www.nidec-asi.com

ELECTRIC POWERSOLUTIONS FOR PIPELINE

APPLICATIONS

Oil & Gas

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Pipeline Applications ExperiencePipeline Applications Experience

NIDEC ASI provides electric power solutions for pumps and compressors in oil and gaspipelines, guaranteeing the best technology and the best operational conditions along the

entire process: from extraction to distribution.Our engineering team fully realizes your dreams and desires, designing customized solutions

which meet our client’s need in terms of: power quality, network connection, power andfrequency flexibility, low maintenance costs and time, machine durability, optimization of

capital expenditure, best allocation of available space.

With over 40 years of experience we work in close collaboration with End Users, Engineeringand OEM in order to develop the best global solutions for pipeline field operations.

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Electric Power SolutionsMeeting the operational needs

Meeting the operational needs for oil & gas pumps and compressors in terms of operationalspeed range is a primary issue, specific to these applications. The cost, complexity, and

reliability of the drive train will be impacted as more components are added.

To guarantee maximum reliability, uptime and performance in terms of efficiency, electricmotor-drive systems for pump and compressor applications require specific studies

considering all the different operating requirements.

This will affect the motor type, motor size, system configuration, power requirements,network power connection, costs and losses, coupling and operational methodologies.

We meet requirements and desires of our customers, in the selection of the electric motorand drive train configuration, through a customized approach.

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Traditional ApproachApplication up to 5 MW

The traditional approach is usually applied to compressors and centrifugal pumps on oil andgas pipelines where substations are near or else in derivation plants. The motor operates

Direct on Line (DOL) at constant speed and torque.

Today, in order to increase plant longevity and maintain simplicity and costs, the preferredoption for the drive train is to install a softstarter to ramp up the motor to its nominal rated

operating conditions.

Softstarter + Motor Directly Driving Pump or Compressor

Gas

Compressor

N1

N1

Constant 50 or 60 Hz,AC ~ Voltage Electric

Motor Pump orCompressor

Electric Utility orOther Generated

Power

Softstarter

In these types of solutions 2 or 4 poles fixed frequency machines are traditionally used, butthe interest in VFD technologies is steadily growing.

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Softstarter

By starting a motor at a loweffective frequency and thenramping up the speed, motorcurrent and torque can be limitedto near full load values.The Softstarter can provide amotor soft-start while providingfull load torque, also helping toreduce the motor currentrequirements for start-up.

Advantages in using a Softstarter:

• Least severe option for torsionalload and current demand bymotor upon start up means lesswear on equipment

• Guarantees motor can bestarted on virtually any electricalgrid

Medium Voltage Softstarter

3,3 KV up to 15,000 KV

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Incoming line

M

Softstarter

By pass switch

SoftstarterOne Line Diagram

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Plant Phase 1: start up – full efficiency:

The VFD System technologies can beused as Softstarter. With this configurationit is possible to activate a X number ofmotors with a gradual increase of power.This solution permits to optimizefrequency flow, without bearing upon theexternal electrical network and increasinglife span machines.

Plant Phase 2: changes in conditions

In this second phase Flexibility andOptimization of initial investiment are key -needs.

In this phase the drive is used not only tostart the motors but also to adjust thespeed to the required load, thus savingenergy.

VFD SolutionsFlexibility & Life Cycle Management

VFD

M

M

Pumpor

Compressor

Pumpor

Compressor

N° motors

Another option would be to use a VFD as a softstarter. This solution requires a higher intialcapital investment but guarantees maximum flexibility for future operation.

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Silcovert SPrinciple one line diagram for one Softstarter system

11 kV – 50 Hz Line Power

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13,2kV-60Hz Power Supply line

3bBy_passCircuitBreaker

2b OutputCircuitbreaker

Mot.Protect.

1InputlineCircuitBreaker

SILCOVERTSVTN

2a OutputCircuitbreaker

M 2

SynchronizationUnit

M1

3aBy_passCircuitBreaker

Mot.Protect.

Asynchronous Motor 1-2One run. the other isStand-by (reserve)

NIDEC ASI SCOPEOF SUPPLY

Silcovert TNPrinciple one line diagram for one Softstarter system

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Retrofitting can be handled in one of two ways:

• Control - room space management. Thestation can easily be designed from thebeginning to accomodate the futureinstallation of the VFD. In this case NIDECASI can act as consultants, providing theengineering team with the Dimensions andElectrical schemes to size the originalstation.

