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8.

UNIT 92 / STEAM GENERATION

8.1 Selection of main equipment and process flow scheme

8.1.1 Steam generators selection


Steam will be generated in the Refinery as medium-pressure steam (nominal 16 barg) and low-
pressure steam (nominal 4.5 barg). Clean condensates will be recovered for re-use where
practical. Steam is generated in the Hydrogen Plant, but additional production is required to
balance the demand.
Medium pressure steam boilers shall ensure this additional production.
Steam boilers will provide sufficient capacity to cope with the Refinery maximum requirements.
The boilers shall be also capable of fulfilling the normal demand in case of unavailability of one
of them.
The boilers will be of water tube type, equipped with boiler feed water economizer, evaporator
and super-heater. There will be two forced draft combustion air fans (1 in operation, 1 spare) and
one induced draft boiler recirculation fan per boiler (to be confirmed by boiler vendor). All air
fans are electric motor driven.
Imported sweet gas is used as single source of fuel. A pilot gas knockout drum is to be provided
in Unit 93 to ensure no liquid carry-over to the burners.
A common set of continuous and intermittent blow down facilities will be provided. Boilers blow-
down shall be directed to the cooling water return header in order to limit the extent of make-up.

8.1.2 Boiler feed water


Boiler feed water is a mixture of condensates recovered from the steam users and desalinated
water as make-up. LS steam is used to degas the water in a thermal deaerator. Boiler feed water is
pumped to boilers and other users by means of 3 x 50 % pumps, among which two of them are
steam turbine driven.
Desalinated water after dechlorination as single source of make-up to deaerator (no condensates
recovery) has to be considered as a basis of design of the deaerator and chemical treatment.

8.1.3 Water treatment


Chemical injection at the deaerator is being contemplated as follow:
 Oxygen scavenging

 Volatile amine injection
In addition, phosphates shall be injected separately into boiler drums.

8.2 Sparing philosophy


As mentioned already in previous paragraph, there will be 3 x 50 % boiler feed water pumps (two
in operation, one in stand-by), among which two are to be steam turbine driven. One steam
turbine driven pump will be normally in operation, together with the electrical motor driven one.
Boilers: see § 8.1 & § 8.3.

Other equipments: no spare to be provided, due to either their high degree of reliability (example:
deaerator) or the ability to by-pass their functions for a limited period of time (example:blow
down facilities).

8.3 System design capacity

8.3.1 Steam generation


Steam boilers will provide sufficient capacity to cope with the Refinery maximum requirements,
corresponding to the kerojet stripping with live steam, in the condensate fractionation unit, or to
the case where the hydrogen plant is out of service. However, the steam generation system may
be maintained in operation to fulfill the demand resulting from the Fractionation section only in
service.
The following cases are not considered as basis for design:
 Steam consumption associated to smokeless flaring (steam rate for smokeless flaring will only
be a result of its actual availability, however note that for smokeless flaring steam requirement
is considered to be about 18 t/h, as per LR1 EPC).

 Unit 12 Condensate heater decoking.
However, it is assumed that if required, missing capacity will be fulfilled by means of steam
import from LR1 refinery since LR1 and LR2 steam systems are interconnected.
The boilers shall also be capable of fulfilling the normal demand in case of unavailability of one
of them (for maintenance reasons for example).
These principles lead to a solution with two boilers, both being normally in operation (50 / 50).
The boilers design capacity shall be at least 10 t/h each catering for the maximum demand as
mentioned above (about 20 t/h) to which about a 30 % margin is added (refer to LR1 FEED/EPC
documentation). The retained boiler capacity is identical to LR1 FEED/EPC: 13t/h each.
The associated facilities (blow-down and imported sweet gas to boilers) shall comply with the
same.

8.3.2 BFW generation


The deaerator and the two BFW pumps in operation shall have their design capacities based on
two boilers operating at design capacity. Associated chemical treatment facilities shall follow the
same rule.

8.3.3 Desalinated water make-up to deaerator


The design flow rate of desalinated water-make-up to deaerator shall be based on:
 Boilers at design flow

 Condensates return nil

8.4 System sizing and over design factors


See above for boilers, deaerator and chemical treatment facilities.
Boiler feed water pumps shall have a rated capacity of 110 % of the design capacity as defined
above. They shall be able to deliver their rated flow under normal pressure conditions at the boiler
and their design flow when boilers drum relief valves are relieving.

