先减压式油田注水恒流堵塞器动力学和可靠性的研究
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摘要
分层注水是目前我国应用最为广泛的提高石油采收率的方法,对我国的石油增产稳产具有重要意义,其中分层流量控制是分层注水方法的核心技术之一。随着中老油田开发过程中注采不平衡问题的积累和非均质复杂断块油层的开发,使得油田井层间渗透率和压力产生不平衡,这要求分层注水方法的分层更加细化,而传统固定水嘴堵塞器存在测调工作量大和流量受地层和注水压力影响的缺点,因此急需新的替代技术以适应当前注采工艺的要求。
恒流堵塞器具有测调工作量小、结构简单及成本低等优点,是一种理想的分层注水流量调节方法。但现有恒流堵塞器存在流量调节精度较低和使用可靠性较差的缺点。针对这一问题,本文结合黑龙江省科学技术攻关项目“分层注水恒流堵塞器的研制”(编号:GC05A508),利用机械、电子和材料等学科的理论,并采取计算机模拟、地面和井下试验等分析手段,研制出一种新型分层注水恒流堵塞器。
本文提出了先减压式恒流堵塞器结构,分析了其在内泄漏和振动特性等方面的优点。充分考虑了内泄漏、阻尼力、液压卡紧力及局部流场分布等因素的影响,采用键合图理论,建立了先减压式恒流堵塞器的动力学模型,为分析其静动态特性提供了基础。
建立了先减压式恒流堵塞器的计算流体力学与键合图理论相结合的混合仿真方法,对先减压式恒流堵塞器的静态特性和稳定性进行了分析。试验表明,仿真结果准确可靠。同时还对该恒流堵塞器的结构进行了优化与改进,在控制好加工成本的基础上,使其静动态特性满足了实际应用要求。
对恒流堵塞器的主要失效形式进行了研究,在流体-颗粒两相流理论、颗粒动力学、三体磨损与污染卡紧理论的基础上,建立了污染磨损和卡紧的数值模拟方法。在Matlab平台上对先减压式恒流堵塞器的污染磨损和卡紧进行了计算,比较了配合间隙、阀芯振动的影响。同时,还研究了该恒流堵塞器的阀口冲蚀和阀内气蚀,采用Fluent软件对冲蚀和气蚀进行了数值模拟,分析了二者对该恒流堵塞器流量特性的影响。模拟结果与实际相符,可为结构优化提供依据。
搭建了恒流堵塞器地面试验台,对先减压式恒流堵塞器的流量特性和可靠性进行了试验。在综合分析、计算和试验的基础上确定了恒流堵塞器的结构、材料和关键部位表面处理方法。结果表明所采用的理论和数值模拟方法可有效地对恒流堵塞器的流量特性和可靠性指标进行分析,所研制的恒流堵塞器在流量调节精度和可靠工作寿命等方面都可以满足油田分层注水技术的要求。
本文还提出了将恒流堵塞器和井下分层测调仪结合使用的分层注水流量调配方式,分析了该方案的可行性,对具体实施方案、机械结构、电路组成和软件结构进行研究。
The separated layer water injection is the most popular EOR (Enhanced Oil Recovery) technology in China now, and it is of far reaching importance for the increasement and stabilization of the petroleum production. The flow control of each layer is a key matter of this technique. With the enhancement of the voidage-injection imbalance and the exploitation of the complicated heterogeneous fault-block oil field, the confliction among wells or layers is becoming more and more serious. This leads to the gradual increasement of the layers in the water injection scheme. But the conventional fixed-nozzle blanking plug has many defects such as the hard work of the flow measure and adjustment, instable water flow rate and so on. So the requirement for new technique is urgent now.
The constant flux blanking plug has many advantages such as convenient application, simple structure and low cost. But current constant flux blanking plugs have some problems in the flow characteristics and reliability. This raises the difficulty of the application. Based on theories in the mechanical engineering, electronic engineering and materials engineering together with the methods such as the theoretical analysis, computer simulation and experimental analysis, a new type downhole constant flux blanking plug has been developed. This research is financed by the Heilongjiang Key Science and Technology Project of China“Research and Development on the Constant Flux Blanking Plug Used in the Separated Layer Water Injection”(GC05A508).
