Bharat Heavy Electricals Limited, Tiruchirapalli
PowerPowerPowerPower----Gen India, 2012Gen India, 2012Gen India, 2012Gen India, 2012 BHEL’s Role in Cleaner Environment
Bharat Heavy Electricals Limited, Tiruchirapalli
PowerPowerPowerPower----Gen India, 2012Gen India, 2012Gen India, 2012Gen India, 2012 BHEL’s Role in Cleaner Environment
Contents
BHEL Steam Generators
Design Features of Supercritical Once Thro’ Boilers
• Major Systems
• Startup System
• Pressure part Arrangement
• Firing System
• High Temperature Materials
Major Differences between Supercritical and Subcritical Boilers
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BHEL Utility Units - A SummaryUnit Rating, MW
No. MW No. MW
30 4 120 4 120
60 16 960 16 960
67.5 9 607.5 8 540
70 14 980 9 630
80 14 1120 3 240
100 6 600 6 600
110 39 4290 39 4290
120 31 3720 27 3240
125 7 875 1 125
130 2 260 2 260
150 17 2550 0 0
200 24 4800 20 4000
210 116 24360 114 23940
250 58 14500 34 8500
270 34 9180 0 0
300 1 300 0 0
500 82 41000 54 27000
525 6 3150 2 1050
600 22 13200 0 0
660 12 7920 0 0
700 1 700 0 0
800 4 3200 0 0
TOTAL 519 138393 339 75495
Contracted Commissioned
62 % Total
Installed
Capacity of
India is
Contributed by
BHEL Utility
Sets
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Unit Contracted Commissioned
VU 40 46 45
VU 40 S 15 15
VU 60 38 19
MU 3 3
VP 23 16
V2R 17 17
HRSG 177 121
AFBC 72 59
CFBC 28 10
Others 28 28
Total 447 333
BHEL Industrial Units - A Summary
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After supplying more than 950 boilers,
BHEL is currently adopting
Advanced Steam Cycles to Improve the
Environmental & Economic Performance of
India’s Power Generation
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Once Through Supercritical Technology for
Higher Unit Ratings 660 MW to 1000 MW
BHEL under license from Alstom offers Once through supercritical
technology to Indian power utilities with the following benefits
�Increased efficiency
�Lower Fuel consumption
�Lower emission levels of CO2 NOX SOX
�Lower operating costs
�Greater operational flexibility
These benefits are possible because of the higher steam pressures
and temperatures which are the hallmark of the technology
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Reference List of Supercritical Boilers
NTPC / BARH 2 x 660MW
APPDCL / Krishnapatnam 2 x 800 MW
PPGCL / BARA 3 x 660 MW
RPCL / Yermaras 2 x 800 MW
RPCL / Edlapur 1 x 800 MW
KPCL / Bellary 1 x 700 MW
LPGCL/Lalithpur- BHL 3 x 660 MW
DB Power / Singrauli 2 x 660 MW
NTPC / Mouda St. II 2 x 660 MW
18 Boilers
Contracted
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Design Features of 660 MW
Supercritical Boilers for
Indian Coal Fired Power Stations
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Salient Features of Boiler
Pulverised coal fired
Once through, evaporator suitable for
variable pressure operation
Single reheat
Tilting Tangential firing System
Dry Bottom
Balanced draft furnace
Side mill layout
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Dry Bottom
Balanced draft furnace
High performance Bowl Mills
Two Nos. of Axial FD Fans
Two Nos. of Axial PA Fans
Two Nos. of Axial ID Fans
ESP to meet reqd. outlet concentration
Salient Features of Boiler (Contd.)
