SEAL OIL SYSTEM TIRODA THERMAL POWER
ies OPERATION AND PROJECT 1980 MW (2x660 MW
Proven HeSr#® | MAINTENANCE MANUAL | PHASE 1+ 1*660 MW Phase)
D> pose
Project:
TIRODA THERMAL POWER PROJECT
1980 MW. (2x660 MW Phase | + 1*660 MW Phase II)
Tiroda, Gondia District, Maharashtra Ef
‘Owner:
ADANI POWER MAHARASHTRA LIMITED
x TIRODA, MAHARASHTRA
ADANI GROUP
Owner's Consultant: FICHTNER Consulting Engineers (India) Private Limited
and
BLACK & VEATCH
‘Owner's Engineer:
APML DOCNO. Revision
SEAL OIL SYSTEM OPERATION AND MAINTENANCE MANUAL
_ SSN Heras Tap
VENDOR DOC. No. TRIYQUAASORS64. Revision o
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[Document no. TRrvaoAd6oF Sea Page 1 of 25 |
Boa up‘SEAL OIL SYSTEM TIRODA THERMAL POWER
tif 25 OPERATION AND PROJECT 1980 MW (2660 MW
SIAISHA GESTS | MAINTENANCE MANUAL | PHASE 1 + 1x660 MW Phase Il)
CONTENTS
CLAUSE NO DESCRIPTION PAGE NO
1 DESCRIPTION OF THE SEAL OIL SYSTEM... sd
1.1 General. ve
1.2. Functional Description. seo
1.3. Generator Gland Seals .. 4
14 Oil Supply...... 5
1
1
Le
1
1
1
2.2 Receiving nec
2.3 Handling,
.5 Defoaming Tanks.......
6 Seal Oil Pumps.
7 Regulator Valves...
8 Pressure Equalizing Valves.....0.00somne
9 Seal Oil Coolers
10 Pressure Reducing Valve...
11 Hydrogen-Side and Air-Side Scal Oil Filters...
12 Hydrogen Side Drain Regulator
13. Seal Oil System Backup Sources.
14 Air Side DC Motor Time Starter...... 1B
13. Generator Bearing Drain Loop Seal Oil Tank 13
RECEIVING, HANDLING AND STORAGE OF THE SEAL OIL SYSTEM ssssccsscseees 14
DL General nse
4 Protection during Storage ...
3. ERECTION OF THE SEAL OIL SYSTEM waesnensnson cette 1S.
3.1 General... 15
3.2 Assembly of Seal Oil System... 1S
3.3. Hydrogen Side Drain Regulator .. 1s
| DOCUMENT NO.: TR/YQOA460F564 Page 2 of 25"SEAL OiL SYSTEM TIRODA THERMAL POWER
OPERATION AND. PROJECT 1980 MW (2x660 MW
MAINTENANCE MANUAL | PHASE | + 1x660 MW Phase II)
Hines
SANGHA! ELECTRIC
3.4 Flushing of the Seal Oil System ..... 16
4 OPERATION OF THE SEAL OIL SYSTEM ...sssnensnnnennernee peceibta
4.1 Initial Operation of Oil System.. 17
42 Adjustments While Running... 19
4.3 Normal Operation 20
4.4 Operation without Hydrogen Side Seal Oil Pump... 20
4.5 Operation with Generator Shutdown... 21
4.6 Operation of Seal Oil Pumps. we 2d
5 MAINTENANCE AND INSPECTION OF THE SEAL OIL SYSTEM... aD
5.1 General. 22
5.2 Monthly Maintenance 22
5.3. Scheduled Outage Maintenance. 2D
6 SIGNALS OF SEAL OWL SYSTEM....... 24
6.1 Defoaming Tank Level-High 0.
6.2 Seal Oil Pressure-Low 24
6.3. Air Side Seal Oil Pump-Off. nnn 24
64 Seal Oil Turbine Backup Pressure-Low ....
6.5 Hydrogen Side Level-LoW -iccssecntsneuseoes
6.6 Hydrogen Side Seal Oil Pump-Off....
6.7 Air Side Seal Oil Backup Pump-Running
6.8 Gas Side Seal Oil Backup Pump-Running ssccocseon
| DOCUMENT NO.: TRYQUA460F564 Page of 25 |ip eS OPERATION AND PROJECT 1980 MW (2660 MW
~ SEAL OIL SYSTEM TIRODA THERMAL POWER
SHANGHAI ELESTRIS | MAINTENANCE MANUAL PHASE | +1*660MWPhasell) |
1 DESCRIPTION OF THE SEAL OIL SYSTEM
1.1 General
The Seal Oil System consists of a seal oil unit, associated piping to and from the generator, and
the gland seals, which are an integral part of the generator and are located at each end of the stator
frame.
