ICHPSD-2015 GENERATING EQUIPMENT G.P.Patel, MD, UJVN Ltd., Dehradun Purushottam Singh, Director (Operations), UJVN Limited Pankaj Kulshreshtha, DGM (RMU), UJVN Limited Vivek Atreya, DGM (Tech.), UJVN Limited Jaipal Singh, EE (Monitoring), UJVN Limited ABSTRACT This paper describes the generating equipment of hydroelectric power plants and how they work to convert energy from water into electricity. Water flowing from the penstock is allowed to enter the power generation unit, which houses the turbine and the generator. When water falls on the blades of the turbine the kinetic and potential energy of water is converted into the rotational motion of the blades of the turbine. The rotating blades cause the shaft of the turbine to rotate thus converting the energy into mechanical form which produces alternating current in the coils of the generator. Moving water spins a turbine, the turbine spins a generator and electricity is produced with the energy already within the flowing water. Before discussing the generating equipment let us have a brief of power of water and other important parts of hydro power generating system. 1. The Power of Water When watching a river roll by, it's hard to imagine the force it's carrying. If you have ever been white-water rafting, then would have felt a small part of the river's power. White-water rapids are created as a river, carrying a large amount of water downhill, bottlenecks through a narrow passageway. As the river is forced through this opening, its flow quickens. Flood is another example of how much force a tremendous volume of water can have. Hydropower plants harness water's energy and use simple mechanics to convert that energy into electricity. Hydropower is based on simple concepts. Flowing water spins a turbine, the turbine spins a generator and electricity is produced in the generator. Many other components may be in a system, but it all begins with the energy already within the flowing water. What Makes Water Power Water power is the combination of head and flow. Both must be present to produce electricity. Water is diverted from a stream into a tunnel/power channel and is directed downhill through the turbine (flow) in a typical hydro system. The vertical drop (head) creates pressure at the bottom end of the penstock. The pressurized water emerging from the end of the penstock 548 International Conference on Hydropower for Sustainable Development Feb 05-07, 2015, Dehradun creates the force that drives the turbine. More flow or more head or both produces more electricity. Electrical power output will always be slightly less than water power input due to turbine and generator and water conductor system efficiencies. Head is water pressure, which is created by the difference in elevation between the water intake and the turbine. Head can be expressed as vertical distance (meters) or as pressure viz. kg/cm2. Net head is the pressure available at the turbine when water is flowing and will always be less than the pressure when the water is turned off (static head) due to the friction between the water and the water conductor system called penstock or valves etc. Penstock diameter has an effect on net head. Flow is water quantity, and is expressed as “volume per time,” such as gallons per minute (gpm), cubic meter per second (Cumecs), or liters per minute (lpm). Design flow is the maximum flow for which hydro machines are designed. It will likely be less than the maximum flow of stream (especially during the rainy season), more than minimum flow, and a compromise between potential electrical output and economics related. Head and flow are the two most important things about the hydro power station site. We must have these measurements before discussing a project. Power Conversion & Efficiency The generation of electricity is simply the conversion of one form of energy to another. The turbine converts the energy in the flowing water into mechanical energy at its shaft, which is then converted to electrical energy by the generator. Energy is never created; it can only be converted from one form to another. Some of the energy will be lost through friction at every point of conversion. Efficiency is the measure of how much energy is actually converted. The theoretical power (P) available from a given head of water is in exact proportion to the head and the quantity of water available. P= Q × H × e × 9.81(kW) Where P H Q e - Power at the generator terminal, in kilowatts (kW) - The gross head from the pipeline intake to the tail water in meters (m) - Flow of water, in cubic meters per second (m3/s) -The efficiency of the plant, considering head loss in the penstock/power channel/hydraulic system and the efficiency of the turbine and generator, 9.81 is a constant and is the product of the density of water and the acceleration due to gravity (g) 549 ICHPSD-2015 Net Energy = Gross Energy x Efficiency While some losses are inevitable as the energy in moving water gets converted to electricity, they can be minimized with good design. Each aspect of hydro system—from water intake to turbine-generator alignment to transmission wire size—affects efficiency. Turbine design is especially important, and must be matched to specific head and flow for best efficiency. A hydro power system is a series of interconnected components. Water flows in at one end of the system, and electricity comes out the other. Here is an overview of these components; 2. Dam/ Water Diversion (Intake) The dam is the most important component of hydroelectric power plant. The dam is built on a large river that has abundant quantity of water throughout the year. It should be built at a location where the height of the river is sufficient to get the maximum possible potential energy from water. 