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Boiler Parameters
Description Unit 660 MW (Supercritical)
500 MW
(Sub critical)
Boiler Parameters - BMCR BMCR
SH steam flow t/h 2120 1625
SHO pressure kg/cm2(a) 256 179
SHO/RHO temp. oC 568/596 540/540
Feed water temp. oC 294 254
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Description
(Source/Type)Unit Design Coal Worst Coal Best Coal
Proximate Analysis
Fixed Carbon % 26.00 23.00 32.00
Volatile matter % 19.00 18.00 22.00
Moisture % 15.00 17.00 12.00
Ash % 40.00 42.00 34.00
Total % 100 100 100
HHV kcal/kg 3300 2800 4000
Ultimate Analysis
Carbon % 31.37 28.93 40.08
Hydrogen % 3.40 2.40 3.50
Sulphur % 0.40 0.5 0.36
Nitrogen % 1.5 1.45 1.78
Oxygen(difference) % 7.75 7.26 8.03
Moisture % 15.0 17.0 12.0
Ash % 40.0 42.0 34.0
Carbonates + Phosphorous % 0.58 0.46 0.25
Hard Grove Index 55 50 60
Fuel Analysis - Coal
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General Arrangement of Steam Generator – Elevation
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General Arrangement of Steam Generator – Plan
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Plan Area Loading kCal/h/m2 4.75x106
EPRS Loading kCal/h/m2 190,000
Volumetric Loading kCal/h/m2 106,920
Furnace Heat Loadings
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NTPC / BARH 2 x 660 MW
CoalFuel
568 / 596 oC Temperature
255/54.65 kg/cm2 (g)Pressure
2120/1708.2 t/h.Steam Flow
Customer scopeDust Collector
2 Nos. Axial ReactionID Fan
2 Nos. Axial ReactionPA Fan
2 Nos. Axial ReactionFD Fan
4 Nos. Airheater
9 Nos. Bowl MillMill
Major Auxiliaries
Parameters at SHO / RHO
BARH II – 2 x 660 MWProject
National Thermal Power CorporationCustomer
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Customer Prayagraj Power Generation Company Limited
Project PRAYAGRAJ STPP, PHASE-I, 3x660 MW, BARA
Parameters at SHO / RHO
Steam Flow 2095.4/1706.9 t/h.
Pressure 255/54.33 kg/cm2 (g)
Temperature 568 / 596 oC
Fuel Coal
Major Auxiliaries
Mill 7 Nos. Bowl Mill
Airheater 2 Nos. Tri-Sector AHs
FD Fan 2 Nos. Axial Reaction
PA Fan 2 Nos. Axial Reaction
ID Fan 2 Nos. Axial Reaction
Dust Collector Customer Scope
PPGCL / PRAYAGRAJ STPP, 3x660 MW, BARA
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DB POWER (MP) LIMITED / Gorgi DBP - 2 x 660 MW
Customer DB POWER (Madhya Pradesh) Ltd.
ProjectGorgi DBP(MP)L 2x660 MW STPP, DEOSAR,
Singrauli
Parameters at SHO / RHO
Steam Flow 2120.0/1696.1 t/h.
Pressure 255/53.91 kg/cm2 (g)
Temperature 568 / 596 oC
Fuel Coal
Major Auxiliaries
Mill 8 Nos. Bowl Mill
Airheater 2 Nos. Tri-Sector AHs
FD Fan 2 Nos. Axial Reaction
PA Fan 2 Nos. Axial Reaction
ID Fan 2 Nos. Axial Reaction
Dust Collector 4 Nos
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CustomerLalitpur Power Generation Company
Limited
Project Lalitpur Super Critical TPP, 3x660 MW
Parameters at SHO / RHO
Steam Flow 2110/1697.8 t/h.
Pressure 255/53.98 kg/cm2 (g)
Temperature 568 / 596 oC
Fuel Coal
Major Auxiliaries
Mill 8 Nos. Bowl Mill
Airheater 2 Nos. Tri-Sector AHs
FD Fan 2 Nos. Axial Reaction
PA Fan 2 Nos. Axial Reaction
ID Fan 2 Nos. Axial Reaction
Dust Collector 4 Nos.