Or• NIDEC ASI can provide the installation of

the complete solution in container ready tobe connected to the existing plant.

We support the installation of the Variable Frequency Drive System both as a new buildand through retrofitting. This allows our customers a choice in their investment planning.

TN VFD in Container

VFD SolutionsInvestment planning

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Some applications will require the use of a Variable frequency drive (VFD) from the beginningto vary the pump or compressor speed. Typically, these are higher power applications orinstallations where the flow rate is not constant throughout the year. The VFD works to varythe input frequency and voltage supplied to the electric motor.

NIDEC ASI supplies VFD Technologies incomplete Fully Integrated Packagesconsisting of:

• Switchgear

• Drive Transformer

• VFD

• Disconnectors (supplied by a third part)

• Electric Motor or Motor/Generator

VFD PackagesApplication up to 30 MW

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the highest efficiency on the market today (lower energy consumption)

the Lowest Maintenance Costs

the Highest reliability (no down time means higher productivity)

Load VFD VFD+Transf+motor Power Factor% Efficiency % Efficiency % %

100 98.6 – 98.0 97.3 – 96.1 0.96

75 98.5 – 97.5 97.7 – 95.8 0.97

50 98.0 – 97.0 97.5 – 95.0 0.98

VFD SolutionsLife Cycle Cost Evaluation

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Efficiency of the electric motor drive train will be determined by the losses. The gearbox isone of the main significant causes of drive train component losses. Typically, these are onthe order of 5 to 8 %(*).

(*) “Application guideline for electric motor drive equipment for natural gas compressors”, Gas Machinery Research Council Southwest ResearchInstitute, Jan 2008

Electric Utility or OtherGenerated Power

Electric

MotorVFD Gas

Compressor

N1

Variable freq

AC ~

Variable

speed

N1Electric

MotorVFD Gas

Compressor

1Constant 50 or 60 Hz,

AC ~ Voltage

Single motor Directly Driving a Gas Compressor with VFD (without Gearbox)

Electric Motor with VFD (with Gearbox)

Electric

MotorVFD

Variablefreq AC ~

Electric Utility or OtherGenerated Power

Constant 50 or 60 Hz,

AC ~ Voltage GearboxN1

Fixed Speed Ratio,

Variable Speed

N2 Gas

CompressorElectricMotorVFD

Gearbox GasCompressor

To optimize the elecrtic motor’s efficiency the installation of tailor – madesolutions is a primary need

Optimize Electric Motors EfficiencyTo reduce component losses eliminating Gearbox

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Motor Side connection

• Torque distortion

• Motor thermal stresses

• Train dynamics

• Train operability

Subsystems

• Transformers

• Power Converters

• Control system

• Auxiliaries

Grid Side connection

• Current & voltage distortion

• Power factor

• Filters

~

=

~

=

Electric Drive

EM

Integrated Engineering ApproachTypical Electric Drive System

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Torque Input from VSDS

0 20 40 60 80 100 120 140 160 180 2000

100

200

300

400

500

600

700

800

900

1000

frequency in Hz

torq

ue

harm

onic

inN

m

torque spectrum at 3300 rpm and 33 MW

Damping torque response by control algorithms

1st torsional mode

2nd torsional mode

MCL1402FR9E

EM

3MCL1403MCL1402FR9E

EM

3MCL1403MCL1402FR9EFR9EFR9

EMEM

3MCL1403

Steadfast Drive

Drive Control

MCL1402FR9E

EM

3MCL1403MCL1402FR9E

EM

3MCL1403MCL1402FR9EFR9EFR9

EMEM

3MCL1403MCL1402FR9E

EM

3MCL1403MCL1402MCL1402FR9EFR9EFR9E

EMEM

3MCL14033MCL1403MCL1402MCL1402FR9EFR9EFR9E

EMEM

3MCL14033MCL1403MCL1402FR9EFR9EFR9E

FR9

EM

EM3MCL1403

Steadfast DriveDrive

Drive ControlDrive Control

Optimizing Max Ripple at Torsional Modes in Speed Range…

20 25 30 35 40 450

200

400

600

800

1000

Fundamental frequency, Hz

To

rqu

eA

mp

litu

de

,N

m@

Rip

ple

fre

qu

en

cie

s…

|Fsw - 21f0|

|Fsw - 15f0|

20 25 30 35 40 450

200

400

600

800

1000

Fundamental frequency, Hz

To

rqu

eA

mp

litu

de

,N

m@

Rip

ple

fre

qu

en

cie

s…

|Fsw - 21f0|

|Fsw - 15f0|

Speed/fundamental frequency (Hz)