3. Water Reservoir The water reservoir is the place behind the dam where water is stored. The water in the reservoir is located higher than the rest of the dam structure. The height of water in the reservoir decides how much potential energy the water possesses. The higher the height of water, the more its potential energy. The high position of water in the reservoir also enables it to move downwards effortlessly. The height of water in the reservoir is higher than the natural height of water flowing in the river. This helps to increase the overall potential energy of water, which helps ultimately produce more electricity in the power generation unit. The intake is typically the highest point of hydro system where water is diverted from the stream into the tunnel/penstock/power channel that feeds the turbine. A diversion can be as simple as a screened pipe dropped into a pool of water, or as big and complex as a dam across an entire creek or river. A water diversion system serves two primary purposes. The first is to 550 International Conference on Hydropower for Sustainable Development Feb 05-07, 2015, Dehradun provide a deep enough pool of water to create a smooth, air-free inlet to pipeline. The second is to remove dirt and debris. Trash racks and rough screens can help stop larger debris, such as leaves and limbs, while an area of quiet water will allow dirt and other sediment to settle to the bottom before entering the pipeline. This helps reduce abrasive wear on the turbine. Another approach is to use a fine, self-cleaning screen that filters both large debris and small particles. 4. Intake or Control Gates These are the gates built on the inside of the dam. The water from reservoir is released and controlled through these gates. These are called inlet gates because water enters the power generation unit through these gates. When the control gates are opened the water flows due to gravity through the penstock and towards the turbines. The water flowing through the gates possesses potential as well as kinetic energy. 5. Surge Tank/Surge Shaft A surge tank is an additional storage space or reservoir fitted between the main storage reservoir and the power house (as close to the power house as possible). Surge tanks are usually provided in high or medium-head plants when there is a considerable distance between the water source and the power unit, necessitating a long penstock. Surge shaft is located at the end of tunnel. It is a well type structure of suitable height and diameter to absorb the upcoming and lowering surges in case of tripping and starting of the machine in the power house. The surge shaft is provided with gates to stop flow of water to the penstock if repairs are to be carried out in the penstock or inlet valves 6. Penstock Protection Valve The Penstock protection valves are provided after the surge shaft to facilitate maintenance of the penstocks. The valves are of butterfly type. The BF valves are operated hydraulically with provision of pressure accumulators in case of power failure. 7. The Penstock The penstock is the long pipe or the shaft that carries the water flowing from the reservoir towards the power generation unit comprising of the turbines and generator. The water in the penstock possesses kinetic energy due to its motion and potential energy due to its height. Penstocks are the water conductor conduit of suitable size connecting the surge shaft to main inlet valve. It allows water to the turbine through main inlet valve. At the end of the penstock a drainage valve is provided which drains water from penstock to the draft tube. In case of 551 ICHPSD-2015 long penstock and high head, butterfly valve is provided just before the penstock. It takes off from the surge shaft in addition to spherical valve at the end of the penstock acting as the main inlet valve. The total amount of power generated in the hydroelectric power plant depends on the height of the water reservoir and the amount of water flowing through the penstock. The amount of water flowing through the penstock is controlled by the control gates (Wicket gates). 