LPGCL / LALITPUR SUPERCRITICAL TPP, 3 x 660 MW
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Supercritical Boilers- Major Systems
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SC Steam generator
Boiler Steam Pressure above the critical point Critical Point
221 bar, 374 º c
S
T
1
2
3
4
Entropy
Tem
per
atu
re
1 - 2 Feed Water Pumping Process 2 - 3 Heat addition in the Feed
Water Heaters & Boiler 3 - 4 Expansion in HP Turbine 4 - 5 Reheating in Boiler 5 - 6 Expansion in IP & LP Turbine 6 - 1 Heat rejection in Condenser
5
6
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Supercritical Boilers
Supercritical pressure boiler has no drum and heat absorbing
surface being, in effect, one continuous tube, in which the water &
steam generated in the furnace water walls passes through only
once hence called ‘Once through Supercritical pressure boilers’
The water in boiler is pressurized by Boiler Feed Pump, sensible
heat is added in feed heaters, economizer and furnace tubes, until
water attains saturation temperature and flashes instantaneously
to dry saturated steam and super heating commences.
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The Concept
The mass flow rate thru’ all heat transfer circuits from
Eco. inlet to SH outlet is kept same except at low loads
wherein recirculation is resorted to protect the water
wall system
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� Increased mass flow
through spiral waterwall
tubing, or improved heat transfer through rifled
vertical wall tubing.
� No fixed evaporator end
point
� No thick wall components
Features
Once Through Boiler Flow Diagram
Evaporator
Water separator
Feedwater
Economizer
FW-
Pump
Live steam
Superheater
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Once through Supercritical Boilers
Major differences from Drum type boiler :
Evaporator system
Low load Recirculation system
Separator
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STEAM TO TURBINESTEAM TO TURBINE
SHSH
DRUM
SEPERATING
VESSEL
EVAPORATOR
EVAPORATOR
ECO.
ECO.
(LOW LOAD &
CIRCULATION PUMP
START-UP)
FEED
FEED
CIRCULATION TYPE
ASSISTED
Circulation Systems
Drum Type Once-through
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Once -through Operating Range
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Once -thru Boiler
Requirements :
Stringent water quality
Different control system compared to drum type
Low load circulation system
Special design to support the spiral furnace wall weight
High pressure drop in pressure parts
Higher design pressure for components from feed pump to
separator
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Features of Once Through Steam Generator
To ensure adequate mass flow rates through water wall,
spirally wound water wall tubes are used.
Start-up and low load system up to 30-40% BMCR required.
Feed water quality requirements are very stringent.
Can be designed for both sub-critical and super-critical
pressures.
Ideally suited for sliding pressure operation due to the absence
of thick walled components.
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Once -thru Boiler
Evaporator system :
Formed by a number of parallel tubes
Tubes spirally wound around the furnace to reduce number
of tubes and to increase the mass flow rate thru’ the tubes
Small tube diameter
Arrangement ensures high mass velocity thru the tubes
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• Reduced number of
tubes with pitch.
• Increased mass flow.
• Mass flow rate can be
selected by number of
tubes.
