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96085

CABLE SIZING - AVOID SHORTCUTS AND DO IT RIGHT

Donn K. Kelly
Parsons Power Group
2675 Morgantown Road
Reading, PA 19607
5,610-855-2001fax
610-855-351
Joseph R. Jancauskas
Parsons Power Group
633 Chestnut Street, Suite 400
Chattanooga, TN 37450
423-757-8029, 423-266-0922fax

accommodatethese new materials. Further, the regular revision


ABSTRACT of the various applicable codes and standards also requires a
The task of selecting power cable and wire types along with flexible evaluation and selection process.
the sizing of the conductors for specii5c applications is a very At the same time that the number of choices is increasing and
important part of the design of any electrical system. the codes are changing, there is the constant pressure on the
Unfortunately, this is a task that is often performed with a design organizationto prepare the complete design more quickly
minimum of effort and with little consideration for all of the and at a lower cost. These pressures have lead many design
relevant design issues. The resulting tragedy is that improper organizationsto reduce the selection and sizing process to the
selection and sizing can easily increase the installed cost of a use of a few application tables based on past experience and a
facility while also reducing the reliability of the complete simplification of the many criteria. These simpfications r e d m
system. This paper outlines some of the considerations that the cost of the design, but can result in errors and/or a life cycle
should be applied to cable selection each and every time. It then cost that is higher than necessary. Selection tables are
suggests the design for a computer based tool which will convenient, but the built-in assumptions are almost always
facilitate the selection process without resorting to overlooked.
simplifications. The conclusion is that cable and wire can be Thus the objective is to develop a process for cable and wire
readily sized properly if the power of present day personal selection and sizing that will ensure that all the performance,
computers are used to evaluate the various criteria and economic regulatory, and economic factors have been considered while
options. minimizing the engin- design cost.
The major areas that need to be evaluated are:
OBJECTJVE OF CABLE SELECTION AND SIZING 1. Ampacity Considerations
When selecting and sizing cable and/or wire for a power 2. Voltage Drop Considerations
distribution system there are a large number of criteria to be 3. Short Circuit Considerations
considered. These include criteria to ensure that the conductor 4. Overcurrent Protective Device Considerations
sue is sufficient to avoid the overheating of the conductor and 5. Economic Considerations
the terminals of connected equipment as well as criteria to 6. Insulation Material Considerations
ensure that the voltage drop will not be excessive. In addition,
there is the ever present objective to " i z e cost. In some 1. AmDacitv Considerations
cases this will be the total life cycle cost which includes the The true objective of all ampacity evaluation is to ensure that
projected value of losses; in other cases the objective will be to the operating temperature of the conductors remains below the
minimize only the cost of material and installation. design limit for the insulating material. As a practical matter
The variety of wire and cable materials, along with the many these evaluations typically become an exercise in the correct
types of raceways and ambient conditions, makes the proper application of a series of table values and rules established by
selection complex. The constant increase in the choice of the National Electric Code (NEC) and by other industry
materials requires that the selection process be able to easily standardsand guides.

