683390 BOWEX COUPLING HUB (M42) 1-5/8" HUB 1
51483370 BOWEX COUPLING SLEEVE (M42) SLEEVE 1
SPARE PARTS FOR 15HP (SK9042) GEARBOX
PART NUMBER DESCRIPTION QTY
25080120 OIL SEAL, DOUBLE LIP 2
25080110 OIL SEAL, SINGLE LIP 2
22012005 AUTO VENT 1
SPARE PARTS FOR 20HP/STD DUTY (250TC)
INPUT ADAPTER
PART NUMBER DESCRIPTION QTY
25055100 INPUT ADAPTER OIL SEAL 1
24631110 INPUT ADAPTER BALL BEARING 1
27206000 SNAP RING 1
24631240 INPUT ADAPTER BALL BEARING 1
27313000 SNAP RING 1
52683390 BOWEX COUPLING HUB (M42) 1-5/8" HUB 1
51483370 BOWEX COUPLING SLEEVE (M42) SLEEVE 1
SPARE PARTS FOR 20HP (SK9042) GEARBOX
PART NUMBER DESCRIPTION QTY
25080120 OIL SEAL, DOUBLE LIP 2
25080110 OIL SEAL, SINGLE LIP 2
22012005 AUTO VENT 1
SECTION 6 – SPARE PARTS
ONE-YEAR RECOMMENDED SPARE PARTS
SPARE PARTS FOR 20HP (250TC) INPUT
ADAPTER
PART NUMBER DESCRIPTION QTY
25055100 INPUT ADAPTER OIL SEAL 1
24631110 INPUT ADAPTER BALL BEARING 1
27206000 SNAP RING 1
24631240 INPUT ADAPTER BALL BEARING 1
27313000 SNAP RING 1
52683390 BOWEX COUPLING HUB (M42) 1-5/8" HUB 1
51483370 BOWEX COUPLING SLEEVE (M42) SLEEVE 1
SPARE PARTS FOR 20HP (SK9052) GEARBOX
PART NUMBER DESCRIPTION QTY
25100060 OIL SEAL, DOUBLE LIP 2
25100050 OIL SEAL, SINGLE LIP 2
22012005 VENT BREATHER 1
SPARE PARTS FOR 25HP (280TC) INPUT
ADAPTER
PART NUMBER DESCRIPTION QTY
25055100 INPUT ADAPTER OIL SEAL 1
24631110 INPUT ADAPTER BALL BEARING 1
27206000 SNAP RING 1
24631240 INPUT ADAPTER BALL BEARING 1
27313000 SNAP RING 1
52683390 BOWEX COUPLING HUB (M42) 1-5/8" HUB 1
51483370 BOWEX COUPLING SLEEVE (M42) SLEEVE 1
SPARE PARTS FOR 25HP (SK9052) GEARBOX
PART NUMBER DESCRIPTION QTY
25100060 OIL SEAL, DOUBLE LIP 2
25100050 OIL SEAL, SINGLE LIP 2
22012005 VENT BREATHER 1
SECTION 6 – SPARE PARTS
A. ORDERING PARTS
Replacement parts for Agitators are available through O’Drill/MCM or its agents
worldwide. The above part lists provide part numbers facilitating simpler
ordering.
O’Drill/MCM carries a full complement of replacement parts for immediate
shipment.
B. FIELD SERVICE
O’Drill/MCM has skilled field service personnel available around the clock. To
request that a specialist visit your location, please contact O’Drill/MCM.
C. CONTACT INFORMATION
To order parts, schedule field services or request additional information, please
contact:
O’Drill/MCM, Inc.
5055 Cranswick
Houston, TX 77041
Phone: 832-782-6300
Fax: 713-460-0320
Toll Free: 1-800-255-6263
Online: http://www.odrillmcm.com