The pressure-reducing first constant flux blanking plug has been put forward, and its merits in internal leakage and vibration are analyzed. The kinetic model of the constant flux blanking plug has been established with the full consideration on the influence of the leakage, damping force, hydraulic lock force, and local flow field, which provides the theory foundation for research the static or dynamic characteristics of the pressure-reducing first constant flux blanking plug.
The mixed-simulation method on the pressure-reducing first constant flux blanking plug has been brought forward on the basis of the computational fluid dynamics and hydro-mechanics. The static characteristic and stability of the pressure-reducing first constant flux blanking plug have been analyzed by this simulation method. The experiments show that the simulation results are precise and reliable. The structural optimization has been done effectively to reduce the production cost and enhance the flow control precision.
The main failure mechanisms of the constant flux blanking plug have been studied. The contaminant wear and lock simulation method has been established based on the theories of fluid-particle two phase flow, particle dynamics, contaminant wear and contaminant lock. The simulations on the wear rates and lock forces have been done using the Matlab software. And the influences of the clearance height and valve spool vibration have been studied. The particle-induced erosion near valve ports and cavitation in the valve pocket have been calculated by the Fluent software, and their influences on the flow characteristic have been analyzed. The simulation results are reasonable and helpful to the design.
The test bench has been designed, and the properties including the flow characteristic and reliability of the pressure-reducing first constant flux blanking plug have been tested by ground and downhole experiments. The structures, materials and surface treatment of the constant flux blanking plug have been optimized on the basis of the theoretical analysis, simulation and experiments to achieve better combination property. The experimental results show that: i) the adopted theoretical and numerical methods are effective in the analysis of the flow characteristic and the reliability; ii) the designed constant flux blanking plug has high performance both in the flow control precision and in the service life.
A new type downhole flow regulating scheme which combines the constant flux blanking plug and downhole testing and regulating system has been brought forward. The practicability has been analyzed, and the preliminary studies on the overall scheme, machine construction, circuit framework, software configuration have been done.
恒流堵塞器具有测调工作量小、结构简单及成本低等优点,是一种理想的分层注水流量调节方法。但现有恒流堵塞器存在流量调节精度较低和使用可靠性较差的缺点。针对这一问题,本文结合黑龙江省科学技术攻关项目“分层注水恒流堵塞器的研制”(编号:GC05A508),利用机械、电子和材料等学科的理论,并采取计算机模拟、地面和井下试验等分析手段,研制出一种新型分层注水恒流堵塞器。
本文提出了先减压式恒流堵塞器结构,分析了其在内泄漏和振动特性等方面的优点。充分考虑了内泄漏、阻尼力、液压卡紧力及局部流场分布等因素的影响,采用键合图理论,建立了先减压式恒流堵塞器的动力学模型,为分析其静动态特性提供了基础。
建立了先减压式恒流堵塞器的计算流体力学与键合图理论相结合的混合仿真方法,对先减压式恒流堵塞器的静态特性和稳定性进行了分析。试验表明,仿真结果准确可靠。同时还对该恒流堵塞器的结构进行了优化与改进,在控制好加工成本的基础上,使其静动态特性满足了实际应用要求。
对恒流堵塞器的主要失效形式进行了研究,在流体-颗粒两相流理论、颗粒动力学、三体磨损与污染卡紧理论的基础上,建立了污染磨损和卡紧的数值模拟方法。在Matlab平台上对先减压式恒流堵塞器的污染磨损和卡紧进行了计算,比较了配合间隙、阀芯振动的影响。同时,还研究了该恒流堵塞器的阀口冲蚀和阀内气蚀,采用Fluent软件对冲蚀和气蚀进行了数值模拟,分析了二者对该恒流堵塞器流量特性的影响。模拟结果与实际相符,可为结构优化提供依据。
搭建了恒流堵塞器地面试验台,对先减压式恒流堵塞器的流量特性和可靠性进行了试验。在综合分析、计算和试验的基础上确定了恒流堵塞器的结构、材料和关键部位表面处理方法。结果表明所采用的理论和数值模拟方法可有效地对恒流堵塞器的流量特性和可靠性指标进行分析,所研制的恒流堵塞器在流量调节精度和可靠工作寿命等方面都可以满足油田分层注水技术的要求。
本文还提出了将恒流堵塞器和井下分层测调仪结合使用的分层注水流量调配方式,分析了该方案的可行性,对具体实施方案、机械结构、电路组成和软件结构进行研究。
The separated layer water injection is the most popular EOR (Enhanced Oil Recovery) technology in China now, and it is of far reaching importance for the increasement and stabilization of the petroleum production. The flow control of each layer is a key matter of this technique. With the enhancement of the voidage-injection imbalance and the exploitation of the complicated heterogeneous fault-block oil field, the confliction among wells or layers is becoming more and more serious. This leads to the gradual increasement of the layers in the water injection scheme. But the conventional fixed-nozzle blanking plug has many defects such as the hard work of the flow measure and adjustment, instable water flow rate and so on. So the requirement for new technique is urgent now.