2341 0-7803-3547-3-7116 $4.00 0 1996 IEEE


By far the most common method is to utilize the ampacity 0 Whether the slueld for medium voltage cables will
tables 310-16through310-19 fromtheNEC. Simpleas thismay be grounded at one or both ends.
be, what is often overloaked are some of the necessary Raceway Characteristics
adjustments required to these values. This includes derating for 0 The type such as conduit, tray, duct bank,or direct
more than three cment-carryingconductors such as countmg the burial..
neutral conductor when there is a majority of high harmonic The number of power carrying conductors in an
current drawing loads. E any portion of the circuit is in an area individual conduit or the design “fill” for a cable
where the ambient temperature is above 3OoC(83T) derating tray.
factors must be applied. An additional common mistake when Whether the conduits or trays are “banked” or can
utilizing 90 “C cable is to choose the ampcity value in the be considered thermally independent.
column for 90 “C cable when the maximum allowable value 0 The use of fire stops or other penetration barriers.
should actually be selected from the 60 “C or75 O C column based Ambient Considerations
on the ratings of the terminations in the equipment being Ambient air and/or soil temperature for the entire
connected. This requitement is somewhat hiddenin Section circuit route, including isolated “hot spots”.
110-14(c)of the NEC which invokes the ratings of any listing 0 Soil thermal resistivity (for duct banks or direct
agencies such as those contained in Underwriter’s Laboratories burial).
“Yellow Book. 0 Exposure to heating by solar radiation (or some
The above paragraph lists just some of the more common other idfared radiation source).
oversights. The task becomes even more complicated by the Once all of the above characteristic have been determined, it
variety of possible raceway configurations,wire and cable types, is then possible to idenm the applicable tables and criteria. In
and ambient conditions greatly complicates the problem. As a many cases a single branch circuit or feeder will be exposed to
result it is first necessary to define considerable information several diEerent set of conditions. Each of these sets needs to be
about each branch circuit or feeder in order to determine the evaluated and the ampacity for various conductor sizes
applicable criteria and tables. To further complicate the issue, determined. Once these various ampacities have been
the NEC recognizes that there are configurationsof raceways and determined and compared to the maximum continuous current
cable types that are beyond the scope of the tables provided. For that the branch circuit or feeder will carry,a “mini”” cable
these cases the NEC requires an evaluation by a quahfied size for ampacity can be defined.
engineer. This reference is equivalent to a requirement for The NEC and other industry standards provide some specific
evaluations in accordance with the various IPCEA and IEEE criteria for duct banks of various configurations Ideally, it
standards that presently exist. should be possible to perform the necessary heat transfer
A significant advance in the state of the art is the publication computations for configurationsof duct banks not covered by the
of IEEE standard 835-1994, “Standard Power Cable Ampacity standards, but the authors have not found this to be economically
Tables”, which provides a necessary update of PCEA Standard feasible at ttus tme. Even wth the commercially available
P46-426, (AIEE S-135-1 and S-135-2). This standard provides software which can perform these calculations, the large amount
a voluminous amount of data on cable mpacities, particularly of variables defining the physical construction of the cable whlr;h
for cables in various duct bank configurations. An important must be collected and input is prolubitive.
addition is the inclusion of a separate ampacity column for The NEC provides some cnteria for the ampacity of cables in
conductors exposed to the sunlight These tables are based on cable tray. However, there are some design practices used in
rigorous technical analysis such as the Neher-NcGrath method, some industries that are not covered directly by the code. In
as opposed to the NEC which no longer has a d e f d b l e basis particular, other industry standads such as ICEA P-54-440/
for its values other than tradition. This results from the original NEMA WC 51, “Ampacities of Cables in Open-top Cable Trays”
values being determined by tests of rubber insulated cables in and the on& heat transfer theory need to be used in the
black painted pipe, which is a far cry from a typical installation following situations:
of today. Trays carrying power trays have tight covers for distances of
So in order to properly evaluate a conductor size for more than a few feet.
ampacity, the following informationmust be known: Trays are to be designed to carry many small power cables
Load Characteristics installed in a “random lay” fashion.
0 Maximum continuous current. 0 Trays are to be installed in a bank (in close proximity) with
* Harmonic content of the load current. other trays carrying (heat producing) power cables
Wire/Cable Characteristics Thus a PC based tool needs be able to apply a variety of
0 The tvpe of wire or cable such as single conductor, Maent type of criteria and equations to evaluate ampacity.
triplexed singles, or multi-conductor cable. These include some that reqwre the solution of some rather
e The Insulation temperature rating. complex heat transfer equations. However, having ths
0 Conductor material (copper or aluminum). capability permits the use of codigurations that may be very cost