8. Main Inlet Valves Main inlet valve works as the gate valve/isolating valve in the water conductor system. It is located before turbine and allows water flow from penstock to turbine. MIV acts as closing valve and cuts the flow of water during an emergency trip. They are of following type: • • 9. Butterfly valve (upto 200 m head) Spherical valve (more than 200m head) Generating Unit Water Turbine, Generator, Generator Transformer 9.1 Water Turbines Water flowing from the penstock is allowed to enter the power generating unit, which houses the turbine and the generator. When water falls on the blades of the turbine the kinetic and potential energy of water is converted into the rotational motion of the blades of the turbine. The rotating blades cause the shaft of the turbine to rotate. In most of the hydroelectric power plants there are more than one power generating unit. There is large difference in height between the level of turbine and level of water in the reservoir. This difference in height, also known as the head of water, decides the total amount of power that can be generated in the hydroelectric power plant. The turbine is the heart of the hydro system, where water power is converted into the rotational force that drives the generator. For maximum efficiency, the turbine should be designed to match specific head and flow. There are different types of turbines and proper selection requires considerable expertise. Turbines can be divided into two major types. • Reaction turbines use runners (the rotating portion that receives the water) that operate fully immersed in water, and are typically used in low to moderate head systems with high flow. Examples include Francis, propeller, and Kaplan. 552 International Conference on Hydropower for Sustainable Development Feb 05-07, 2015, Dehradun • Impulse turbines use runners that operate without being immersed, driven by one or more high-velocity jets of water. Pelton turbine is an example of Impulse Turbines. Impulse turbines are typically used with moderate-to-high head systems, and use nozzles to produce the high-velocity jets. Figures of Reaction and Impulse Turbines Kaplan Turbines Tubular Turbines Francis Turbines Inclined jet Turbines Tubular Turbines Pelton Turbines Each turbine type can be designed to meet vastly different requirements. The turbine system is designed around net head and design flow. These criteria not only influence which type of turbine to use, but are critical to the design of the entire turbine system. Minor differences in specifications can significantly impact energy transfer efficiency. The diameter of the runner, front and back curvatures of its buckets or blades, casting materials, nozzle (if used), turbine housing, and quality of components all affect efficiency and reliability. 9.1.1 Reaction Turbines Reaction turbine uses the pressure energy and kinetic energy of water flow, is divided into Kaplan, Propeller, Francis, Tubular (bulb turbines, pit turbines, etc.) according to the water flow movement direction inside the runner area. Its components and parts: flume (spiral casing), water distributor, runner, draft tube, shaft and bearing etc. Kaplan turbine The Kaplan turbine is an inward flow reaction turbine, which means that the working fluid changes pressure as it moves through the turbine and gives up its energy. Power is recovered 553 ICHPSD-2015 from both the hydrostatic head and the kinetic energy of the flowing water. The design combines features of radial and axial turbines. Its main parts usually include Blades, hub, main shaft, runner cone, and rotating mechanism. Kaplan turbines are now widely used throughout the world in high-flow, low-head power production. The Kaplan turbine was an evolution of the Francis turbine. Its invention allowed efficient power production in low-head applications that was not possible with Francis turbines. Application scope of heads: 10m~70m. According to whether the runner blade is movable or not in operation, it is divided into two categories: axial movable-blade type and axial fixed-blade type. The blades of axial fixed-blade turbine are fixed on runner hub is also called as Propeller Turbine. The place angle of blades cannot be changed in operation. As its efficiency curve is relatively steep, it is suitable for small load change or the station to adjust the running amount of the units in order to adapt to the load variation. It has the advantages of simple structure and low cost, while the disadvantage is that its efficiency will decline sharply when deviating from the design condition. According to its characteristics, the axial fixed-blade turbine is commonly used in the hydropower station with small output, low water head and small head variations. The axial fixed-blade turbine has larger flow capacity and the improved cavitation performance than axial movable-blade turbine, but it cannot meet the requirements of the hydropower stations whose head and load change is too big. Axial movable-blade turbine is also called Kaplan Turbine, its blades are usually operated by the oil pressure relay installed in the runner hub and can be turned according to head and load changes in order to keep the optimal coordination between the activity of the guide vane angle and the blade angle to enhance average efficiency. The maximum efficiency of this kind of turbine has been more than 94%. It has the advantages of small size and light weight, while the disadvantage is limited flow capacity when available head increases, large cavitation coefficient, complicated structure, high cost. The axial movable-blade turbine is commonly used in the large and medium-sized hydropower station where output and head vary widely. 