Features
Spiral Tube Arrangement
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Once -thru Boiler - Furnace Wall
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Spiral Water wall Tubing
Lateral Heat Flux Profile
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Sliding Pressure Supercritical Design
Spiral Wall Windbox
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� Supercritical boiler Separated Over Fire Air (SOFA) assySupercritical boiler Separated Over Fire Air (SOFA) assySupercritical boiler Separated Over Fire Air (SOFA) assySupercritical boiler Separated Over Fire Air (SOFA) assy
� Complex Burner Panel using 41.3 mm tubesComplex Burner Panel using 41.3 mm tubesComplex Burner Panel using 41.3 mm tubesComplex Burner Panel using 41.3 mm tubes
� 2020 complex multi2020 complex multi2020 complex multi2020 complex multi----plane tube bendsplane tube bendsplane tube bendsplane tube bends
� 12 bends in each 5.4 m length12 bends in each 5.4 m length12 bends in each 5.4 m length12 bends in each 5.4 m length
� Fabrication of T22 tubes with Gr 12 scalloped platesFabrication of T22 tubes with Gr 12 scalloped platesFabrication of T22 tubes with Gr 12 scalloped platesFabrication of T22 tubes with Gr 12 scalloped plates
SOFA burner SOFA burner SOFA burner SOFA burner
panelpanelpanelpanel
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SPIRAL WALL SUPPORT
Support
Fingers
Spiral to Vertical Transition Area - Load Transfer
Sliding Pressure Supercritical Design
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� Supercritical boiler Spiral Furnace Wall AssemblySupercritical boiler Spiral Furnace Wall AssemblySupercritical boiler Spiral Furnace Wall AssemblySupercritical boiler Spiral Furnace Wall Assembly
� 115 membrane wall panels using 41.3 mm tubes115 membrane wall panels using 41.3 mm tubes115 membrane wall panels using 41.3 mm tubes115 membrane wall panels using 41.3 mm tubes
� 5000 multi5000 multi5000 multi5000 multi----plane tube bends for wall openingsplane tube bends for wall openingsplane tube bends for wall openingsplane tube bends for wall openings
� 4500 tube butt joints for spiral4500 tube butt joints for spiral4500 tube butt joints for spiral4500 tube butt joints for spiral----vertical transitionvertical transitionvertical transitionvertical transition
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Furnace Wall Designs
Spiral Wall Configuration Vertical Wall Configuration
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Supercritical Boiler with Vertical wallUnit Mwe: 750
Max. Continuous Rating: 2522 t/h
SH Outlet Press: 262 bar
SH Outlet Temp: 568°C
RH Outlet Temp: 596 °C
Fuel: Sub-bituminous
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SCREEN TUBESSMOOTH TUBING
FRONT WALLRIFLED TUBING
SMOOTH TUBINGFROM THIS ELEVATION
ALL WALLS
SIDE WALLRIFLED TUBING
REAR WALLRIFLED TUBING
ARCHRIFLED TUBING
HANGER TUBESSMOOTH TUBING
FRONT WALLRIFLED TUBING
SIDE WALLRIFLED TUBING
Vertical Wall Sliding Pressure Supercritical Design
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Vertical Furnace Wall Design
Vertical tube furnace walls will provide all the operational benefits
of the currently popular spiral design while significantly reducing
the cost and construction time for the furnace and providing some
reduction in pressure drop.
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Vertical Wall Design - Advantages
The tubes are self supporting.
Transition headers at spiral/vertical interface are avoided.
Ash hopper tubing geometry simplified
Corners are easier to form
Reduced pressure drop, auxiliary power
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Spiral Vs. Vertical Wall Comparison
• Spiral Furnace System Applicable for all
size units
• Benefits from averaging of lateral heat
absorption variation (each tube forms
a part of each furnace wall)
• Simplified inlet header arrangement
• Large number of operating units
• Use of smooth bore tubing throughout
entire furnace wall system
• One material utilized throughout
entire waterwall system
• No individual tube orifices – Less
maintenance & pluggage potential
• Vertical Furnace Wall System Limited to
larger capacity units .