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effective, but are not easily evaluated using the limited criteria of 12.44.1for continuos operation. This is not as limiting as it
the NEC. sounds because the power factor during inrush for standard
motors is about 0.20. As a result, when the voltage drop in the
2. Voltacle Drop Considerations cable is subtracted vectorially from the source voltage, the
If you were to ask ten engineers to solve the same voltage resultant voltage is much higher than is the absolute value of the
drop problem, it is likely that each would use a different solution voltage drop in the cable would imply. NEMA MG-1 does go an
method with a different set of simplifjmg assumptions. For such to state that the only way that you can really tell if a motor will
a basic technical function it seems odd that there has not been start is to perform a detailed transient motor starting analysis
any standardized solution method. Even the numerous which will require obtaining the speed-torque curves for both the
simplifying nomograms are not similar, and some even resort to motor and the loads as well as the inertias of each. Given that
giving solutions in non-real world units such as “amperes per obtaining this data for relatively small motor loads is often not
hundred feet”. Just selectmg the criteria for voItage drop is practical, ensuring that a voltage of over 90% is supplied during
mostly dependent on the policies of individual designers. motor starting is a way to provide reasonable engineering
While the NEC provide some general criteria, the application assurance that the design is adequate.
of these criteria to specific design problems can result in In order to perform these various evaluations the following
different design solutions. For example, the total drop allowed information must be determined:
in a feeder and branch circuit combination is 5%, with no more 0 The conductor material and the preliminary size.
than a 3% maximum in each (NEC articles 210-19, FPN 4 and The resistance and reactance of the preliminary size and
215-2, FPN 2). It is rare to come a cross written project criteria type of wire or cable.
where the specific allocation of voltage drop is defined. This 0 The steady state design load current and power factor.
becomes a problem when there is more than one circuit between 0 The design inrush (starting)current and power factor.
the supply and the load. There could be a power feed from a 480 The computation for voltage drop is somewhat more difficult
V untt substation to a motor control center, tiom the motor because an “exact” solution requires an iterative computation.
control center to a 480 V power panel, and then from the power The voltage drop depends upon the load current, but the load
panel to the load. The allowable 5% would need to be split up current depends of the voltage at the load terminals, but this
among each of these three circuits. voltage depends upon the voltage drop that is being calculated.
The NEC criteria might not be stringent enough on a large In the past equations that provide a conservative approximation
project that includes several levels of voltage transformation. have typically been used. With a FY based tool an exact solution
Even if the transformer tap settings are optimized, the voltage can be obtained with the use of appropriate tools that can
drop caused by the transformer impedances may require the use perform the necessary iterativecomputations.
of more restrictive critexia than that dictated by the NEC to Once again, the evaluation of wire and cable selection for
ensure adequate voltage is supplied to critical equipment under steady state and inrush voltage drop is relatively easy once the
worst case conditions. necessary information has been determined. However, it is
The normal design approach consists of several steps. The important to remember that the only way to fully determine that
fEst is to ensure that the circuit voltage drop (under steady state voltage drop is not excessive to perform a series of load flow
design load conditions) meets the applicable criteria (NEC or studies. Just performing a single load study for the nominal
other project criteria). If the circuit feeds a load such as a motor design conditions is not enough. Variations in the source voltage
with an in-rush current, the next step is to evaluate the voltage and impedance should be investigated, as well as major
drop during this in-rush. The third step is to model the entire variations in operating loads which are expected A good
system with a load-flow program to determine the voltage at the example would be the difference seen during full load conditions
terminals of critical motors and other loads under both steady as compared to startup Conditions.
state and transient conditions. This last step is ofien neglected
because of the engineering effort (cost) involved. However, it is 3. Short Circuit Considerations
the only way that any assurance can be provided that critical In addition to the standard concerns for ampacity, good
loads will fimction and not be damaged by “worst case” engineering practice includes ensuring that wire and cable is
conditions. What is often overlooked is that under worst case sized so that the conductor insulation is not damaged in the event
low voltage conditions the full load current draw of a constant of a short circuit. This is particularly important for large cables
kVA load such as a motor will increase, which canhave a protected by large circuit breakers that require several cycles to
significant impact cm cable and protective device sizing. open in response to a fault. During these several cycles the
The NEC does not provide any criteria for evaluating voltage temperature of the conductor can increase to a very high
drop during transients such as motor starting. Standard motors temperature as the result of the resistive heating from the fault
are rated to start (with loads of maximum rated inertia) with a current.
minimum of 90% of nameplate voltage at the motor terminals in The various conductor insulation materials have an
accordance withNEMA MG-1-12.44.2. This seems odd because emergency temperature rating, in addition to the more commonly
90% of nameplate voltage is the same cntena in NEMA MG-I- recognized continuous temperature limit. These emergency

