ML070590715
| ML070590715 | |
| Person / Time | |
|---|---|
| Site: | Oyster Creek |
| Issue date: | 10/31/1986 |
| From: | MPR Associates |
| To: | GPU Nuclear Corp, Office of Nuclear Reactor Regulation, NRC/OGC, NRC Region 1 |
| References | |
| MPR-953 | |
| Download: ML070590715 (205) | |
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I 1 MPR ASSOCIATES, INC.
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I GPU MUCLEAR CORPORATION
,I OYSTER CREEK NUCLEAR GENERATING STATION
- TORUS SHELL THICKNESS MARGIN I MPR-953 I
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Prepared for GPU Nuclear Corporation I Parsippany, New Jersey October 1986 WASHINGTON. D.C. 20036 202-659-2320 I
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CONTENTS Sect?on Page
- 1. INTRODUCTION 1.1 Purpose 1-1 1,2 Background 1-1 1.3 Scope 1-2
- 2.
SUMMARY
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- 3. Df scuss ION 3.1 Stress Margin 3-1 3.2 Other Sources of Margin 3-1 3.3 1983 Inspections and Repair 3 -2
- 4. REFERENCES 4- 1
- 5. APPENDICES Appendix A - Stress Margin.
Appendix B - Other Sources o f Margin Appendix C - 1983 Inspection Reports i
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Section 1 I NTRODUCTlON 1.1 PURPOSE This report presents the results o f analyses to determine the margin i n the thickness o f the Oyster Creek torus shell. The torus she71 thickness margin is determined i n order t o determine t h e corrosion allowance for the inside and outside surfaces of the torus shell.
1.2 BACKGROUND
In accordance w i t h the requirements of NUREG-0661, "Safety Eva1uation Report, Mark I Containment tong-Term Program," the Oyster Creek torus was reanalyzed f o r newly defined loads for postulated p l a n t accidents and transients. As a result o f these analyses, plant modifications were designed and installed i n 1983 t o reinforce the existing torus structure. These modifications included she?J hoop straps and midbay saddles, As part o f these m o d i f i c a t i o n s , the original coatings on the inside and outside surfaces o f the torus shell were removed. Inspections o f t h e torus she?? in 1983 revealed pitting corrosion on the inside surface o f the shell below the water line. Repair criteria were established which defined an acceptable e f f e c t i v e metal toss due t o corrosion based OR Mark I Program stress analysis resufts.
Corroded areas not meeting the criteria were repaired by weld overlay.
After installation of the torus structural modifications and weld repafr, the inside surface of the torus shell was recoated with a protective coating. No 1-1
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07/10/06 11:41:19 coating was applied to the outside surface o f the torus shell. In 1986, a Material Nonconformance Report (MNCR), Reference (I), identified general corrosjon on the outside surface of the torus shell. Accordingly, wall thickness measurements were taken t o determine the metal loss due to the observed corrosion, and analyses were performed t o determine a corrosion allowance for the torus she1 I .
1.3 SCOPE The scope o f this report i s t o document t h e basis for margin in the torus shell thickness which may be considered as a corrosion allowance, This scope includes:
Review o f Mark 1 Containment torus stress analysis results t o determine the minimum thickness f o r which the torus shell would meet ASME Code allowable stress values. This inctudes formally documenting the analyses and corrosjon a1 lowance criterfa used.
Review o f the manufacturers' material certificates t o determine actual p l a t e thickness and strength.
Determination o f underthickness tolerance p e r m i t t e d by the ASME Code.
Review of the 1983 GPUN torus inspection reports to determine the maximum depths of pftting corrosion which. were not weld repaired.
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M P R ASSOCIATES. INC.
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I Section 2
SUMMARY
I Torus she1 1 thickness margins have been determined based on calculated stresses, actual materi a7 properties, actual plate thicknesses, and ASME Code pemftted I undertolerance. Results are presented in Table 2-1, Also t a b u l a t e d in Table 2-1 are t h e maximum corros'ion depths l e f t i n the torus shell following the 1983 I inspections and repairs.
I As shown in Table 2-1, the calculated stress margin exceeds the maximum corrosion depth l e f t in the torus shell f o r a71 regions o f the torus. The difference
-I between the stress margin and maximum corrosion depth can be considered a s ' a corrosion allowance. The mater1 a? property and ASME Code permitted undertolerance I: margins could be used to j u s t i f y a d d i t i o n a l corrosion allowance i f needed, I
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I Torus Shell Thickness Margin (inch) haximua Depth of Cormsion TORUS SHELL Stress Margin Material Pmaertv Mkgl.6 .
Plate Thickness Margin
~%%$
Undertolerance Left in TONS Shell After 1983 Repairs I LOCATION !