Torsional Mode Analysis

Integrated Engineering ApproachIntegrated Mechanical & Electrical Design

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Operatingperformance

SiteConditions

Shaft Line &Vibration

Cooling &Maintenance

• Reduce Complexity

• Optimize choice of motorTechnology

• Minimize Costs

• Guarantee MaximumReliability & Availability

• Maximize Flexibility

• Optimize choice of MotorTechnology

• Maximize OverallPerformance

• Optimize deviceresponse & Stress

• Improve System Design

• Optimize AuxiliarySystems

• Optimize Maintainability

Our engineering team performs specific studies to develop customize concept based on thecharacteristics of each plant.

Integrated engineering approach regards all aspects related to all technology selectionprocess, taking into consideration thermal and mechanical performance under diverseoperating conditions to minimize harmonics and identify the optimal trade off between

Voltage and Current to guarantee maximum stability of the system:

Integrated Engineering ApproachMechanical Design For Electric Motors

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Motor Power Vs. Speed

compressor load points

speed margin @ const. power

rated speed

cubic power (quadratic torque)

Motor Torque Vs. Speed

compressor load points

quadratic torque

rated speed

speed margin

Motor Voltage & Current Vs. Frequency

V/Hz = const

rated speed

voltage

current

The load features

• Quadratic load Vs. speed are ingeneral required for the VSDSdesign.

• Speed range must be well definedfrom the beginning – critical speedsmust be avoided – maximumoperating speed and the over-speed(120%) shall be mechanically verified– lower speed shall be compatiblewith motor cooling and bearingsdesign.

• In case of an operational speedmargin (example 110% speed),constant power will be consideredaccording to the rated power of theVSDS. Otherwise, with quadratictorque load, the VSDS should beoversized and rated accordingly(example 133% power).

• Compressor load can be highlyinfluenced by the process (gaspressures/temperatures), so propermargins must be considered.

Integrated Engineering ApproachMotor Design – Operating parameters

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Russia - Sakhalin Island LNG Plant

High Power Traditional Solution 4 poles

Sakhalin is a large Russian island in the NorthPacific and is crossed by the one most importantpipeline of Russia.

The strong cold and the other extreme weatherconditions, constantly wear out the electrical andmechanical equipment of the pipeline

Due the site conditions, NIDEC ASI provided thebest solution for the customer, choosing the criticalcomponents to guarantee proper performanceat -50°C.

Integrated Engineering ApproachMotor Design – Site Conditions

Technology: Shell / JGC

Scope Of Supply:n.2 21 MW LCI drives Silcovert Sn.2 motors plus 4 MW fixed speed

motors for Overhead StabilizerCompressors

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Integrated Engineering ApproachMotor Design – Site Conditions

Qatar - Ras Laffan Re-injections Plant

High Power Induction motor + PWM-NPC Solution

Ras Laffan Industrial City is the Qatar's main site forproduction of liquefied natural gas and gas-to-liquid.

In the desert (Ambient temperature +54°C) and in themaritime environment, structural integrity is vulnerableto wind blown sand and to saline of the sea, thereforethe equipment had to be sealed against the elementsand positioned in areas where they were least at risk.

NIDEC ASI supplied the right equipment and the bestsolution, resolving the problems of its customers

Scope Of Supply:n.3 CR 1000 Y 4 – 13.7 MW 11 kV 50 Hz

dual shaft end for gas re-injectionscompressors

n.2 CR 900 X 4 9.6 MW Silcovert GN 2x 3300 V for NGL 4 & NGL 5

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Example of Rotor Dynamics Analysis

Shaft ModelExample of Prediction ofRotordynamic ResponseUnbalance ResponseDeflection ShapeDynamic Couple UnbalanceSpeed = 6060 rpm

z x

y

Integrated Engineering ApproachMotor Design – Shaft Line & Vibrations

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Note to the traditional approach

LCI machines have longer shaft line Complex mechanically Torque pulsations from the electric system Only low pressure restart