The deaerator shall have a hold-up time of 20 minutes between normal level and low-level alarm
based on design flow.

8.5 Operating conditions


Normal steam conditions at Utility boilers outlet: 16 barg / 270 °
c. Deaerator normal operating condition: 110 °C
BFW pressure conditions: as dictated by Utility boilers requirements.

8.6 Material selection


Piping material shall be carbon steel basically, except for chemicals and desalinated water make-
up.
9. UNIT 92 / STEAM DISTRIBUTION & CONDENSATES RECOVERY

9.1 Selection of main equipment and process flow scheme

9.1.1 General scheme


The two utility boilers and the Hydrogen generation unit produce the MS steam to balance the
normal continuous demand from Unit 12 (stripping and vacuum package), the steam turbine
driven BFW pumps, the flare for smokeless operation, and the let down to LS steam as required.
Unit 12 generator on heavy gas oil rundown and the BFW pump steam turbine ensures the LS
steam production. LS steam is consumed in normal operation at the sour water stripper, at the
steam tracers and at H2 unit. Let down of MS steam balances the demand.
Condensates from LS steam Users shall be recovered and cooled down to 50 °C. The reason of
this cooling is the use of part of these condensates in a process section (for amine wash) where a
higher temperature is not allowed. Condensates are recovered in a drum to be nitrogen blanketed
and equipped with skimming facilities. They are pumped back to users (deaerator and amine
water wash in normal operation) through a filter, which retains particles for protection of
downstream facilities from erosion.

9.1.2 Control and operation


MS header
Nominal pressure of the MS header is achieved by the control of the Utility boilers firing from a
master pressure controller. In case the utility boilers get to their minimum turndown, excess steam
shall be let down to LS. In case overpressure arises on MS header, a pressure controller will vent
excess steam to atmosphere. Relief valves achieve the ultimate protection of the system.
LS header
A controller acting on the MS to LS let down regulates the pressure of the LS header. In case
overpressure arises on LS header, a pressure controller will direct excess steam to the excess steam
condenser. If not sufficient or in case this excess steam condenser is not available, the controller will
vent the excess to atmosphere. Relief valves achieve the ultimate protection of the LS system.
Note concerning the excess steam condenser: the need of such excess steam condenser has to be
confirmed by EPC Contractor. In effect, its usefulness is linked to several parameters like the
actual boilers size and turndown, the actual Hydrogen unit steam production, the actual user
consumptions and so on. It might also be decided later on, regardless of “on paper” results, to
keep this condenser as an additional flexibility means. This issue shall therefore be reassessed
later on at EPC stage.
Condensates
In case of contamination of the recovered condensates with hydrocarbons, an in-line analyzer will
divert them automatically to the oily contaminated water effluent network.
Low-pressure condensates at users outlet (sour water stripper reboiler, LPG vaporizer…) shall be
routed to the steam condensate cooler. Return headers shall be maintained in pressure by a
pressure control valve located close to the cooler, so as to avoid in-line flashing.

9.2 Sparing philosophy


Pumps shall be spared. The condensates particle filter shall be of a duplex type.
Other equipments: no spare to be provided, due to either the improbability of failure or the ability
to by-pass their functions for a limited period of time (example: steam excess condenser).

9.3 System design capacity


Generally speaking, the system or sub-systems shall be designed on the basis of an exhaustive
analysis of operating situations (like operation of intermittent users, trip of producers or trip of
steam / condensates condensers / coolers).
Some examples are given below:
 MS steam letdown station: to be sized on the basis of LPG vaporizer in operation

 MS header relief valve, pressure controlled vent and excess to air condenser valves: to be sized
on maximum instantaneous MS steam consumer trip (i.e. Unit 12 trip)

 LS header relief valve, pressure controlled vent valve and excess steam condenser: to be sized
on the basis of maximum instantaneous excess resulting from the trip of one major LS steam
consumer (i.e. LPG vaporizer)

9.4 System sizing and over design factors
Condensate pumps and air coolers shall have a rated capacity of 110 % of the design capacity
determined as depicted above in § 9.3.
The condensate drum shall have a hold-up time of 5 minutes between normal level and low-level
alarm on the basis of the design flow.