The purpose of the Seal Oil System is to:
(1) Provide sealing oil to the gland seals maintaining a constant differential pressure of seal oil to
hydrogen to prevent the escape of hydrogen gas from the generator, and control the oil
pressure equalization between air side and gas side.
(2). Provide lubrication to the gland seals to prevent seal wear.
3) Provide a means of minimizing the amount of air and moisture entering the generator.
(4) Dissipation the heat from the seal oil due to the friction between seal rings and rotor shaft,
and control the seal oil temperature in a specified limit,
(5) Filtering the seal oil through the self-clean filters, without interrupting the oil flow.
(6) Multi-backup in air side seal oil supplies ensuring the system safe operation.
(7) 2x100% oil filters and 2100% oil coolers both in air side and in gas side.
The seal oil unit is normally located on the floor beneath the generator. The unit contains the
majority of assemblies that make up the Seal Oil System.
1.2 Functional Description
The Seal Oil System is a self-contained system that supplies oil to the gland seal rings. It is
separated into an air-side seal oil supply and a hydrogen-side seal oil supply. Each of these
supplies contains a shell-and-tube type of oil cooler to maintain an acceptable oil temperature
range. Edge-type filter units in both supplies prevent contaminants in the oil from damaging the
system or the gland seal rings.
The Seal Oil System uses motor-driven, screw oil pumps to provide the necessary oil pressure.
Valves regulate the pressure oil to the
gland seal rings and between the air-side sone, eae
and hydrogen-side seal oil supplies
Pressure and temperature devices
constantly monitor the Seal Oil System sense?
while operating, counmeasenne
1.3. Generator Gland Seals
Since the rotor shaft ends of the
hydrogen cooled turbine generator must
be brought out of the gas tight enclosure,
means must be provided to prevent the
escape of gas along the shaft. Gland
seals supplied with oil under pressure
are used for this purpose. The action of
these seals is shown in Fig. 1 Generator §RS55S540400%8.,
Gland Seal
Oil is supplied to two annular grooves in
the gland seal ring, From these grooves the oil flows both ways along the shaft thru the clearance
[DocuMeNT No.: TRrvaoaasorse4 | Page 4 of 25
Hastie SEAL OIL SYSTEM TIRODA THERMAL POWER
fines OPERATION AND PROJECT 1980 MW (2x660 MW
Shey nssils | -MAINTENANCE MANUAL | _ PHASE I + 1*660 MW Phase I)
space between the shaft and the inner diameter of the gland ring. As long as the oil pressure in the
circumferential groove exceeds the gas pressure in the machine, oil will flow towards the
hydrogen (gas) side of the seal and prevent the escape of hydrogen from the generator. The
Purpose of having two feed grooves in the gland rings to provide separate hydrogen side and air
side seal oil systems, The details of this will be explained later, but it might be noted here that
when the feed pressures in these two systems are properly balanced there would be no flow of oil
in the clearance space between the two feed grooves. Oil supplied by the air side of the Seal Oil
System flows outward along the shaft toward the bearing. This prevents release of absorbed air or
moisture into the generator. Oil supplied by the hydrogen side of the system flows inward along
the shaft toward the inside of the generator, This keeps the air-side seal oil from contacting the
hydrogen and prevents escape of absorbed hydrogen to the outside atmosphere.
Because the air-side and hydrogen-side seal oil feeds are separate, high hydrogen purity is
maintained.
The gland seal ring restricts and directs the flow of oil though the seal, This ring can move
radially with the shaft, but is kept from rotating by a stop pin on the supporting structure. Oil
leaving the gland seal rings at each end of the generator is caught in chambers on each side of the
seal
The air-side seal ofl drains back into the bearing drains. This oil and the lubrication oil from the
generator bearings drain to the loop seal tank. The loop seal keeps hydrogen from getting into the
lubrication oil reservoir if hydrogen escapes past the seals, The gas is then discharged by the loop
seal vapor extractor.