Traditional LCI approach - Gas turbine driver - Large compressors:PropaneMixed RefrigerantNitrogen

High speed

G/TLCI

driven motorLP Comp HP Comp

LCI Electric system

Integrated Engineering ApproachMotor Design – Shaft Line & Vibrations

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4 Pole Solution - Gas turbine driver - Large compressors:PropaneMixed RefrigerantNitrogen

Note to the 4 Pole approach

Shorter shaft lines to reduce vibrations Power compensation for high temperature turbine derate No torque pulsations from the electric system Full pressure restart (Higher starting torque) Regenerative to the network independent from the speed Power factor correction and/or filters are not necessary

High speed

G/TParallel drive driven

motor/generator LP Comp HP Comp

4 pole motor w/Parallel Drive Electric System

Integrated Engineering ApproachMotor Design – Shaft Line & Vibrations

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Rotor Winding Head Ventilation

Integrated Engineering ApproachMotor Design – Cooling

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Stator

Rotor

Stator end windings

Rotor retaining rings

Rotor fans

NCVC1: Number ofradial ventilationslots in endchambers

NCVC2: Number ofradial ventilationslots in centralchamber

Internal Ventilation

Integrated Engineering ApproachMotor Design – Cooling

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Bearings supplied by Top manufacturers, designed accordingto our specifications to maximize up time.

Critical Components for Maintenance

Level I components

• bearings and bearing seals• air-to-water heat exchangers• pressurizing system

Level II components

• windings (stator & rotor)• excitation system windings• shaft seals• instrumentation

Level III Components

• gaskets and seal on fixed components• hold-down bolts and alignment shims• painting• terminal box components• soundproof insulation

Integrated Engineering ApproachMotor Design – Maintenance

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• Optimize AuxiliarySystems

• Optimize Maintainability

SwitchingDevice

• Assure device reliability

• MinimizeCosts

DriveTopology

ControlStrategy

Packaging

• Reduce Complexity

• Reduce Parts count

• Maximize Flexibility

• Optimize choice of DriveTechnology

• Maximize OverallPerformances

• Optimize device response &Stress

• Improve System Flexibility

The same care is taken in the choice of Drive Topology and overallsystem design

Integrated Engineering ApproachDrive System

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Thyristor/SCR IGBT/IEGT IGCT

• Current controlled device

• Semi-controlled (turn-on only)

• Highest V-I rating @ lowestcost

• Mature technology

• Voltage controlled device

• Fully controlled

• Faster switching

• Module (mature) orpress-pack (emerging)

• Proven technology

• Current controlled device

• Fully controlled

• Lower conduction loss

• Press-pack packaging

• Proven technology

Integrated Engineering ApproachDrive System – Switching Devices

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• Complexity @ high power

• Complex failure modes

• Use IGBT and IGCT

• Distortion

• More subsystems to get highperformances

• Extensively adopted in Steel industry

• Easy & flexible to control

• Use IGBT, IGCT, IEGT

LCI VSI (3-Level NPC) VSI (Stacked H-bridge)

NIDEC ASI has significant knowledge in drive topologies and can offer customers theright choice for their application

Integrated Engineering ApproachDrive System – VFD Circuit Topology

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Our MV ProductsDrive Topology

Silcovert SThyristor based LCI

for synchronousmotors providesspeed regularity,monitoring andbraking torque

regulation

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Series HAir cooling: up to 8100 KVAWater cooling: up to 18700

KVA (higher power onrequest)

Voltage: up to 7200 V(12000 V on request)

Series NAir cooling: up to 10400

KVAWater cooling: up to24000 KVA (higherpower on request)

Voltage: up to 3300 V

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High Speed Solutions

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High Speed CapabilityMotors Types and Ratings

A

B

C

24000

Exxon / QatarGas – RasGasHS 4-pole turbo motor-generator

PetrocanadaHS 2-pole turbo motor

Transco / TennecoHS 2-pole induction motor

A

B C

20

10

0

30

40

50

60

70

80

2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000

MW

Consolidated

New

Under discussion

Delivered

Recent projects update

rpm

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HS Motors vs gasTurbine

Electrical Solutions

• Best flexibility• Lower noises• Lower maintenance costs(> 10 years continuous field operation

demonstrated)

