2/27/24, 3:08 PM Technical Paper: API 676 compliance of progressive cavity pumps | Delta p - Pumps & Systems Blog

Technical Paper: API 676 compliance of

progressive cavity pumps
By R N - 3. August 2018

Owing to their operating principle and their roots in waste water treatment, Progressive
Cavity Pumps (PCP) come with typical deviations against petrochemical standard API 676.
Some of these deviations are inevitable, others can be healed. It is a preservative headache
and topic of discussion for project engineers to understand and identify which of these
deviations are relevant, critical or acceptable for their project.

Progressive cavity pumps are positive displacement pumps that handle fluids gently and
with minimal shear or agitation / turbulence / emulsifying. They manage fluids of highest
viscosity and highest solids content, even abrasive or large particles. They can generate
high pressure, 48 bar and more. They are suitable for high vapor pressure (low NPSH) as
well as multiphase fluids. Due to linear performance curve and low pulsation they are
suitable for dosing applications. Flow direction can be reversed simply by reversing the
motor rotation.

In the oil & gas industry PCP are often applied to convey sludge or oily water, or in
situations where light hydrocarbons raise the vapor pressure to a level where other pump
types would cavitate. A forte of PC pumps is vertical semi-submersed installation on a
drum; open/closed drain drums or flare knock-out drums are a frequent application.

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The following table compares some basic requirements of API 676 and petrochemical
applications on the one hand, and typical waste water applications on the other hand.

Feature Waste Water Treatment Petrochemical / API 676

Operating pressure max 6 bar, rarely higher 12 to 24 bar, often higher

class 150 (19 bar) or class 300

Design pressure 10 to 16 bar (DIN PN16)
(49 bar)

Flange norm EN 1092, DIN 2501 ASME B16.5

packing gland, component cartridge machanical seal

Shaft sealing
mechanical seal API 682

grey cast iron, carbon steel,

Material of 316L stainless steel, Duplex
EN and ISO standards
construction stainless steel, ASTM standards

Material traceability not required at least material certificate 3.1

Casing Drain not required flanged casing drain

Drive integral geared motor gear and motor separated

Explosion protection rarely always

Skid: welded frame with full-

Base plate simple U-beam
length drip pan and lifting lugs

Integration of
rarely often (API 682 seal plans)
accessories

Highly corrosive environment:

Corrosion protection low requirements ISO 12944 Kat. C4 (Onshore) to
C5-M (Offshore)

Let us look at the two critical issues that give rise to most discussion and customization.

Casing design

Welded constructions with their associated high effort of engineering, procedure approval,
fabrication, non-destructive examination, inspection and documentation are needed to meet
such requirements.

Fig. 1 Progressive Cavity Pump based on API 676

requirements

Shaft Seal
PCP typically have rotor joints with cardanic articulation to allow for the eccentric rotor
movement. A rotor with such joints comes with assembly restrictions that are not
compatible with installation of an API 682 mechanical seal which is bolted to the pump

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2/27/24, 3:08 PM Technical Paper: API 676 compliance of progressive cavity pumps | Delta p - Pumps & Systems Blog

casing. PCP design typically clamps the seal housing between the pump casing and a
lantern. As a result, the mechanical seal cannot be fully API 682 compliant; it can be a
heavily engineered seal in spirit of API 682 at best.
Most PCP vendors use bespoke universal cartridge seals tailored to the needs and
dimensional restrictions of the pump type.
Other deviations and exceptions are rooted in the PCP principle itself and cannot – or need
not – be avoided. Again we look at reasons and consequences:

1. First and foremost, the progressive cavity principle is based on permanent tight contact
(clamping) of a steel rotor and elastomer stator. There is no gap.

Elastomer can never be fabricated with the same precision as steel; this results in
performance tolerance exceeding the limits of API 676 (para 8.6.3) which is +3/-0% of
characteristic capacity; a PCP can typically manage +10/-5%; tolerance is even higher
for small pumps or high pressure. The only standard that correctly takes into account the
characteristics of a PCP is the ancient German VDMA 24284 which is why PCP vendors
still refer to it for test tolerance.