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temperature limits can be obtained form the wire or cable the protective device is often actuated by protective relays or
manufacture or can be estimated based on available industry direct acting elements that include a delay mechanism. This
literature. For example, typical EPR insulation rated for a delay is used to provide device coordination so that a minimum
continuous conductor temperature of 90°C has an emergency amount of the electncal disb.ibution system is deenergized in
temperature rating of 250°C. the event of a fault on a particular branch circuit. Thus the
In order to evaluate a specific wire or cable selection it is length of these coordination delays must be included in the time
necessary to know the following information: that the cable must withstand the fault without damage.
The conductor material and the (preliminary) size. Udortunately, wire or cable for these feeder circuits must often
* The emergency temperature rating of the conductor be selected long before the “coordination studies” have been
insulation material. performedand the exact values of the delay are know.
The maximum available short circuit current. Therefore, it is common practice to conservativelyestimate the
The time required for the circuit breaker (or other device coordination time delay for these feeder circuits. Again the
protecting the circuit) to clear the postulated fault. choice is left to the individual designer to select a suitable value.
Unfortunately, determining some of these values is not as Once the vatious values have been selected, the computation
simple as it might appear at first glance. ”here are several of the estimated conductor temperature is a relatively simple
possible values for the “maximum short circuit current.” The process. The formulationscan be found in many standard
fxst question that must be answered is whether the value is to references. These references commonly also include graphs or
correspond to a fault postulated to the load end of the circuit or nomograms to facilitate the manual evaluation of conductors
at the source end. Many designers consider that the appropriate sizes. However, with today’s PC based tools the equations are of
value to use is for a fault at the load end of the circuit. Their more interest. The equations are based on basic physical models
argument is that there is no value in protecting the conductor and the assumption that none of the heat produced in the
insulation for faults that could OCCUT along the length of the cable conductor is dissipated into the conductor insulation, which is a
since the fault itself can only occur if there is major damage to reasonable approximation for an event that has a length of a few
the cable. However, other designers argue that the short circuit cycles. The most important aspect of the equations is the
value correspondingto the source end of the cable should be recognition that the rate of heating increases as the conductor
used. By using this value the possibility of peripheral damage temperature increases. This occurs because the fault current is
from burning of the conductor insulation is avoided. In addition, not significantly reduced by the increased resistance (in the
it is often economically important to be able to repair fault circuit) but the losses are directly proportional to this increasing
damage and return an existing circuit to service, without resistance.
replacing the complete circuit. For example, it is common In summary, given the necessary data and preferences,
practice to repair the damage that OCCUTS from “dig-ins’’ to direct evaluating the size of wire and cable to ensure that the insulation
buried cables. By using the fault current value for the source end will not be damaged by a short circuit is easy. The process is
of the circuit, the fault damage can generally be limited to the even easier if a PC based tool is used. In order to provide this
immediate location of the fault. The f i l choice is thus left to prokction it IS common in medium voltage circuits to choose a
the individual designer and the perception of the economics minimum conductor size such as 4/0. What is more a c u l t is to
applicable to a part~culardesign situation. make the determination ifit will be economicallyjustifiable to
The next problem is to select the appropriate values for the provide the larger cable sizes necessary to prevent short circuit
fault current. It is common practice to use the symmetrical fault damage €or all low voltage circuits.
current value that is typically provided by short circuit analyses
used for checking circuit breaker ratings. Unfortunately, this 4. Overcurrent Protective Device Considerations
value is not really applicable since individual conductorswill see Ideally it should be possible to select a wire or cable size
significantly higher currents due to the asymmetrical offset and based on the load and environmental conditions and then to
the decay of the current that can occur between the initial value provide a matchug overcurrent protective device (setting).
and the calculated value that applies at the time of breaker Unfwtunatly, the existing rules in the NEC and other standards
interruption. For (small) half-cycle breakers it is best to use the are sufficiently complex that it is possible to have a branch
instantaneous or “momentary” value. For larger breakers which circuit or f& circuit where the conductor size must be
require several cycles, the asymmetrical current at the first half increased because of the (setting of) the overcurrent protective
cycle is a good compromise value. Remember the objective is to device. This occurs most often when using molded case breakers
select a value that will allow a good estimate of the heating that have a fmed ratmg. In general, the NEC requires that the
effect on the individual circuit conductors. wire or cable ampacity be at least equal to the “next smaller
Determining the time for the protective device to the clear standard device r a m . ”
the fault is relatively easy. Tlus information is normally Thus another feature needed in a cable sizing tool is the
available from the device manufacturer. However, this value can ability to check the cable ampacity against the long time setting
not be used directly unless the protective devices is activated by (or continuous current r a w ) of the circuit overcurrent protective
an “instantaneous” ovacurrent element. For large feeder circuits device.

