Relationship between torque and density in agitator

An agitator is essentially a centrifugal load. This means that the power-to-speed ratio is
typically a square function. In most agitators, the actual relationship between torque and
density is:

(Shaft Power) * (Fluid density) * (Shaft speed)^2 * (Impeller diameter)^5

Torque = --------------------------------------------------------------------------------------------------------(2 * pi)
So ... as the density increases by 15 percent, the required torque will also increase by 15
percent. Which, given the formula above, means the shaft power will also increase by 15
percent - and require at least 15 percent higher current (since the efficiency and power
factor go down as loading increases above 100 percent of nameplate rating due to
thermal effects).
It sounds to me like someone on the agitator side didn't do their homework on the fluid
properties - or didn't choose the correct diameter impeller for the agitator. On the motor
side, if the machine is running slightly fast (i.e. lower-than-expected cage resistance in
the rotor, for example) the power draw - and, consequently, the current draw - will also be
higher than expected.
As far as being able to operate continuously in the above-unity service factor region:
machines are rated in one of two ways. Most often, the rating is specified as an alowable
rise at 1.0 service factor, with non-injurious heating at the above-unity condition. Other
instances have a slightly higher allowable rise at the continuous overload condition,
which automatically means the machine will have lesser rise at unity service factor.
A class B rise according to NEMA MG 1 corresponds to an 80 C rise above ambient at
unity - or a 90 C rise at continuous overload. Note that only only one of the two can be
actually specified! This is because temperatures are more or less related to the square of
the current. Therefore as the current increases (by 15 percent), the heat generated will
increase by (1.15^2) = 1.323 or approximately 30-32 percent. For a machine already
operating at the allowable temperature rise (say 80 C over ambient), this would mean an
increase in operating temperature of roughly 25 C. This would put the machine well past
the maximum allowable temperature for class B and into the class F operating range.
Having the higher class H insulation in the machine is helpful, certainly. But it is not the
real solution. It just means the machine will last a little longer, as the thermal degradation
of the insulation proceeds over the life of the equipment. A far better solution is to get the
right size equipment (from the original equation above), and install it - whether that is the

motor or the impeller or both.

Regardless whether the choice is to "get it right" or just "run the machine into the
ground", the relay will need to change to a higher current rating.