The constant flux blanking plug has many advantages such as convenient application, simple structure and low cost. But current constant flux blanking plugs have some problems in the flow characteristics and reliability. This raises the difficulty of the application. Based on theories in the mechanical engineering, electronic engineering and materials engineering together with the methods such as the theoretical analysis, computer simulation and experimental analysis, a new type downhole constant flux blanking plug has been developed. This research is financed by the Heilongjiang Key Science and Technology Project of China“Research and Development on the Constant Flux Blanking Plug Used in the Separated Layer Water Injection”(GC05A508).
The pressure-reducing first constant flux blanking plug has been put forward, and its merits in internal leakage and vibration are analyzed. The kinetic model of the constant flux blanking plug has been established with the full consideration on the influence of the leakage, damping force, hydraulic lock force, and local flow field, which provides the theory foundation for research the static or dynamic characteristics of the pressure-reducing first constant flux blanking plug.
The mixed-simulation method on the pressure-reducing first constant flux blanking plug has been brought forward on the basis of the computational fluid dynamics and hydro-mechanics. The static characteristic and stability of the pressure-reducing first constant flux blanking plug have been analyzed by this simulation method. The experiments show that the simulation results are precise and reliable. The structural optimization has been done effectively to reduce the production cost and enhance the flow control precision.
The main failure mechanisms of the constant flux blanking plug have been studied. The contaminant wear and lock simulation method has been established based on the theories of fluid-particle two phase flow, particle dynamics, contaminant wear and contaminant lock. The simulations on the wear rates and lock forces have been done using the Matlab software. And the influences of the clearance height and valve spool vibration have been studied. The particle-induced erosion near valve ports and cavitation in the valve pocket have been calculated by the Fluent software, and their influences on the flow characteristic have been analyzed. The simulation results are reasonable and helpful to the design.
The test bench has been designed, and the properties including the flow characteristic and reliability of the pressure-reducing first constant flux blanking plug have been tested by ground and downhole experiments. The structures, materials and surface treatment of the constant flux blanking plug have been optimized on the basis of the theoretical analysis, simulation and experiments to achieve better combination property. The experimental results show that: i) the adopted theoretical and numerical methods are effective in the analysis of the flow characteristic and the reliability; ii) the designed constant flux blanking plug has high performance both in the flow control precision and in the service life.
A new type downhole flow regulating scheme which combines the constant flux blanking plug and downhole testing and regulating system has been brought forward. The practicability has been analyzed, and the preliminary studies on the overall scheme, machine construction, circuit framework, software configuration have been done.