9.5 Operating conditions


MS steam at unit Block BL
Minimum / Maximum pressure (barg): 15 / 16
Minimum / Maximum temperature (°C): 235 /
275 LS header
Nominal conditions: 4 barg / 175 °C
Pressure / temperature at generators (Unit 12 generator and MS to LS let down station) shall be
4.5 barg / 175 °C.
Condensates
As per User requirements
(refer to “Utility conditions”)

9.6 Material selection


Piping material shall be carbon steel basically.

13. UNIT 84 / FLARE SYSTEM

13.1 Selection of main equipment and process flow scheme

13.1.1 Design concept


The flare system collects vapours from relief valves on individual units, minor vent flows of
hydrocarbons and hydrocarbon (off spec LPG) from cold flare collection system and ensures the
Hydrogen and the hydrocarbons are combusted before release to the atmosphere.
The controlling design concept for the flare system is based on either a general power failure
scenario where all electrically driven equipment ceases to operate or the maximum individual
relief case, whichever the greatest is. Other relief scenarios have lower relief loads.
For the general power failure case, the following basis of design and considerations will be used
in determining the sizing load for the header and flare system:
 The major source of heat inputs to the units during the general power failure are the refractory
and flames in the fired heaters of the condensate fractionation unit (unit 12) and sat gas plant
unit (unit 13).

 Triplicated high pressure switches on the towers shall shut-off the fuel gas supply to the fired
heaters (burners and pilots) in Units 12 and 13 through a 2 out of 3 voting system managed by
the ESD system. Advanced control monitoring systems within the DCS and/or the PLC shall
also initiate shut-off of the main fuel gas supply based on other parameters, such as loss of
power.

 With no combustion in the heater radiant section, about 30 % of the normal heater duty shall
be assumed to continue being supplied to the tubes due to continuing black box radiation from
the refractory.
Under a normal scenario, the tubes contain partly vaporized oils and the continuing
vaporization tends to clear the tubes of liquids. Under the worst-case scenario, the radiant
section tubes are assumed to be completely filled with process liquid. The liquid absorbs the
heat and is vaporized into the tower.
For the case of general power failure, the tubes are assumed to be full of liquid and the
safeguarding sequence on the largest potential relief load producer fails. In this scenario, the
largest relief load would originate from the sat gas plant fractionation unit (debutanizer).
However, the design pressure of the debutanizer section (24 barg) as well as the set pressure of
the relief valves provided on the related tower are set at a level that prevents relief from
occurring. Therefore, the largest potential relief load comes out to be from the Unit 12
condensate tower. Corresponding fired heater tubes are assumed to be filled with liquid, and
100 % of the normal absorbed duty continues to vaporize the liquid and send vapors into the
tower.
 Credit (for the sizing / design of the flare system) shall not be taken for electrical equipments
/ services which are maintained in operation in case of total power failure. Those equipments /
services receive back up power from the Emergency Diesel Generator (EDG). The list of those
 items is provided in the chapter “essential load list definition“ of the present document.
However, a credit of 25% of the nominal cooling duty of the overhead air condensers shall
still be considered to account for natural draft cooling (this applies only to the general power
failure case, not to the individual relief scenarios).

Flare system facilities


 The flare riser and tip is to be installed on the existing structure erected for LR1 rise and tip.
The design of the new flare shall therefore take care of its installation without need of shut
down of the LR1 refinery that will be in operation.

The new flare (riser and tip) is to be dismountable, the other one being still in operation.

 No acid flare is to be provided in addition to the hydrocarbon flare system, as per LR1
FEED/EPC documentation. This is based on the consideration that high H2S content relieves
(up to 15-20 % mol) will be diluted by the fuel gas injected at flare headers extremities, so that
resulting concentrations shall not exceed 5-10 % mol H2S, considered to be acceptable for a
standard hydrocarbon flare system.

 All flare sub-headers from all over the Refinery are connected into a main common header
sloped towards the flare K.O. drum, equipped with slop pumps to recycle condensates to the
Fractionation U12. Need of secondary flare drums located at unit Blocks has been investigated
during the course of LR1 FEED/EPC and considered not required. This will have to be
investigated and validated during LR2 EPC phase.