• Less complicated windbox openings
• Traditional furnace water wall support
system
• Elimination of intermediate furnace wall
transition header
• Less welding in the lower furnace wall
system
• Easier to identify and repair tubes leaks
• Lower water wall system pressure drop
thereby reducing required feed pump
power
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Vertical Wall Wind box
Straight Tubes
Only a Few Bends at the Top and Bottom
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Supercritical Boilers- Start-up and
Low load recirculation Systems
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Simplified drain discharge system
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Low load system with circulating pump
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Start-up System
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Separator Separator Separator Separator
vessel for vessel for vessel for vessel for
supercritical supercritical supercritical supercritical
steam generatorsteam generatorsteam generatorsteam generator
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Overview of Firing Systems
Close-Coupled
Overfire Air
Close-Coupled
Overfire Air
CFS Air Nozzle TipsCFS Air Nozzle Tips
Flame Attachment
Coal Nozzle Tip
Flame Attachment
Coal Nozzle Tip
NOx < 0.18 – 0.30 kg/Mkcal*NOx < 0.18 – 0.30 kg/Mkcal*
Furnace
Diagonal
Furnace
Diagonal
Separated
Overfire Air
Separated
Overfire Air
HP Pulverizer
with Dynamic
Classifier
HP Pulverizer
with Dynamic
Classifier
*NOx at furnace outlet
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Wind Box arrangement
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Upper SOFA
on Walls
Lower SOFA
in Corners
Tilt
+/-30o
Yaw
+/-20o
Plan View for SOFA arrangement
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Pressure Parts Arrangement
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Materials
in 660 MW
(Typical)
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Pressure part660 MW
OTSC (Supercritical)
500 MW
(Sub-critical)
Drum Not applicable SA 299 (Carbon Steel)
Vertical Separator SA 335 P91 Not applicable
Water Walls SA 213 T22 SA 210 Gr C
Economiser SA 210 Gr C Sa 210 Gr C
SH T91, TP 347H T11/T22/T91/ TP 347H
RHT12/T23/T91/TP347H/
Super 304HT22, T91, TP 347H
Material Comparison
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Air and gas Path
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Salient Differences between Supercritical
and subcritical Boilers
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Description 660 MW (Supercritical)
600/500 MW(Subcritical)
Circulation System
-Startup low load recirculation
System water walls
Once-Through
Vertical separator with One no.
startup Re-circulation pump
Spiral walls with Plain tubing
Controlled Circulation with
3x50%Boiler water circulating
pumps
Not applicable
Vertical walls with rifled tubing
SH / RH / ECONOMISER
system
- Pressure parts arrangement
- 2 stages of SH with SH platen
located above furnace and final
SH in horizontal pass.
- 2 stages of RH with low
temperature RH located in
second pass and RH finish
pendant located in horizontal
pass
- Single stage economizer
located in second pass below
low temperature RH.
- 3 stages of SH with low temp.
SH located in horizontal pass,
SH panel and SH platen located
above furnace.
- Single stage RH located in
horizontal pass
-Single stage economizer
located in second pass below
low temperature SH.
Gas velocity in pressure part,
m/s
10 10
Firing System Tilting tangential firing with
wind box located in four
corners of the furnace
Tilting tangential firing with
wind box located in four
corners of the furnace
Draft System Balanced draft Balanced draft
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Description 660 MW (Supercritical)
600/500 MW(Subcritical)
Pulverisers 9 nos.HP bowl mill
9/10 nos. bowl mill
Airheaters 4 nos Bi-sector air heater system with 2 nos. primary&2 nos. secondary.
2 nos. Regenerative Trisector air heater system or 4 nos Bi-sector air heater system with 2 nos. primary&2 nos. secondary.
Fans Axial FD, Axial PA and Axial ID-2nos each
2 Axial FD, 2 Axial PA and 2 Radial ID with VFD
ESP outlet dust concentration
18 mg/Nm3 18 mg/Nm3
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Higher pressure, higher SHO/RHO temperature and higher
feed water temperature has been adopted for improving the
cycle efficiency.
Drum has been eliminated and vertical separator with start-
up recirculation system is used for loads below 40% BMCR.
Two stage SH and two stage RH has been adopted.
Axial ID fans are used in place of radial ID with VFD.
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SUMMARY
OTSC plants offer better cycle efficiency
Proven technologies leading to lower GHG emissions and lesser
fuel burnt
BHEL has the technology for offering 660/700/800 MW
supercritical units
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Gearing-up to introduce Advanced Ultra
supercritical boilers (AUSC)
AUSC Boilers (300 ata, 700 °C / 700 °C) will
be developed based on OTSC technology
Test Facility (400 bar, 700 Deg. C) installed
and tests are on to collect critical design
data
BHEL is one among the Five MNC’s to have
this facility
Member of the National Technology
Mission program to install AUSC plant by
2017
Advanced Ultra Super Critical Plants
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