554 International Conference on Hydropower for Sustainable Development Feb 05-07, 2015, Dehradun Francis turbine Francis turbine can be designed for a wide range of heads and flows and is the most common water turbine in use today. The Francis turbine has the characteristics of simple structure, small size, low cost, high efficiency at full capacity (typically over 92%) and stable in running, applicable to a wide range of water heads. Francis turbines generally are the most efficient solution for heads ranging from 40 to 600 meters; Runner diameters ranges from 1.0 m ~ 10.0m, Installable capacity ranges from 200 kW ~ 800000 kW. The Francis turbine is a type of reaction turbine, a category of turbine in which the working fluid comes to the turbine under immense pressure and the energy is extracted by the turbine blades from the working fluid. A Francis turbine consists of the following main parts: Spiral Casing, Guide & Stay Vanes, Runner Blades, Draft tube, etc., Wicket gates around the outside of the turbine's rotating runner adjust the water flow rate through the turbine for different water flow and power production rates. In addition to electrical production, Francis turbines may also be used for pumped storage, where a reservoir is filled by the turbine (acting as a pump) driven by the generator acting as a large electrical motor during periods of low power demand, and then reversed and used to generate power during peak demand. These pump storage reservoirs act as large energy storage sources to store "excess" electrical energy in the form of water in elevated reservoirs. This is one of only a few ways that temporary excess electrical capacity can be stored for later utilization. Main parts of Francis turbine Spiral casing: It makes the water flow to produce circular motion, guides the water flow evenly and axis symmetrically into the turbine. Top Cover& Pivot Ring: It is located in the periphery of the runner, consists of the upper and lower ring and the upright column. It is the skeleton of turbine, bears the loads of turbine pier and external parts, transmitting them to the lower foundation and supporting the movable guide vane. Stay Vane: Streamline shape to guarantee strength and stiffness. Its numbers are half of the movable guide vane. Water distributor: It adjusts the discharge of turbine and changes the output according to the load change of the Unit. It also guides the water flow into the runner as tangent direction to form speed-torque. Draft tube: The function of draft tube is to guide water flow into downstream channel and recycle part of kinetic energy and potential energy. 555 ICHPSD-2015 Tubular turbine The Tubular type turbine is usually the best choice for exploitation of tidal power and hydraulic power with extremely low heads and extremely large flow rates. This has the advantages such as large discharge, high flow speed, high efficiency and less excavation, etc. The variations are Bulb, Pit, Siphon and S types according to their structural types. The water diversion parts, runner and water drainage parts of Tubular turbine are on one axial line. The water flows directly and straightly through the runner without spiral casing. The water flow is axial from the pipe inlet to the draft tube outlet. Application scope of heads: 2m~25m, Runner diameters: 1.0m ~ 7.2m, Installable capacity: 200 kW ~ 200000 kW. Tubular turbine generally has two categories: fully tubular and half tubular. The half Tubular turbine is divided into bulb, pit and shaft extension types, etc. The generator’s rotor of the full tubular type unit is on the outer circle of turbine’s runner, whose application is less because of its difficult sealing. For half Tubular turbine, the generator is separate from the hydro turbine. 9.1.2 Impulse turbines Impulse turbine use the kinetic energy of water flow, is divided into pelton type, inclined-jet type and cross-flow type. The inclined-jet type and cross-flow type turbine only applies to small turbine. Its components and parts: spray pipe, baffle plate, runner, housing casing, shaft and bearing etc. 556 International Conference on Hydropower for Sustainable Development Feb 05-07, 2015, Dehradun Pelton turbine The Pelton type turbine is usually the preferred turbine for hydropower, when the available water source has relatively high hydraulic head at low flow rates, where the Pelton wheel is most efficient. They have the advantages such as compact structure, small size, low operation maintenance cost, low cost because of less excavation and less investments, etc. and disadvantages like inadequate energy recovery and lower efficiency than other types of turbines. Application scope of head: 80m~1200m, Runner diameter: 0.6 m ~ 3.5m, Installable capacity: 200KW ~ 20000KW. Their shaft arrangements are either vertical or horizontal and they may have single nozzle, twin or multi-nozzles. Main parts of Pelton turbine Nozzle, runner, support parts and deflector parts. Major components: rotating parts (runner, main shaft etc), nozzle parts (nozzle and related control), seat parts (seat, cover, spiral casing etc), pipeline parts (distributing pipe, brake piping, expansion joint etc), bearing parts and others. Core part is the runner and nozzle for structure. Inclined-jet turbine Inclined-jet turbine: The pressure energy of water flow is changed to velocity energy by the nozzle, since leaving the nozzle, the water flow is not in a closed system, but forms the free jet in the spiral casing filled with atmosphere, and at the same time there are 3-4 buckets receiving the free jet from the same nozzle with unequal-sized discharge. There was a fixed angle (usually take 22.5 degree) between the jet center of nozzle exit and the inlet water plane of runner. 