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Dampf Kolben Engineering Corporation

Pune, Maharashtra

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Dampf Kolben presently manufacture pumps which are horizontal, single acting, reciprocating type piston pumps. These pumps are suitable especially for high pressure and low flow duties and are designed as per the latest International Standards, to suit various stringent applications. The designs are ideal for food, chemical, pharmaceutical, process and service industry.+ Read More

Nature of Business

Manufacturer

Year of Establishment

1995

High Pressure Cleaning Systems
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High Pressure Cleaning Systems find various different applications in the industry. The system essentially consists of a high pressure motor driven piston / plunger pump, low pressure suctn and high pressure discharge hose and a gun. Different types of nozzles can be used on the gun head to get various different types of jet patterns. Applications start right from simple vehicle washing to complex de-scaling of red hot steel. These systems can be either operated manually or can be automated using a Pressure switch.
  • Manually operated System :
  • Manually operated option can be considered only for objects with smaller sizes and batch quantities. In this mode, the pump needs to have a bypass connection which should be manually operated.
  • Automated System - Pressure Switch (S) :
  • Pressure switch helps in automatically stopping the pump as soon as the set pressure is achieved. It comes with an analog scale and calls for manual resetting which is cumbersome and time consuming. Hence, these types of systems are usually used when the test pressure is constant either permanently or at least for a substantial batch quantity.

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Pulley Driven Pumps
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Pulley Driven Pumps

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Pulley driven pumps offer flexibility in operating speeds. As the pump flows are directly proportional to the operating speeds, exact flow requirements can be addressed by using appropriate types and sizes of pump and prime mover pulleys. These pumps are extremely efficient being pulley driven and run almost pulsation free on account of lower operating strokes. This feature also helps in considerably reducing the noise and vibration levels. Pulley driven pumps series pumps are compact in size and offer excellent aesthetic value. Due care must be taken in selecting pulley material, type and size. Proper belt selection will ensure expected speed and torque transmission.

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Hydrostatic Test Pumps
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Hydrostatic Test Pumps

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Hydrostatic testing is the most commonly used procedure for checking the performance of pressure parts eg. vessels, cylinders, boilers, tubes etc. Hydrostatic testing is mandatory for safety of all pressure parts as it assures its strength and stability when operated under desired pressure.
The following are the benefits of hydrostatic testing:
  • Leak detection and its exact location. (Non-Destructive Method)
  • Verification of pressure vessel design, eg. Proof & Burst pressure (Destructive Method)

The testing procedure is simple and easy. Incompressible fluids like oil and water are used for this test. The vessel which is to be examined is filled with anyone of these fluids. Very commonly water is used as a medium being most inexpensive and almost incompressible.This test will confirm leakages if any along with manufacturing defects and / or enduring change in shape of the vessel. To make leak detection easier, red or fluorescent dye is sometimes added. Safety standards normally recommend pressure 

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Pipe Lines Connectors
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Pipe Lines Connectors

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Connectors are used for extending the pressurized pipe lines of the pumps. For pressures above 5 bar, these must be either machined from bar stock or forged. While using flexible pressure hoses, the connectors to be used are provided with chamfered faces at both the ends on the inner side. A semi spherical shaped component inside the nuts at the end of flexible hoses, takes a firm seat on this chamfered face to offer the expcted sealing. Remember, precisely machined connectors offer a metal to metal line contact resulting in excellent sealing even at extremely high pressures.

These are also used for mounting additional accessories like pressure gauge, pressure switch, relief valve etc. in the discharge line. These are machined out of specific grades of materials to suit the particular application. Welding procedures / setups are extremely important when applications involve pumpages with high pressures and temperatures.

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Flexible Hoses
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Flexible Hoses

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Piston / plunger pumps comparatively have higher pulsating flows. Small lengths (approx. 3-4 feet ) of flexible hoses on suctn as well as delivery side of the pumps offer a remarkable results. High pressure wire braided rubber hoses are normally used on the discharge side whereas on the suctn side, low pressure nylon braided PVC hoses are preferred.

  • Absorb line pulsations thereby reducing the vibrations in the fixed pipe lines.
  • Can be removed very easily and hence the pump maintenance becomes far more easier.
  • Offer greater flexibility in pump piping as they can easily accommodate minor dimensional variations.
  • Are light in weight and practically do not load the suctn and discharge end connections.
  • Suitable grades available for wide range of pressures / temperatures and liquids.
  • Offer excellent sealing, even at high pressures.(hydraulic crimping assures a high quality joint.)

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Breather Plug
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Breather Plug

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The churning of lube oil inside the crankcase increases its temperature during the pump operation. When the pumpage is hot, the heat is directly transferred to oil by conduction. Hot oil slowly heats up the air above its surface. This hot air expands and exerts pressure on the oil surface thereby resulting in leakage of oil through either CLO stem hole or oil seals. Thus, it is extremely important to provide a passage to the hot air directly to the atmosphere. Conventional oil cap with centre hole fail to offer this on account of eventual blockage of cap hole by dust or any other floating media from the surroundings.Breather Plug provides a zig-zag path for the air by virtue of its typical design.It is extremely difficult for the dust / floating particles to travel through this path and to clog it.This phenomenon of ensuring escape of hot air to the atmosphere and intake of fresh air (this happens when the pump is stopped.) is called as Crankcase Ventilation.