14 Oil Supply
The Seal Oil System P&ID shows how a gland seal ring is supplied with oil and how two separate
oil feeds are used to seal the generator rotor shaft
The hydrogen-side seal oil is shown being supplied to the inside groove of the generator shaft seal:
after use, the oil drains into the defoaming tank. From the defoaming tanks, the oil drains to the
hydrogen-side drain regulator. ‘This drain regulator is located in the seal oil unit, The drain
regulator acts as a reservoir for the oil used in the hydrogen-side seal oil loop. If excess oil builds
up in the regulator tank, float-operated drain valve 10MKWO6AA101 opens and releases the
excess oil to the air-side oil drain. If the tank level is too low, float operated valve
10MKW06AA102 opens to allow makeup oil from the air-side pump to fill the tank to the
connect level,
Hydrogen-side oil from the drain regulator feeds the suction side of the motor-driven
hydrogen-side seal oil pump. The oil is pumped through the hydrogen-side oil cooler and oil
filter.
The air-side and hydrogen-side seal oil must be kept at the same pressure (84kPa above the
hydrogen gas pressure in the generator) to prevent any interchange of oil across the gland seal
rings. Pressure equalizing valves 10MKW36AA101 and [OMKW3SAA\101 sense the pressure at
the gland rings and adjust the hydrogen-side seal oil pressure to the seal oil pressure being
maintained at the air side of that gland seal ring holding the hydrogen-side and air-side oil
pressures equal results in a minimum interchange of oil at the gland seal ring. This causes the
hydrogen-side seal oil to flow only to the hydrogen side of the system and the air-side seal oil to
flow only to the air side, A bypass valve 1OMKW1SAA202 around the hydrogen-side pump
allows part of the total output of the pump not needed by the pressure equalizing valves to return
to the suction side of the pump.
The air-side seal oil is fed to the outer groove in the gland ring. After flowing through the gland
DOCUMENT NO.: TR/YQUA460F564 Page 5 of 25 |SEAL OIL SYSTEM TIRODA THERMAL POWER
tines OPERATION AND PROJECT 1980 MW (2660 MW
BANGIN EEESTES | MAINTENANCE MANUAL | PHASE I + 1x660 MW Phasol)
ring outer groove, this oil drains to a common drain with the bearing lubrication oil
‘The bearing oil and air-side seal oi! are returned to the loop seal tank, where oil vapors and
hydrogen gas (if present) are drawn off by the loop seal vapor extractor. The loop seal tank is the
source of oil for the air-side seal oil pump. The loop seal tank also acts as a safety feature if a
gland seal ring fails. Although unlikely, failure of a gland seal ring can result in sudden surge of
hydrogen through the drain line.
An oil-filled loop keeps hydrogen from going directly back to the reservoir. A vent to atmosphere
is provided on the upstream or inlet side of this loop. Any hydrogen flowing through the bearing
drain line is carried out of the system before enough pressure is built up to blow the oil out of the
loop seal and allow the hydrogen to reach the lubrication oil reservoir.
Some of the air-side seal oil discharge is bypassed back to the pump suction side by main
differential pressure regulator 1OMKW31AA101. The regulator keeps the air-side seal oil at
84kPa above the hydrogen gas pressure in the generator during normal operation. The air-side
seal oil passes through oil cooler and filter before being supplied to the grooves in the air-side seal
oil gland rings at both ends of the generator.
1.5 Defoaming Tanks
Oil from the hydrogen side of the gland seal rings goes to defoaming tanks. The defoaming tanks
slow the oil velocity and provide a surface arca that permits hydrogen bubbles to escape, reducing
oil foaming.
The defoaming tanks are located in the bearing brackets of the generator. Standpipe overflow
connections maintain the oil level in the defoaming tanks. There is a defoaming tank for each
gland seal and a trap in the drain Line between the two tanks. The trap keeps the difference in gas
pressure at the two ends of the generator from circulating oil vapors through the generator.