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5. Insulation Material Considerations As is the case for other evaluation, data is needed in order to
In most projects there are no special restrictions on the choice proceed. For an economic evaluation the following must be
of wire or cable insulating materials. So long as the material is known:
recognized by the applicable standards, the choice can be based 4 The cost of energy, includmg some estimate of the change in
on economics. However, the following types of installations will this cost over time.
restrict the choice of materials: 4 The expected load (current) on the circuit and the number of
Where the insulation is exposed to the effects of weather hours per year that the load will be operating.
and direct solar radiation (such as an outdoor cable tray or a 4 The length on the circuit.
pole line). 4 The cost of the alternative materials per unit length. This
Where the insulation is subject to periodic or continuous includes both the wire or cable and the raceway alternative.
immersion in water (such as in a duct bank or direct burial). 4 The method of installation, the type of raceway, and the
Where the conductor insulation or cablejacket will be difficulty of installation includmg the height or difficulty of
exposed of oil or petroleum vapors. access. Thls can very with both the type and size of wire
Where the circuits will be routed through a cable tray (or and the type of raceway.
other open support structure) within an ventilation plenum. e The labor effort associated with the method of installation
Where certainmaterials are restricted to avoid major and difjkulty on installation.
economic consequences in the event of a fre. For example, e The cost and productivity of labor for the project location.
many power generation facilities and computer centers As is obvious from the length of the a b v e list, making an
restrict the use of PVC cable insulation because of the economic evaluation can be difficult and expensive. As a result
corrosive vapors that result when the material is burned. these evaluations are usually only made for large feeder circuits.
These special situation normally do not require any specific However, if a good PC based tool is available and the data has
analysis, but it is important to ensure that they have been been collected for those large circuits, smaller circuits can often
considered when selecting the type of wire or cable and type of be evaluated for a reasonable amount of effort in data collection.
raceway or support. One of the functions of a good PC based
tool is the formal documentation that these factors have been DESIGN OF COMPUTER BASED TOOL
considered. The best way to start the development of any computer based
tool is to define the output that the tool is to produce. This
6. Economic Considerations output is what provides value. Focusing on this output will focus
The objective of any economic evaluation depends to some on the real requirements for the tool.
extent on wfio is paying for the study and who is paying for the During the author's work on the development of a PC based
actual wire and cable. Ideally, studies should be aimed at tool, the needs of different type of projects defined the need for
minimizing the life cycle cost of a project. Thus the study should several different types of output. The following is a summary of
include the cost of the material (wire and cable), the cost of the types of projects and the nature of the printed outputs that
installation, and the cost of the energy lost in the cables over the
life of the facility. Simple commercial A list of the feeder circuits with
Tlus last consideration,the cost of the energy lost, is often facilities: the sue of wire for the type of
left out of evaluations. There are several reasons for this. First, wire insulation selected for the
the designer is often placed in a commercial position where there project. Branch circuits sizes are
is an economic incentive to "izethe construction cost with based simply on the panel board
no incentive to minimize the ultimate operating cost. In breaker r a m .
addition, it is often difficult to define a meanin@ operating cost Industrial facilities A list of the feeder and large
different between two alternatives. For example, consider a and large branch circuits with wire or cable
branch circuit that feeds receptacles used primarily for commercial projects: sue and a brief indication of the
incandescent lighting. Increasing the conductor size for this basis for the selected sue.
branch circuit will reduce the losses in the circuit; however, the Where alternatives are
total epergy used by the circuit may actually increase very considered these can be listed
slightly because incandescent lamps are essentially constant separately.
resistance devices. Further how do you estimate the amount and Power generation, The same listing described for
type of lights that will actually be connected to a circuit that government, and industrial facilities supplemented
feeds convenience receptacles? On the other hand, branch specialty projects: with a worksheet for each circuit
circuits that supply fixed VA loads such as permanently installed that defines all of the evaluations
motors can be evaluated and the results are sometimes performed by the computer and
surprising. the results of these evaluations.