引文
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68 Borutzky W, Barnard B, Thoma J, et al. An Orifice Flow Model for Laminar andTurbulent Conditions. Simulation Modeling Practice and Theory, 2002, 10: 141-152
69 Broenink J F. 20-SIM Software for Hierarchical Bond-graph/block-diagram Models. Simulation Practice and Theory, 1999, 7: 481-492
70 冀宏, 傅新, 杨华勇. 非全周开口滑阀稳态液动力研究. 机械工程学报, 2003, 39(6): 13-17
71 Naudascher, Rockwell. Oscillator-model Approach to the Identification and Assessment of Flow-Induced Vibration in a System. Journal of Hydraulic Research, 1980, 18(1)
72 Naudascher, Wang. Flow-Induced Vibrations of Prismatic Bodies and Grids of Prisms. Journal of Fluids and Structures, 1993, 7: 341-373
73 Donald J B, Wang J. Discrete Vortex Model of Flow Over a Square Cylinder. Journal of Wind Engineering and Industry Aerodynamics, 1997, 67: 37-49
74 李伟锋, 刘海峰, 龚欣, 等. 平面射流拟序结构的离散涡模拟. 华东理工大学学报(自然科学版), 2005, 31(6): 319-322
75 Chorin A J.Numerical Study of Slightly Viscous Flow.Journal of Fluid Mechanical,1973,57:785-796
76 Amini A, Owen I. A Practical Solution to the Problem of Noise and Vibration in a Pressure-reducing Valve. Experimental Thermal and Fluid Science, 1995, 10(1): 136-141
77 Crow S C,Champagne F H.Orderly Structure in Jet Turbulence.Journal of Fluid Mechanics,1971,48:547-591
78 Peter G, Robert P, Sheldon W. A Strong Interaction Theory for the Creeping Motion of a Sphere between Plane Parallel Boundaries. J. Fluid Mech, 1980, 99: 739-783
79 Peskin C S. Flow Patterns Around Heart Valves: A Digit Computer Method for Solving the Equations of Motion. Ph.D. Dissertation, Albert Einstein College of Medicine, 1972
80 Takeo Kajishima, Saotshi Takiguchi. Interaction Between Particle Clusters and Particle-induced Turbulence. International Journal of Heat and Fluid Flow 2002, 23: 639–646
81 杜道山, 方亮, 李从心. 三体磨料塑变磨损中磨粒运动方式的研究. 润滑与密封, 2004, 166(11): 66-68
82 李方俊. 液压阀污染卡紧与污染磨损的研究. 北京科技大学博士后研究工作报告, 1996, 9
83 Bingley M S, Schnee S. A Study of the Mechanisms of Abrasive Wear for Ductile Metals Under Wet and Dry Three-body Conditions. Wear, 2005, 258: 50-61
84 李方俊, 周士瑜. 滑阀污染敏感尺寸的确定. 机床与液压, 1996(2): 51-54
85 杨勇, 孙军, 潭杰祥. HD20/205 型恒流定量水嘴在油田注水上的应用. 油气井测试, 2004, 13(4): 90-92
86 Russell R, Gai H, Barrilleaux M F, et al. Design, Analysis and Full-scale Erosion Testing of a Downhole Flow Control Valve for High Rate Water Injection Wells. SPE Annual Technical Conference and Exhibition, Houston, Texas, U.S.A. September 26-29, 2004
87 Russell R, Shirazi S A, Macrae J. A New Computational Fluid-Dynamics Model to Predict Flow Profiles and Erosion Rates in Downhole Completion Equipment. ATCE 2004, Houston, Texas USA, September 26-29, 2004
88 Casland M, Gai H, Barrilleaux M F, etc. Predicting and Mitigating Erosion of Downhole Flow-Control Equipment in Water-Injector Completions. ATCE 2004, Houston, Texas USA, September 26-29, 2004
89 Habib M A, Badr H M, Ben-Mansour R, et al. Numerical Calculations of Erosion in an Abrupt Pipe Contraction of Different Contraction Ratios. Int. J. Numer. Meth. Fluids, 2004, 46: 19-35
90 戴丽萍, 俞茂铮, 王贤钢, 等. 超临界汽轮机再热第一级叶片固粒冲蚀特性的数值分析. 热能动力工程, 2004, 19(7): 347-350.