1.6 Seal Oil Pumps
The Seal Oil System contains four motor driven pumps: air-side seal oil AC pump, hydrogen-side
seal oil AC pump, air-side seal oil DC backup pump and hydrogen-side seal oil AC backup pump.
Each pump consists of three components: an electric motor, a flexible coupling, and a rotary
pump. The air-side seal oil pump and two hydrogen-side seal oil pumps use AC powered motors.
The air-side seal oil backup pump is powered by a DC motor. The motor and pump are coupled
with a flexible coupling.
The pumps are positive-displacement, rotary types with three screws. The motor drives the pump
screws and forces the oil through as the screws. The body of the pump is cast iron. The shaft is
steel and is sealed by a mechanical seal. This seal is designed to help prevent oil leaks around the
shaft
Each pump is monitored by a differential pressure switch across the discharge and suction piping,
Four pressure switches are mounted on the gauge panel and are set to alarm when an abnormal
condition occurs. The air-side and hydrogen-side seal oil pump pressure switches,
10MKW11DPO01 and 1OMKW1SDP001, tur on an alarm when the differential pressure acrose
the pump decreases to 3SkPa, indicating that the pump is off. Air-side and hydrogen-side seal oi
backup pump pressure switches, 1OMKW13DP001 and 1OMKW16DP001, tum on an alarm when
the differential pressure across the pump increases to 35KPa, indicating that the pump is
operating
High pressure seal oil backup pressure switch IOMKW1IDPOOI transfers to the non-operated
state when the pressure at the scals decreases to a limit indicating that the high pressure seal oil
backup pressure from the lube oil reservoir is low. This switch can also provide a contact input to
DOCUMENT NO.: TR/YQOA460F 564 Page 6 of 25 |
WAG}SEAL OIL SYSTEM TIRODA THERMAL POWER
OPERATION AND PROJECT 1980 MW (2x60 MW
MAINTENANCE MANUAL PHASE I + 1x660 MW Phase II)
bipes
computer.
Relief valve 1OMKW11AAS01 keeps the air-side seal oil pumps from over pressurizing the air
side lines. Relief valve 10MKWISAASOI prevents overpressure in the hydrogen-side seal oil
lines. Both valves are set to relieve at 0.8MPa.
1.7. Regulator Valves
The Seal Oil System has two differential pressure regulating valves, 1OMKW31AA101 and
10MKW32AA101. Except for how they seat, these valves are physically the same, Each valve
has double-seated poppets, flanged inlet and outlet ports, and a pressure head with an intemal
bellows, The differential pressure setting of the valve is adjusted by increasing or decreasing the
compression of the spring. The compression offsets the pressure from the sensing lines connected
to the pressure head,
A cross-sectional view of a typical regulator valve is shown in Fig 2 for main and Fig 3 for
backup. The functional description is given in the following paragraphs. ‘The valves are
functionally shown on seal oil system P & ID.
1) Main (Bypass) Differential Pressure Regulator Valve
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Fig. 2 Seal Oi Differential Pressure Regulator (main)
Main differential pressure regulator valve 10MKW31AA101 keeps air-side seal oil pressure at the
gland seal rings at 84kPa above the hydrogen ges pressure in the generator enclosure. The
pressure head of the valve has two sensing lines connected to regulate the opening and closing of
the double-seated poppets. The top connection uses the oil in the defoaming tank to sense the
hydrogen gas pressure of the generator enclosure. The bottom connection on the pressure head
monitors the air-side seal oil pressure. Adjusting the spring compression in the vaive allows the
valve to regulate the air-side seal oil pressure at 84kPa above the hydrogen gas pressure in the
generator enclosure.