2345
The design of the outputs is presently in progress has taken a d e s and standards that apply to the process of wire and cable
considerable effort. There is a constant conflict between the selection. If a suitable design can be developed the cost of
need for brevity and simplicity and the need to inform users of maintaining the tool w ill be greatly reduced since program
the details of the process used for the wire or cable selection. changes will not be required for each new edition of a code or
One of the solutions available with the PC is to provide some of standard. A M e r incentive for the authors is that their
the detailed information as a screen display so that the user can company is providq designs throughout the world and a rule
understand details of the evaluation, while still keeping the based design will allow the quick incorporation of the rules for
printed output in a .summary form. individual counties, as well as the differences in mm2cable sizes
Once the nature and content of the outputs have been defined utilized by the various countries.
it is possible to determine the data that must be provided to the
program to produce the required output. In order to design a tool CONCLUSIONS
that is usable by a variety of types of projects, the authors have In assembling this paper it has been the authors’ intent to
suMvided the data into the following categories: bring together in one place a clear definition of the many diverse
0 Project options including the codes and standards that criteria that should be applied when selecting wire and cable for
apply, the preferred materials, default values for criteria electrical power distribution systems. A further purpose of
such as allowable percent of voltage drop, and whether defining these criteria has been to defme the characteristics of a
economic evaluations are to be included. PC based tool that is under development to facilitate the
Library data including the requirements of the various d e s selection of wire and cable. Without such a tool today’s system
and material characteristics designer cannot practically perform all the evaluations necessary
0 Circuit specific data which can be further subdivided as to properly perform wire and cable selection.
follows: Perhaps a larger reveiation in assembling this paper has been
0 ’Loaddata the lack of any type of comprehensive guide to performing such a
0 Circuit physical design data such as length basic task as cable sizing. The sheer number of simplifying
0 Environmental factors and raceways which can tables that are available has been overwhelming. Having to
include “many” d&rent combinationsof conditions investigate the details and design basis behind these tabies
applicable to one circuit. which has made the authors realize how much has usually been
The third aspect of the tool design is the definition of the taken for granted.
general environment and the development tools to be used. In the interest of minimizing cost during the design phase of
Because of the current popularity of Windows= the authors have a project, m p l e tables and nomograms are hard to beat, and the
elected to this environment. The authors have also concluded authors are not suggesting that they need to be completely
that all data, both input and results, should be stored in a eliminated. With the type of pc-based tool described above,
common database format. l h s decision is based on the previous homogenous areas of a project can be fully evaluated, and then a
experience of the developers which has repeatedly shown this simple table of applicable cable sizes for given loads can be
approach to have many benefits and few disadvantages. The two handed to the designers who are routing the circuits. The critical
main advantages are the convenience of moving to a new difference is that the simplified sizing table has a detailed
“plafform” when an existing “plafform becomes obsolete and the calculationlevaluationbehind it that adequately defines all of the
ability to link the results of applications together. relevant design issues.
The choice of development tools has been more difficult. Perhaps just as important as hamg someone perform the
The use of a standard database tool such as Microsoft AccessTM detailed evaluations is “gsure that all personnel involved
has the advantage of permitting easy development of output with cable selection are adequately indoctrinated into the
reports and data input screen forms. The use of a more general complete design process. This will enable the users of the
purpose programming tool such as Microsoft Visual BasicTM simplified tables to be able to identify circuits which do not fall
provides more flexibility and better performance (speed). The within the parameters and assumptions of the simplified tables
use of a mathematics engine such as Mathcadm has the and have the necessary special evaluations performed.
advantage of simplifyinsthe programming of complex In today’s environment of mobile technical personnel, it
computations, especially those that require iterative solutions. seems that each person performs cable sizing the way he did it at
At this time the authors have not yet settled on a choice of his last job. This can lead to design mors, cost inefficiencies,
development tools since the design of the tool is just being and operational problems. It is time to utilize the tools that are
completed. available to stop taking shortcuts and do it right - for such a basic
One of the challenges that the authors hope to address in the technical function as cable sizing the time is long overdue.
design is the ability to allow the definition of the various
evaluations without changq the actual progm code. This is
very desirable because of the ever changing nature of the various

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