A consequence of the clamping contact is that the stator is a wear part, to be exchanged
at regular intervals that depend entirely on the application and are hard to predict. Non-
stop operation over three years as required by API 676 (para 6.1) is not something a PCP
can guarantee.

2. There is the eccentric kinematic of the rotor and its impact on vibration:

For a given capacity, vibration levels of a PCP are necessarily higher than other API 676
pump types based on concentric motion. A standard PCP may exceed the limit of 3.8
mm/s (para 6.11).

This low frequency vibration is inherent in the design and not a sign of trouble, thus
vibration monitoring makes little sense.

Vibration is a critical issue and limiting factor only for vertical semi-submersed PC pumps,
where the shaft can become several meters long. [ILLU long BE pump]

3. PCPs typically operate at slow speed 100 – 300 rpm, about 10-20% of a centrifugal
pump. Thus:

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There is no motive for precise alignment or balancing. PCP baseplates are typically not
designed with precision machined pads and jacking screws that facilitate alignment.

Shaft bearings are grease lubricated and typically sealed / lubricated for life. Elaborate oil
lubrication systems with associated monitoring and cooling function are not needed but
nevertheless specified by API 676 / API 614 and present in the mind of project engineers
familiar with other pump types.

It is common practice for PC pump design to omit dedicated shaft bearings altogether
and use the gearbox bearings to support the shaft – this is called “block pump” and it can
omit also the coupling.

Shaft seals do not generate much heat by friction, therefore, seal cooling is rarely needed
and standard seal plans offered by PCP vendors may minimize or omit the cooler, as a
deviation from API 682.

Finally, there are those exceptions that are related to sourcing and US standards. API
standards usually cross-reference other API standards or US manufacturing standards.

4. Gearbox and bearings

API 676 references AGMA and ABMA standards and requires gearboxes > 18 kW (25 HP)
to conform with AGMA 6010, or even API 677.

API 677 gears are generally not available for the typical power ratings and drive
configuration of PCP. Please refrain from specifying API 677; pump vendors could not
comply even if they wanted to.

Outside the Americas the AGMA and ABMA standards are not used. European gear
manufacturers will design and calculate according to DIN 3990 or ISO 6336. American
and European gear standards are not compatible because they are based on different
physical models and basic assumptions. It is also not possible for the vendor to
demonstrate that a gearbox designed to DIN/ISO is ‘equal or better’ to an AGMA design,
which is a frequent requirement of project engineers trying to circumvent the issue.
Sometimes this leads to a hot debate of almost religious dimensions without practical
result. Comparative papers by gear specialists can be found on the web. However, it is
absolutely safe to assume that a gearbox following European standards will perform just
as well.

5. IEC/IEEE

API 676 requires motors to follow IEEE 841.

However, most international projects outside the Americas prefer IEC motor standard.
IEEE 841 motors are only produced in the Americas; import by European pump vendors
raises the price and lead time.

6. Welding

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API 676 references ASME BPVC IX for welding of pressurized parts and AWS D1.1 for
structural welding.

While ASME IX is customary in Oil&Gas applications, most European workshops are

basing their fabrication on ISO standards which result in a quality level at least equal to
ASME IX. Welders may be additionally qualified to ASME IX but if you make that a firm
requirement you may raise the price tag without benefit. The economical decision is to
leave this choice to the Vendor.

Welding to AWS D1.1 is unusual in Europe and hardly available. Welding of non-pressure
or structural parts according to ISO welding standards should be allowed or tolerated.

Project engineers preparing or evaluating a bid typically spend many hours in discussion
with pump vendors to identify which of these points are relevant for the actual project,
which can be accepted to cut cost, and which are viewed critically by the client so that a
concession request becomes necessary, adding to the time.

Range of API 676 compliant pumps

To provide project engineers with smooth sailing and purchasers with favorable price and
lead time, Seepex introduced a new range of horizontal PC pumps that are designed based
on API 676 requirements – the BNA pump range (Fig. 1). Main features are:

heavy-duty cast casing with design pressure 50 bar

flanges class 300

standard flanged casing drain

high nozzle loads

full uncompromised compliance to API 682 Cat. 2 / API 610 for shaft seals

materials suitable for corrosive or harsh environment and for fluids including Chloride and
H2S

RN

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