 A cold flare system shall be provided in order to mitigate the cold temperature in the LR2 flare
system. The cold flare system collects U14 and U93 cold relief sources discharging liquid
C3/C4. The liquid is retained in a local flare KO Drum and the vapour is heated up.
Downstream of the heater, the cold flare system is connected to the main flare network.

 A water seal drum shall be provided in-between flare KO drum and Flare riser. The design of
the drum shall prevent from pulsating flows and combustion. Potable water shall flow
continuously to the drum at a relatively low rate and at a high rate when replenishing of the
water seal inventory is needed. The drum will be equipped with skimming facilities.
Continuous seal water flow and intermittent skimmed oil flow from the drum shall be
recovered in a sump. It will be equipped with oily water pumps to route the content
(essentially water) back to the sour water stripping unit (Unit 19).

 The flare tip shall be provided with MS steam injection for smokeless combustion. Injection
rate will be up to available steam boilers capacity. A velocity seal shall also be provided to
limit air ingress potentials.

 Fuel gas shall be injected at Units header extremities to ensure purging and over-pressurization
of the flare system, thus preventing from air ingress. The same may applies to the seal drum if
required.

13.2 Sparing philosophy


Slop and oily water pumps shall be provided with one spare.
Other equipment: no sparing to be provided, as per common practice.

13.3 System design capacity


Plant sub-headers
The plant sub-headers shall be sized on the basis of the maximum discharge rate from the
corresponding plant.
Main header, KO drum, seal drum and flare (gas path)

These facilities shall be sized, on a hydraulic standpoint, on the basis of the most stringent
discharge case.
KO drum and seal drum shall be designed according to API 521 criteria.

KO drum liquid storage


Hold-up capacity: 20 minutes between high- high level and normal level, or maximum amount of
liquid condensed in line (following a gaseous discharge) if no dual phase or liquid releases to the
flare are undergone.

13.4 System sizing and over design factors

13.4.1 Flare stack height


Radiation levels will determine the flare height and shall be based on the most stringent relief
case, which might be different from the maximum discharge case governing disposal system
hydraulics. Simultaneous occurrence of releases shall be considered from both Refineries (LR1
and LR2) in the power failure case.
Flare tip and riser diameter shall be such that a maximum velocity of 0.5 Mach in the flare stack
shall not be exceeded and that a maximum total pressure drop of 0.3 bar in the flare tip, the flare
stack and the water seal is obtained.
The molecular weight of the gas released to the flare in case of loss of condensation at the
condensate tower should be around 90. For such MW, emissivity can only be predicted. A
minimum value of 0.2 shall be considered (to be defined during EPC phase).
A wind speed of 14 m/s shall be considered for the flare sizing (in line with assumptions usually
done for Projects in the same area).
Design value for solar radiation is to be taken as 0.9 kW/m² (285
Btu/h/ft²). The air relative humidity to be considered is 35%.
An average air temperature (dry bulb) of 26.7°C shall be considered (it corresponds to the annual
average temperature).
The API RP-521 method modelling the single point source method of Hajek and Ludwig shall be
used.
The recommended radiation level from API RP-521 is 4730 W/m² in operating areas at grade or
on elevated operating platforms where operators are under administrative control by the plant and
wearing appropriate clothes.
According to RLIC regulation, the maximum radiation level allowed at the Refinery fence is
2840W/m² (including solar radiation).

13.4.2 Main header sizing


Design velocities in the main relief header should not exceed 0.4 Mach.

13.4.3 Over design factors


No over design factor shall be considered on the top of the design figures defined above, except
for slop and oily water pumps for which rating shall be 110 % of maximum flow.

13.5 Operating and design conditions


Design mechanical pressure of the flare system shall be 3.5 barg minimum.

 During normal operation, the flare system is operated at a slightly positive pressure to prevent
from air-in leakage by mean of Fuel gas sweeping.

 Temperature = ambient in normal operation. Design temperature shall be evaluated based on
maximum temperatures deriving from both single discharges and common failure cases.

13.6 Material selection
All Plant sub-headers and headers
In general, plant sub-headers and headers shall be specified for moderate wet H2S service, and
will be in CS + 3 mm corrosion allowance. LTCS to be applied if required due to cold reliefs.
KO drum, seal drum and associated pumps
These facilities shall be specified for severe wet H2S service. Drums will be in CS + 6 mm
corrosion allowance. The slop and oily water pumps shall be specified as well for severe wet H2S
service.