557 ICHPSD-2015 Characteristics and application scope of Inclined-jet turbine Application scope of heads: 15m~300m, Applicable discharges: Q=0.089~8.30m3/s, Runner diameters: 0.05m ~ 5m, Installable capacity: 500KW ~ 6000KW, Types and Structures of Generators: Vertical, Horizontal; Bearing, Bearing Bush, Adjustment and governing methods: Automatic, Manual and Electric. Suitable for small hydropower stations which are of high water head and small water flow. Features: Simple structure, easy installation and maintenance, sufficient output, low noise, normal running, and reliability quality. Disadvantages: Low efficiency. 9.2 Drive System/ coupling between the turbine and generator. The drive system couples the turbine to the generator. At one end, it allows the turbine to spin at the rpm that delivers best efficiency. At the other, it drives the generator at the rpm that produces correct voltage and frequency—frequency applies to alternating current (AC) systems only. The most efficient and reliable drive system is a direct, 1:1 coupling between the turbine and generator. This is possible for many sites, but not for all head and flow combinations. In many situations, especially with AC systems, it is necessary to adjust the transfer ratio so that both turbine and generator run at their optimum (but different) speeds. These types of drive systems can use either gears, chains, or belts, each of which introduces additional efficiency losses into the system. Belt systems tend to be more popular because of their lower cost. 9.3 Generators It is in the generator where the electricity is produced. The shaft of the water turbine rotates in the generator, which produces alternating current in the coils of the generator. It is the rotation of the shaft inside the generator that produces magnetic field which is converted into electricity by electromagnetic field induction. Hence the rotation of the shaft of the turbine is crucial for the production of electricity and this is achieved by the kinetic and potential energy of water. Thus in hydroelectric power plants potential energy of water is converted into electricity. The capacity of hydro generator normally ranges from 100 kW to 800 MW and the 558 International Conference on Hydropower for Sustainable Development Feb 05-07, 2015, Dehradun range of its voltage is 0.4-13.8 kV; The insulation class includes B/F-grade. Hydropower generator is driven by hydro turbine. Types of hydro generator: According to its axis location, hydro generator is usually divided into two types: horizontal and vertical. Large and medium-sized units usually adopt the vertical type layout, whose max. speed can reach 750 rpm. While horizontal type usually is used for medium and small capacity units, whose max. speed can reach 1500 rpm. Horizontal type generators Vertical type generators As per its excitation mode, Hydro generator can be classified as brushless excitation unit and excitation with brush generator. Structure of hydro generator Hydro generator usually consists of the following major parts: Rotor, stator, frame, thrust bearings, guide bearings, cooler, brake, etc. The rotor and stator are the main parts of the generator for electromagnetic effect. Other parts are for support or subsidiary use. The rotor is the main part for transforming energy and delivering torque, which consists of the main shaft, rotor frame, magnet yoke (torus) and pole, etc.. Stator consists of base, iron core and threephase winding coil, etc.. Stator core is made of cold-rolled silicon steel, which can be made into an entirety and split structure as per the manufacturing and transportation requirements. The type of cooling for Hydro Generator usually uses closed loop air cooling (ONAN). The huge capacity unit is suitable to use water cooling to cool the stator directly. If both the rotor and stator need to be cooled at the same time, it should be dual cold water cooling inside turbine generating unit. The installation structure of the hydro generator The installation structure of the hydro generator is confirmed by the type of turbine. It mainly includes the following styles: Horizontal structure Usually, the horizontal hydro generator drives by Pelton turbine. Horizontal turbine usually uses two or three bearings. The structure of two bearings is short in 559 ICHPSD-2015 its axial length, compact structure, and easy to install. But when the combined critical speed can’t meet the requirement or the bearing load is large, three bearing structure should be used. Vertical structure The domestic hydroelectric generating units widely use vertical structure. Usually, the vertical hydro generator drives by Francis or Kaplan turbines. It also can be classified as hanging and umbrella type. It is called hanging type that thrust bearing of generator is upper on the rotor. While it is called umbrella type, its thrust bearing of generator is under the rotor. Head, Flow, & Efficiency Whether a hydro system generates a few watts or hundreds of megawatts, the fundamentals are the same. Head and flow determine