• Higher efficiency• Lower cost• Smaller size• Lower noise• No air pollution

• Reduction of power lossesin the drive system

• Smaller size• Higher reliability• Lower maintenance (time - cost)• Lower noise

HS motors vs. conventionalmotors with gear boxes

High Speed SolutionsMain Advantages

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Transco 205:Operating andMaintenance CostComparison

Electric Motor Driven Compressor Stations: $10/hp/yr

Gas & Steam Turbine Driven Stations: $35/hp/yr

Gas Reciprocating Engine Driven Stations: $55/hp/yr

Parameter Recip. Turbine Electric

Total Installed Cost 1.00 0.65 0.52

Space Requirement 1.00 0.75 0.65

Maintenance 1.00 0.60 0.15

Spare Parts 1.00 0.60 0.40

Environmental 1.00 0.80 0.10

Availability 96% 98% 99%

Fuel Efficiency 31-40% 21-36% 35-45%

Economic Comparison3700 kW (5000 hp) System

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High Speed ApplicationsOne Line Diagram SVTN 24 Pulses

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References High Speed Motors

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NIDEC ASI works in close collaboration with Project engineering management and Endusers and the OEM supplier to guarantee that equipment is fully tested

before being shipped on site.

Routine tests (according to IEC & IEEE standards);

up to 10 MW @ 9000 r/min: no load tests at motor speed range supplied by amotor-generator set.

Factory facilities, no job equipment needed;

greater than 10 MW @ 9000 r/min: no load tests at motor speed range.

Job transformer, converter, capacitors and other equipment needed;

Main Testing Area for Drives: 2500 kVAExtra power if needed for PCS testing: 1300 kVA

Machines & System Testing CapabilitiesUp to 10 MW

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In order to meet the challenges of de-risking largepowered motors we can provide full load machinetesting in back-to-back full load configuration atour Monfalcone Italian facility if 2 or more machineshave been ordered.We are able to support our customer with completetest in back to back configuration (IEEE 112) forapplications up to 75 MW.

MGSCR1120Z4Motore / motor

MGSCR1120Z4Generatore /Generator

1 2 3 4 5 6 7 8

Convertitorifrequenza / VFD“Perfectharmony”

Ecc / excQ+P Q+P

Quadro interruttori 33 kV / HV Switchgear

Q+P Q+P

S/S Generazione Potenza / Power generation S/S

Unità di commessa / Job Units

Autotrasformatore di prova 10/33 kV /10/33 kV Tool Autoransformer

“Turning-gear” & “pre-charge”10 kV / 415 V

IPT4 IPT3 (T3)

Q+P

G1

GSCR1000Z4

G2

SIG 10 Z4

IG2 (T2) SG1

M

CR 630 Y4

Convertitore frequenza SVGN

/SVGN Frequency Converter

Trasformatore abbassatore 10/3,3 kV /10/3.3 kV Step-down Transformer

IPT1 (T1) SG

IPT2

10 kV /415 V

10 kV /380-220V

Cabina stabilmento 20 kV / 20 kV Plant Cabin

Nuo

voin

terr

utto

re/new

brea

ker

Perdite / losses

Trasformatori VFD /VFD Transformers

Back to back testing is a completetest which gives our customer

additional assurance aboutmachine’s efficiency.

PDS System Testing CapabilitiesBack to Back - Full Load Testing Up to 75 MW

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We work closely with the compressor suppliers to conduct complete string tests at their facilities.This guarantees the final end user that there will be no surprises or risks in the field.

Test stand layout

back-to-back test: electric motor

coupled with a generator and 30

MW resistor banks

Thread 1

Thread 2

Thread 3

Thread 4

M33kV / 3 kV

MV Switchgear

G

Active Partener in String TestsString test at OEM facility

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Stand alone unit capability:

Data log

Basic analysis

Ethernet communication

Re configurable acquisition tasks

Customizable / expansible

Available for Hazardous area

Data signals:

Inputs for vibration probes (mechanical data)

Input for speed sensor (mechanical data)

Inputs for line current / voltage (electrical data)

Excitation current (synchronous machines)

Inputs for Pt100 (thermal data)

Outputs (alarm, trip, status)

Local network USB

Remote connectionEthernet

Remote Diagnostics System

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On this project, for example, diagnostics were managed from Japan via internet from ourfactory in Italy using our drive’s remote diagnostics capabilities.

Our drive control system can be easily integrated and interfaced with existing ControlSystems.

Remote Diagnostics Demostration

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