14. ESSENTIAL LOAD LIST DEFINITION

14.1 Introduction
The objective of this study is to define the list of essential electrical consumers that shall be
connected to the back-up power supply system of the refinery.
The back-up power supply system will be ensured by Emergency Diesel Generator (EDG). It will
allow for the safe shutdown of the refinery

14.2 Electrical power supply system

14.2.1 Main power supply


The main power will be supplied to the refinery through LR1 and the QGEWC (KAHRAMAA)
electrical grid.

14.2.2 Essential power supply


The back-up power supply will be provided by 3 x 40% EDG.
The back-up power supply system will ensure continuous operation of critical equipment in the
event of loss of normal power supply. It will allow for the safe shutdown of the refinery.

14.3 Definition of the essential load list

14.3.1 Essential items selection principles


First principle: maintain in operation vital equipments / facilities.
Second principle: To limit the extent of release to the flare in case of power failure, part of the
condensing system of the condensate Fractionator is put on back-up supply.
List of vital consumers
The back-up power shall be supplied to all critical consumers:
 Firewater pump

 Storm water pumps

 Flare knockout drum pumps

 Potable water pumps, chiller package and condenser for chiller package

 Service water pumps

 General facilities:

- Control room
- Emergency lighting
- HVAC associated to vital areas (control room etc…)
- DC charge / ASP
- UPS
- Administrative Building

Absorbed
Item N° Designation Power
kW (Note1)
91-P8301 Fire water Pump 397
90-P8709 A Storm / Fire water collection pump 133 (Note2)
90-P8709 B Storm / Fire water collection pump spare 133(Note2)
90-P8710 Storm / Fire water collection pump (spare in warehouse) 34(Note2)
90-P8401 A Flare slop Pump 19
90-P8401 B Flare slop Pump Spare 0
90-P9404 A Potable water distribution pump 20
90-P9404 B Potable water distribution pump spare 0
90-Y9405 Potable water chiller package 58
90-Y9405 Condenser for potable water chiller package 22
90-P9403 A Service water feed pump 10
90-P9403 B Service water feed pump spare 0
Emergency lighting / control room and substations 201
DC Charges / ASP / UPS 219
HVAC 1914
Administrative Building 875
SUBTOTAL 3735
Notes:
1. Absorbed power values are indicative only. Refer to the Electrical consumer list
255/82/00/EL/CN/NA/001.
2. Intermittent Services. Not included in subtotal
Fire water pump is considered having a flow rate of approximately 930 m3/ h each. Total fire
water demand is 1844.5 m3/h maximum. This demand is met by one electrical driven pump (930
m3/h) & other diesel driven pump (930 m3/h).
The back- up power consumption is an estimate based on LR1 + delta if any and shall have to be
confirmed at EPC stage.
14.3.2 Other consumers that have to be connected to the emergency power supply

Process consumers:

Absorbed
Item N° Power
kW(Note1)
82-P1205 A Condensate fractionator Bottoms Product Pump 273
82-P1205 B Condensate fractionator Bottoms Product Pump Spare 0
82-E1212 Condensate fractionator 1st stage condenser (8 motors out of 8) 119
82-E1213 Condensate fractionator 2nd stage condenser (8 motors out of 16) 241
82-P1209 A Condensate fractionator reflux pump 125
82-P1209 B Condensate fractionator reflux pump spare 0
90-Y9201 A Boiler package – Blower 40
90-Y9201 B Boiler package – Blower 40
90-Y9201 A Boiler package – Gas recirculation fan 9
90-Y9201 B Boiler package – Gas recirculation fan 9
Analyzer and analyzer shelter 24
Unit-16, FG COMPRESSOR AUX L.O. PUMP A 3
Local cubical analyzer 9

TOTAL 892

Notes:
1. Absorbed power values are indicative only. Refer to the Electrical consumer list
255/82/00/EL/CN/NA/001.
In order to reduce the flare load in case of general electric power failure, the motors of the unit 12
Condensate Fractionator air condenser and associated reflux pumps are to be connected to the
back-up power supply.
In order to ensure hydrocarbon circulation in the condensate heater to prevent coking due to full
vaporization of the heater hold-up, the Heavy gas oil pumps are also to be connected to the back-
up power supply.
As no specific requirement to keep the recycle compressor in service in case of power failure is
specified in UOP Schedule A, it was decided not to consider connecting the NHT Products
condenser to the back-up power.
The same applies with AXENS, whose PDP mentions no specific requirement to keep the
Kerosene HDT recycle compressor in service.
See § 14.4.4 for the summary of total back-up power supply.