91 Forder A, Thew M, Harrision D. A Numerical Investigation of Solid Particle Erosion Experienced Within Oilfield Control Valves. Wear, 1998, 216: 184-193
92 Haugen K, Kvernvold O, Ronold A, et al. Sand Erosion of Wear-resistant Materials: Erosion in Choke Valves. Wear, 1995, 186: 179-188
93 Oka Y I, Okamura K, Yoshida T. Practical Estimation of Erosion Damage Caused by Solid Particle Impact Part 1: Effects of Impact Parameters on a Predictive Equation. Wear, 2005, 259: 95-101
94 董刚, 白万金, 张九渊, 等. 几种工程材料的冲蚀行为的研究. 材料科学与工程学报, 2004, 92(6): 909-913
95 Wood R J K, Jones T F, Ganeshalingam J, et al. Comparison of Predicted andExperimental Erosion Estimates in Slurry Ducts. Wear, 2004, 256: 937-947
96 弓永军, 纯水液压控制阀关键技术研究, 浙江大学博士学位论文, 2005, 4
97 Dirke M V, Krautter1 A, Ostertag1 J, et al. Simulation of Cavitating Flows in Diesel Injectors. Oil & Gas Science and Technology, 1999, 54(2): 223-226
98 Nishimura A, Assanis D N. A Model for Primary Diesel Fuel Atomization Based on Cavitation Bubble Collapse Energy. ICLASS2000, Pasadena, CA, July 16-20, 2000
99 Donald P S, Douglas A. Robertson, Leo M. Demonstration of Cavitation Life Extension for Suxtion-stage Impellers in High Energy Pumps. TAMU Pump Show, 2004: 103-115
100 Wu J Y, Senocak I, Wang G Y, et al. Three-dimensional Simulation of Turbulent Cavitating Flows in a Hollow-jet Valve. Computer Modeling in Engineering & Sciences, 2003, 4(6): 679-689.
101 Wang G Y, Inanc S, Wei S, et al. Dynamics of Attached Turbulent Cavitating Flows. Progress in Aerospace Sciences, 2001, 37: 551-581
102 董刚. 材料冲蚀行为及机理研究. 浙江工业大学硕士学位论文, 2004, 3
103 Bedkowsi W. Relations Between Cavitation Erosion Resistance of Materials and their Fatigue Strength Under Random Loading. Wear, 1999, 230: 201-209
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66 Suzuki K, Nakamura I, Thoma J U. Pressure Regulator Valve by Bondgraph. Simulation Practice and Theory, 1999, 7: 603-611
67 Borutzky W. Bond Graph Modeling from an Object Oriented Modeling Point of View. Simulation Practice and Theory, 1999, 7: 439-461
68 Borutzky W, Barnard B, Thoma J, et al. An Orifice Flow Model for Laminar andTurbulent Conditions. Simulation Modeling Practice and Theory, 2002, 10: 141-152
69 Broenink J F. 20-SIM Software for Hierarchical Bond-graph/block-diagram Models. Simulation Practice and Theory, 1999, 7: 481-492
70 冀宏, 傅新, 杨华勇. 非全周开口滑阀稳态液动力研究. 机械工程学报, 2003, 39(6): 13-17
71 Naudascher, Rockwell. Oscillator-model Approach to the Identification and Assessment of Flow-Induced Vibration in a System. Journal of Hydraulic Research, 1980, 18(1)
72 Naudascher, Wang. Flow-Induced Vibrations of Prismatic Bodies and Grids of Prisms. Journal of Fluids and Structures, 1993, 7: 341-373
73 Donald J B, Wang J. Discrete Vortex Model of Flow Over a Square Cylinder. Journal of Wind Engineering and Industry Aerodynamics, 1997, 67: 37-49
74 李伟锋, 刘海峰, 龚欣, 等. 平面射流拟序结构的离散涡模拟. 华东理工大学学报(自然科学版), 2005, 31(6): 319-322
75 Chorin A J.Numerical Study of Slightly Viscous Flow.Journal of Fluid Mechanical,1973,57:785-796
76 Amini A, Owen I. A Practical Solution to the Problem of Noise and Vibration in a Pressure-reducing Valve. Experimental Thermal and Fluid Science, 1995, 10(1): 136-141
77 Crow S C,Champagne F H.Orderly Structure in Jet Turbulence.Journal of Fluid Mechanics,1971,48:547-591
78 Peter G, Robert P, Sheldon W. A Strong Interaction Theory for the Creeping Motion of a Sphere between Plane Parallel Boundaries. J. Fluid Mech, 1980, 99: 739-783