If the hydrogen gas pressure in the enclosure decreases, the air-side seal oil pressure in the
sensing line overcomes the spring compression anid opens the valve. The valve opening causes a
portion of the ait-side seal oil to be retumed to the suction side of the air-side seal oil pump. This
DOCUMENT NO.: TR/YQOA460F564 Page 7 of 25
7a Buf| iy ies
| SHANGHAI ELECTRIC
OPERATION AND PROJECT 1980 MW (2*660 MW
‘SEAL OIL SYSTEM "_TIRODA THERMAL POWER
_ MAINTENANCE MANUAL PHASE I + 1x660 MW Phase I)
bypassing action reduces the air-side seal oil pressure at the gland seal rings. Since pressure
equalizing valves 1OMKW35AA101 and 10MKW36AA101 adjust the hydrogen-side seal oil
pressure fo match the air side, both seal oil flows will be reduced while maintaining the seal oil at
the gland seals at 84kPa above the hydrogen pressure,
If the hydrogen gas pressure increases, the oil in the gas sensing line acts with the spring to close
the valve. This reduces the amount of air-side seal oil bypassed back to the suction side of the
air-side seal oil pump and increases the amount provided to the gland seal rings from the
discharge of the pump, Again, pressure equalizing valves 10MKW3SAAI01 and
10MKW36AA101 act to match air-side and hydrogen-side seal oil to keep both pressures at
84kPa above the hydrogen gas pressure in the generator enclosure,
2) Turbine Backup (Feed-through) Differential Pressure Regulator Valve
Turbine backup differential pressure regulator 1OMKW32AA101 opens when the difference
between the seal oil pressure at the gland seal rings and the hydrogen gas pressure in the generator
enclosure decreases to 56kPa, and the Lubrication Oil System backup sources supply oil pressure
to the air-side seal oil
aC
Fig. 3 Seal Oil Differential Pressure Regulator (backup)
Backup regulator valve 1OMKW32AA101 also senses the air-side seal oil and the hydrogen gas
pressure in the generator. the hydrogen gas pressure is monitored by a connection to the
defoaming tank oil in the same way that main regulator valve 1OMKW31AA101 uses this oil to
sense gas pressure,
Once the generator is synchronized and the seal oil temperature has stabilized between 27 deg C
and 50 deg C, neither regulator valve should normally require any more adjustment to maintain
their set points.
1.8 Pressure Equalizing Valves
The Seal Oil System has two pressure equalizing valves 10MKW3SAA101 and
10MKW36AA101. Bach valve consists of a top and bottom sections refer Fig 4. The top section
is the valve body. The valve body has a double-seat poppet held in place on the valve stem by a
DOCUMENT NO.: TR/YQOA460F564 Page 8 of 25
oa apties OPERATION AND PROJECT 1980 MW (2660 MW
SnangalEcTsS | MAINTENANCE MANUAL PHASE I + 1x660 MW Phase II)
i Se SEAL OIL SYSTEM | TIRODA THERMAL POWER
l
set crew. The flanges are bolted in place in the hydrogen-side seal oil piping, A removable cover
provides access to the valve seats and poppets.
The bottom section of the valve controls the top section. Two threaded pressure connections on
the bottom section are provided for the
hydrogen-side and air-side seal oil sensing
lines. The botiom section of the valve is a
cylinder housing that contains a
Spring-loaded piston. The compression of
the piston spring can be adjusted by a
capped screw on the bottom of the valve.
The two pressure connections admit oil to
the bottom and top of the piston, The
air-side seal oil sensing line feeds oil to
the bottom of the piston. This pressure
forces the piston up, opening the valve. If
the pressure under the piston decreases,
the spring forces the valve closed.
In the Seal Oil System the valves maintain
equal pressure on both sides of the gland sgamomens
seal ring. Valve 1OMKW36AA101 senses Smee as
the airside and hydrogen-side seal oil
pressure across the gland seal ring at the
exciter end of the generator. Valve 1OMKW35AA101 works the same for the gland seal ring at
the turbine end.
Both valves equalize the pressure by adjusting the flow of hydrogen-side seal oil, as shown in Fig
4. When the air-side seal oil pressure increases, the valve opens to provide mote oil to the
hydrogen side until the differential pressure across the gland seal ring is brought back to zero,
When the air-side seal oil pressure decreases, the valve closes to reduce the oil to the
hydrogen-side seal oil until the differential pressure is brought back to zero. The change in
pressure on the hydrogen-side seal oil of each gland seal ring always follows the change in
pressure on the air-side seal oil.