Utilities :
 Steam system
None of the steam consumers appears to be essential:
- Stripping steam to unit 12 can be stopped, the process itself being shut down.
- Flare smokeless steam: in case of power failure, the flare discharge will be at its design capacity
and the smokeless system is not designed for this case anyway. Smokeless steam shall not be
considered as being required in case of power failure.
- Steam to sour water stripper reboiler can be stopped, the sour water stripping unit itself being
shut down.
- LPG vaporizing is not required during power failure
- Need of snuffing steam for the heater and steam lances are not to be cumulated with a total
power failure as agreed with LRC for LR1.
However, the steam system will be maintained in operation in case of power failure by securing
the boilers blowers power supply. Therefore, boilers will be kept as long as deaerator BFW hold-
up and instrument air allow it.
 Cooling water
There is no requirement to keep the cooling water system in service in case of a general power
failure, as all the users will be shut down. Moreover, as air coolers ensure columns condensation,
keeping water coolers in service will not help in reducing the flare load in case of general power
failure.
Rotating equipment:
NHT recycle compressor will stop. Lube oil water cooler is not critical
equipment. KHT recycle compressor and stripper off-gas compressor will stop.
Air compressor: see below.
 Instrument air
There is no requirement to keep the instrument / plant air compressor in service in case of power
failure: the instrument air receiver allows for 30 minutes of back up air. After this delay,
instruments will move to their safety position.
 Nitrogen
The nitrogen system remains operational in case of power failure since the cryogenic storage tank
operates under sufficient pressure to provide the nominal 8 bar header pressure.

14.3.3 Conclusion
The list of electrical consumers to be connected to the emergency power supply is as show in the
following table. The Absorbed power values are based on LR1 EPC documentation.
The EDGs are to be sized for 120% of the estimated absorbed power.
Absorbed
Item N° Designation Power
kW (Note1)
90-P8301 Fire water Pump 397
90-P8709 A Storm / Fire water collection pump 133 (Note2)
90-P8709 B Storm / Fire water collection pump spare 133 (Note2)
90-P8710 A Storm / Fire water collection pump (spare in warehouse) 34 (Note2)
90-P8401 A Flare slop Pump 19
90-P8401 B Flare slop Pump Spare 0
90-P9404 A Potable water distribution pump 20
90-P9404 B Potable water distribution pump spare 0
90-Y9405 Potable water chiller package 58
90-Y9405 Condenser for potable water chiller package 22
90-P9403 A Service water feed pump 10
90-P9403 B Service water feed pump spare 0
Emergency lighting / control room and substations 201
DC Charges / ASP / UPS 219
HVAC 1914
Administrative Building 875
SUBTOTAL 3735

82-P1205 A Condensate fractionator Bottoms Product Pump 273


82-P1205 B Condensate fractionator Bottoms Product Pump Spare 0
82-E1212 Condensate fractionator 1st stage condenser (4 motors out of 4) 119
82-E1213 Condensate fractionator 2nd stage condenser (8 motors out of 16) 241
82-P1209 A Condensate fractionator reflux pump 125
82-P1209 B Condensate fractionator reflux pump spare 0
90-Y9201 A Boiler package – Blower 40
90-Y9201 B Boiler package – Blower 40
90-Y9201 A Boiler package – Gas recirculation fan 9
90-Y9201 B Boiler package – Gas recirculation fan 9
Analyzer and analyzer shelter 24
Unit-16, FG COMPRESSOR AUX L.O. PUMP A 3
Local cubical analyzer 9
SUBTOTAL 892

TOTAL 4627

Notes:
1. Absorbed power values are indicative only. Refer to the Electrical consumer list
255/82/00/EL/CN/NA/001.
2. Intermittent Services. Not included in subtotal/total

Total absorbed power is 4.6 MW about and the EDG will be designed for 2.0 MW each.
This value has to be finalized during EPC phase after motors selection.

15. APPENDIX-1

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