how much raw water power is available, and the system efficiency affects how much electricity will come out of the other end. Each component of a hydro system affects efficiency, so it’s worthwhile to optimize the design at every step of the way. 9.4 Transformers Associated with Generating Equipments Generator Transformer Generator Transformer is employed in power plant for stepping up the voltage for transmitting the power to the grid. Electrical power is generated in the power plant at lower voltages (typically generation voltage will be between 0.4kV/6.6. kV/11kV /33kV). In order to transmit the power to long distances voltage has to step up to reduce the losses. Hence in power plants, generation transformer is employed. Rating of the generation transformers will be almost equal to the rating of the generator (11.25MW generating unit will have generating transformer rating about 12MVA). Connection between the generator transformer and power plant generator will be through isolated Phase Bus Duct (IPBD). 560 International Conference on Hydropower for Sustainable Development Feb 05-07, 2015, Dehradun Generator transformers are provided with on-load tap changing mechanism to regulate the terminal voltage. Generator transformer will be Delta (LV side) and Star (HV side) connected with star connection is connected to earth through resistor to reduce the fault currents and protecting the transformer. If Generator Circuit Breaker (GCB) is provided at the generator terminals, power from the grid can be supplied to plant auxiliary loads through generator transformer by opening the GCB when generating unit is not in operation. Some of the points about generator transformer are given below: • • • • • • • This is the main transformer of generating unit used for stepping up the voltage from generating station for the transmission In a generating plant for every generating unit one generating transformer is required Rated voltage on LV side corresponds to the rated generating voltage Rated voltage on the HV side corresponds to rated voltage of the HV bus Usually these transformers are outdoor type LV terminals are connected to the generating terminals via isolated phase bus systems HV terminals are connected to the outdoor busbar by flexible ACSR conductors via overhead flexible bus Unit auxiliary Transformer (UAT) Power plant is provided with Unit Auxiliary Transformers (UAT) connected to the generator terminals through Isolated Phase Bus Duct (IPBD). Unit Auxiliary Transformers provides electrical power to power plant distribution buses by stepping down the voltage from 11kV to 6.6kV/0.4 kV (example). Unit Auxiliary Transformers are rated based on the rating of the loads it has to supply. Onload tap changing mechanism is provided to UATs. They are usually Delta (HV side) and Star (LV side) connected transformers. The neutral of the star point is connected to earth through resistor to limit the fault current during ground faults and to protect the transformer. Some of the points associated with Unit Auxiliary Transformers are listed below: • • • • • The Purpose of Unit auxiliary Transformer is to feed power to generator auxiliaries of that unit These transformers are connected to generators and are used as stepping down transformers. The HV side transformer voltage corresponds to the voltage of the generating unit and the LV side voltage is stepped down to 6.6 kV or 0.4 kV Rated KVA of Unit Auxiliary Transformers is not more than 1% of the generating capacity of the machine These transformers may be outdoor/indoor type transformers One Unit auxiliary transformer is present normally for every generating unit. 561 ICHPSD-2015 Station Service Transformer Station Transformers are employed for supplying power to plant auxiliary loads during the event of starting of the plant or when generating unit is not generating power. Station Transformers are connected to the switchyard bus. LV side of the station transformer is connected to the auxiliary load buses. Station transformer is normally rated for supplying power to the auxiliary loads. On-load tap changing mechanism is provided to regulate the terminal voltage of the transformer. The star point of the station transformer is grounded through resistor. Some of the points related to station transformer are given below: • • • • • In general station service transformer is used for supplying power to auxiliary equipment in the power plant when the plant is not generating any power. Rated HV voltage corresponds to the rated voltage of the outer busbars Rated LV voltage corresponds to the auxiliary bus voltage Rated KVA corresponds to the load of common auxiliaries of the station. This corresponds to the 10% to 15% of the rating of the generating power. These transformers are normally outdoor type. REFERENCES • • • • • • • • • • • www.addnew.com www.brighthubengineering.com www.homepower.com www.ieeexplore.ieee.org.in www.srpnet.in www.bhel.com www.homepower.com http://www.slideshare.net/prasadvejendla/basic-terms-of-hydro-power-plant http://kiran111.hubpages.com/hub/Differenet-Transformers-in-PowerStationhttp://en.wikipedia.org www.fwee.org/nw-hydro-tours/walk...a-hydroelectric.../5-transformer UJVNL’s own experience 562
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