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Constant Level Oiler
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Constant Level Oiler

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The bearing care does not just end at selecting a correct lubricant. Concept of “Bearing Life” puts equal emphasis on the appropriate LEVEL of the lubricant, apart from the right viscosity and purity grades. Bearings dipped below or even above the recommended levels fail to perform on the desired life scale. Equipments like Reciprocating Pumps are most prone to oil losses as the pistons (through oil seals are provided) take away oil traces with every stroke. If the pumpage is HOT ( e.g. Boiler Feed Water ) the oil bath temperature still goes up thereby resulting in additional loss due to vaporization. International standards recommend DAILY check up of the oil level, by dip stick, where no means are provided to automatically maintain this level.  
Constant level oiler (CLO) is a simple still most reliable solution to this problem. This small, light and handy equipment automatically maintains the oil level in the Bearing Housing (or crankcase) by replenishing just the correct quantity of oil from its reservoir cup. Thus, irrespective of the oil level seen inside the cup, the level inside the Bearing Housing is maintained to predetermined perfection.

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Pressure Vessel
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Pressure Vessel

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Piston / Plunger pumps, in comparison to centrifugal pumps, deliver flows with higher pulsations. This can result in vibrations in the suctn and discharge pipelines. This can also enhance cavitation. Increase in stroke length and number of pistons / plungers increases the pulsations. To compensate this, Dampeners are used. These can also be used on the suctn side to reduce cavitaion effects.

Normally, these are vertical air filled vessels deigned to sustain the operating pressures. During the surge in the pipeline, the pumpage enters the dampener and compresses the inside air column. The air acts a cushion and forces back the pumpage when the pressure inside the pipeline reduces. Nitrogen charged dampeners are also popularly used as these are compact in size.

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Pressure Relief Valve
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Pressure Relief Valve

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These are normally spring loaded and come in various sizes. The spring tension can be adjusted which determines the relief pressure. This type of valves are used as safety valves which are expected to operate only in emergency conditions. In view of their pop-up type operation, they are not recommended for controlling the bypass flow. Relief valves should be set at around 10-15 % above the maximum operating pressure.

Unloader valves bypass the total discharge flow back to suction when the pre-decided pressure is created. This pressure value can be adjusted by tightening / loosening the spring fitted on the valve

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Pulleys And Belts
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Pulleys And Belts

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Pulleys and belts are used to transmit the power (torque and speed) from the prime mover to the pump.These are also used for reduction of prime mover speed when pump operating speeds are considerably lower than that of the prime mover.As the life of any reciprocating machine is directly proportional to the number of strokes,these equipments are run at speeds between 100-600 rpms.Low speeds are also ideal for handling hot fluids to avoid cavitation.This type of transmission mechanism offers huge flexibility as pulleys with different sizes can be easily tried out/ replaced at site.The industrial practice is to use pump pulleys of std. sizes eg. 6’’, 8’’, 10’’, 12’’, 14’’ etc.Prime mover pulleys are machined to exact requirement depending on the reduction ratio. 

Reduction Ratio = Dia of pump pulley / Dia of prime mover pulley

Net Pump Speed = Prime mover speed / Reduction ratio

Pump pulleys are usually made of Cast Iron whereas prime mover pulleys are machined out of MS bar stocks.Alluminium casted pulleys being lighter in weight are preferred for smaller pumps especially when the pulley selected has more than one groove.When the application calls for either a frequent start and stop arrangement (eg. boiler feeding in package / coil type boilers) or pump starting against a discharge pressure, the alluminium pulleys are found to quickly wear out at the key way slots.Hence,alluminium pulleys must be provided with a mild steel insert inside the boss.

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Pressure Gauge
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Pressure Gauge

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It is extremely important to have a good quality pressure gauge on any type of pump. Usually, head / pressure calculations are approximate and change drastically with changes in types and makes of piping and piping accessories like valves,belts etc. A pressure gauge mounted directly on the pump offers simplest solution of total head / pressure calculations. Many applications like feeding of a package type boiler, call for varying head / pressure requirement as the coil used in such boilers tend to offer variable pressure drop on account of scaling. Piston / Plunger pumps compared to the Centrifugal version, have higher pulsations. Constantly pulsating force on the pressure gauge movement causes fluctuations in the needle of the gauge. This affects the gauge life considerably and also offers incorrect readings. In view of this, for piston / plunger pump applications, it is highly recommended to use a Glycerine Filled pressure gauge .(remember, these are not expensive as normally believed.) A needle valve below the pressure gauge can further protect it from pulsations. (it is advisable to keep the needle valce in crack open condition. Gauge can be removed online for maintenance / replacement by closing the needle valve.)

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Directly Coupled Models

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  • Extremely easier online service. Valve assemblies can be removed/replaced without opening suction & delivery piping.
  • Greater safety. No rotating parts are exposed as there are no pulleys & belts.
  • Better efficiency being coupled directly.
  • Higher working life of essential components. Pistons are replaced by ceramic plungers. Important machined components are replaced by forged components.
  • Low noise and vibration levels. Extremely low pulsations.
  • Compact design. Consumes much lesser space.

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