79 Peskin C S. Flow Patterns Around Heart Valves: A Digit Computer Method for Solving the Equations of Motion. Ph.D. Dissertation, Albert Einstein College of Medicine, 1972
80 Takeo Kajishima, Saotshi Takiguchi. Interaction Between Particle Clusters and Particle-induced Turbulence. International Journal of Heat and Fluid Flow 2002, 23: 639–646
81 杜道山, 方亮, 李从心. 三体磨料塑变磨损中磨粒运动方式的研究. 润滑与密封, 2004, 166(11): 66-68
82 李方俊. 液压阀污染卡紧与污染磨损的研究. 北京科技大学博士后研究工作报告, 1996, 9
83 Bingley M S, Schnee S. A Study of the Mechanisms of Abrasive Wear for Ductile Metals Under Wet and Dry Three-body Conditions. Wear, 2005, 258: 50-61
84 李方俊, 周士瑜. 滑阀污染敏感尺寸的确定. 机床与液压, 1996(2): 51-54
85 杨勇, 孙军, 潭杰祥. HD20/205 型恒流定量水嘴在油田注水上的应用. 油气井测试, 2004, 13(4): 90-92
86 Russell R, Gai H, Barrilleaux M F, et al. Design, Analysis and Full-scale Erosion Testing of a Downhole Flow Control Valve for High Rate Water Injection Wells. SPE Annual Technical Conference and Exhibition, Houston, Texas, U.S.A. September 26-29, 2004
87 Russell R, Shirazi S A, Macrae J. A New Computational Fluid-Dynamics Model to Predict Flow Profiles and Erosion Rates in Downhole Completion Equipment. ATCE 2004, Houston, Texas USA, September 26-29, 2004
88 Casland M, Gai H, Barrilleaux M F, etc. Predicting and Mitigating Erosion of Downhole Flow-Control Equipment in Water-Injector Completions. ATCE 2004, Houston, Texas USA, September 26-29, 2004
89 Habib M A, Badr H M, Ben-Mansour R, et al. Numerical Calculations of Erosion in an Abrupt Pipe Contraction of Different Contraction Ratios. Int. J. Numer. Meth. Fluids, 2004, 46: 19-35
90 戴丽萍, 俞茂铮, 王贤钢, 等. 超临界汽轮机再热第一级叶片固粒冲蚀特性的数值分析. 热能动力工程, 2004, 19(7): 347-350.
91 Forder A, Thew M, Harrision D. A Numerical Investigation of Solid Particle Erosion Experienced Within Oilfield Control Valves. Wear, 1998, 216: 184-193
92 Haugen K, Kvernvold O, Ronold A, et al. Sand Erosion of Wear-resistant Materials: Erosion in Choke Valves. Wear, 1995, 186: 179-188
93 Oka Y I, Okamura K, Yoshida T. Practical Estimation of Erosion Damage Caused by Solid Particle Impact Part 1: Effects of Impact Parameters on a Predictive Equation. Wear, 2005, 259: 95-101
94 董刚, 白万金, 张九渊, 等. 几种工程材料的冲蚀行为的研究. 材料科学与工程学报, 2004, 92(6): 909-913
95 Wood R J K, Jones T F, Ganeshalingam J, et al. Comparison of Predicted andExperimental Erosion Estimates in Slurry Ducts. Wear, 2004, 256: 937-947
96 弓永军, 纯水液压控制阀关键技术研究, 浙江大学博士学位论文, 2005, 4
97 Dirke M V, Krautter1 A, Ostertag1 J, et al. Simulation of Cavitating Flows in Diesel Injectors. Oil & Gas Science and Technology, 1999, 54(2): 223-226
98 Nishimura A, Assanis D N. A Model for Primary Diesel Fuel Atomization Based on Cavitation Bubble Collapse Energy. ICLASS2000, Pasadena, CA, July 16-20, 2000
99 Donald P S, Douglas A. Robertson, Leo M. Demonstration of Cavitation Life Extension for Suxtion-stage Impellers in High Energy Pumps. TAMU Pump Show, 2004: 103-115
100 Wu J Y, Senocak I, Wang G Y, et al. Three-dimensional Simulation of Turbulent Cavitating Flows in a Hollow-jet Valve. Computer Modeling in Engineering & Sciences, 2003, 4(6): 679-689.
101 Wang G Y, Inanc S, Wei S, et al. Dynamics of Attached Turbulent Cavitating Flows. Progress in Aerospace Sciences, 2001, 37: 551-581
102 董刚. 材料冲蚀行为及机理研究. 浙江工业大学硕士学位论文, 2004, 3
103 Bedkowsi W. Relations Between Cavitation Erosion Resistance of Materials and their Fatigue Strength Under Random Loading. Wear, 1999, 230: 201-209
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