1.9 Seal
‘The Seal Oil System contains four shell-and tube type of oil coolers designed to maintain an
acceptable temperature range (27 to 50 deg C) while the system is in operation, The oil coolers
are horizontally mounted at side of the seal oil unit. Two coolers are used in the hydrogen-side oil
piping; the other two coolers are used in the air-side of the system. Under normal operating
conditions, one of two oil coolers is used in each oil line. Each oil cooler consists of these main
items: a shell assembly, reverse and inlet water chambers, and a removable tube bundle
The stee! shell assembly contains the removable tube bundle. The inlet tube plate and reverse tube
plate of the bundle assembly close the ends of the shell. The rube plate at the inlet water chamber
end is fixed in position and sealed by a gasket. The reverse tube plate on the opposite end of the
tube bundle is a floating plate that can move horizontally within the shell. This movement
prevents damage to the cooler from thermal expansion and contraction of the tube bundle.
‘Two O-rings seal the reverse tube plate. The O-rings are seated in a retainer ring on the oil side
and water side of the shell and chamber joint. Weep holes in the center of this retainer ring will
Fig4 Pressure Equalizing Valve
Coolers
DOCUMENT NO.: TRIYQOA460F564 Page 9 of 25
Bes Hoh eeu!- SEAL Oil SYSTEM TIRODA THERMAL POWER
tines OPERATION AND PROJECT 1980 MW (2x660 MW |
“vase ésvss | MAINTENANCE MANUAL PHASE I+ 1%660MWPhasell) |
show any O-ring leakage on the oil or water side.
‘Tubes are fitted to the tube plates by inserting the tube ends through the holes in the tube plates
and expanding the tubes to form a tight seal. The tubes are designed and tested to operate at
1.0MPa on both the water side and the oil side. The maximum temperature rating of both the shell
side (oil) and tube side (water) is 95 deg C. Atno time, including any cleaning operation, should
the temperature exceed this maximum, The oil coolers reduce the oil temperature by passing oil
over the cooling water tubes in the tube bundle.
The cooling water makes two passes through each cooler. The water enters the inlet water
chamber through one of the two flanged openings on the chamber. A partition inside the inlet
water chamber directs flow down one half of the tubes. The cooling water then enters the reverse
chamber. In the reverse chamber, the water is directed back up the remaining tubes to the other
half of the inlet chamber, where it exits through the other flanged opening. Purchaser-supplied
valves are needed to regulate the cooling water flow and pressure. The inlet chambers and flanges
of coolers contain several plugged openings for chamber water drain and air venting, Both inlet
and reverse water chambers are steel.
Oil enters the coolers through flanged openings in the shell. Baffle plates inside the cooler direct
the oil flow over the cooling tubes inside the shell and lengthen the path of the oil for better heat
transfer. The oil being cooled makes one pass through the cooler.
The RTD should be mounted at inlet and outlet of cooler to monitor the oil temperature in air side
and hydrogen side seal oil lines.
Each oil cooler should have shutoff valves at the oil inlet and outlet. Bypass valves are also
provided for both air side and hydrogen side oil cooler. Bypass valves can direct the flow around
the coolers when the shutoff valves are closed.
1.10 Pressure Reducing Valve
Pressure reducing valve 1OMKW12AA101
reduces the pressure of backup seal oil coming
from the lubrication oil reservoir. The oil
pressure from the main oil pump, which
supplies this backup oil, can exceed the
0.88MPa pressure needed for the Seal Oil
System. When the turbine is operating above
two-thirds speed, the oil pressure at the inlet
side of the pressure reducing valve is about
2.1MPa. The outlet pressure of the valve is
O.88MPa.
‘The pressure reducing valve body is steel. The
seal ring, valve seats, diaphragm, and trim are
stainless steel, The valve has two sections, as
shown in Fig 5. The bottom section contains a
doubte-seated valve with guide bushings on Fig. 3 Pressure Reducing Valve
both the top and bottom sections of the stem.
The valve stem is lubricated by the oil in the valve. The top section of the valve contains a
diaphragm spring, and adjusting screw for setting the valve operating point.
DOCUMENT NO.: TRIYQOA460F564 Page 10 of 25
HARP= SEAL OIL SYSTEM TIRODA THERMAL POWER
a) Fife OPERATION AND PROJECT 1980 MW (2x60 MW
Shancnay evecrais | MAINTENANCE MANUAL PHASE I + 1x660 MW PhaselI)
A decrease in downstream pressure allows the diaphragm spring to open the valve. An increase in