General Shell 0.060 0.013 0 0.010 0.040 1
Adjacent t o Ring Girder Within 1" o f SRV Sqiporting R i n g Girders 0.061-1/
0.013 0 0 .a10 0.050 0' I
4 Within 1" o f NcnSRV \
P Supporting Ring Girders 0,076' 0.a~ 0 0.010 0.ow 0
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Between 1-8" Away 0 From A l l Ring Girders 0.103 0,013 0 0.010 0.040 0-7 P
P Adjacent t o Saddle Flange l b Within I" o f P
P Saddle f l m g e 0.W 0.013 0 0.010 0.035 w Between 1-8" Away From Saddle flange 0.151 0.013 0 0.010 0.040 I!
Adjacent to oru us Straps within 1" o f Straps Remainin Portion of setween Straps 0.057 0.060 0.013 0.013 0
0 0.010 0.010 0.U4D 0.M I1 I
A' This P a r in applies to ring gfhkrs w i t h center SRV supports attached, which am more h i ly loaded than all other SRV sup ortin ring mglrgers. This margin is mservatively considered here ko apply to ring girders wi h sliding or rigid SRV suppoxts a&ache!.
g' This is thering supporting margin for ri girders with rigid SRV supports. This m a r i n iS mnservetively considered hem to apply girders, 3nce nan-SRV supporting ring girders are loa?ed less than SW suworting ring girders.
t o non-SRV
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Section 3 DISCUSSION 3.1 STRESS MARGIN
. Structural reanalyses o f the Oyster Creek torus were performed i n 1982 t o demonstrate that the torus met the stress analysis criteria o f the Mark I Containment Long-Term Program, Results o f these reanalyses are documented i n References ( 2 ) and ( 3 ) .
A p l a n view o f the Oyster Creek torus i s shown in Figure 3-1. Preliminary analyses o f the torus identified the need for reinforcement o f t h e lower half o f t h e shell. As a result, hoop straps and a mid-bay saddte, shown ln Ffgure 2-2, were added t o the torus. Final analyses included the e f f e c t s of t h e structural modifications.
Using t h e stress analysis results o f the Mark I Containment Long-Term Program, ca7culattons were performed to determine the minimum she31 thickness required to meet applicable ASME Code allowable stress values. Results o f these calculations are contained i n Appendix A and tabulated i n Table 2-1. Stress margins were determined for the general shell and for the she77 near discontinuities such as the ring gjrder, saddle flange, and hoop straps, Stress margin is defined as the difference between nominal shell thickness and the minimum required thickness.
3.2 OTHER SOURCES OF MARGIN Three other potential sources o f shell thickness margin were considered, These are :
3-1
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'I ' Material property margfn Plate thickness margin I ASME Code permitted undertolerance I An evaluation of these additional sources o f margin was performed and i s contained i n Appendix B and tabulated i n Table 2-1.. Results o f these evaluations are I summarized 'as follows: .
The m i n i m u m tensile strength o f the plates used i n the Oyster Creek torus is I'I 75 ksi compared t o a rnln.lmum specified tensile strength o f 70 k s i for the A212 Grade B material. AssumSng the allowable stress i s proportional t o the materia? strength, thSs excess material strength .Is equivalent to a shell thickness margln o f 0.013".
- Spot measurements of actual p l a t e thickness show i t t o be only s l i g h t l y B greater t h a n nominal, No additional margin can be attrfbuted t o actual plate thickness.
I Paragraph N-2124(b) o f the ASME Code (Reference ( 4 ) ) permits an undertolerance equal t o the lesser o f 6 percent o f the ordered thickness o r O.OIOil, For the Oyster Creek torus shell with a nominal thickness o f O.385lf, Q.0109' i s c o n t r o l l i n g . This ASME Code p e r m i t t e d undertolerance may be considered t o be a source o f additional thickness margin.
I 3.3 1983 INSPECTIONS AND REPAIR I In 1983 the entire inside and outside surfaces o f the torus shell were cleaned t o bare metal and visually inspected. The inspections revealed p i t t i n g corrosion on I the inside surface o f t h e shell below the waterline, No visible corrosion was observed on t h e portion o f the shell above the waterline.
I The corroded areas and depths o f corrosion were documented f o r each bay (see Appendix C). Repair criteria were developed t o provide a mfnimum of 0.020" margfn I based on Mark I program stress analysis results. No credit was taken f o r other potential sources of margln, e.g., actual material properties o f the plate, actual 1 plate thickness, and permissible ASME Code undertolerance on plate thickeness.
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07/10/06 11:41:19 The repair criteria were as follows:
Acceptable Metal Loss Torus Shell Region Due t o Pittinq C o r n x i o n (Inch)
I 1, General. Shell 0.040 I 2. Near Ring Girder
- a. Within 1 o f Rfng Glrder 0.050
- b. 11g-8t1 Away From Ring Girder 0.080
- 3. Near Saddle Weld
- a. Nithin 1 o f Weld 0.035 b, 1*-8f Away From Weld 0.090 Weld repajr was performed i f the average e f f e c t i v e metal ?oss due t o pitting corrosion exceeded the above depths. Thus, the above metal losses represent t h e I maximum metal losses that may have been left in the torus shell following the 1983 inspections and repairs I
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FIGURE 3-1 UYSTER CREEK'TORUS PLAN VIEW
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HOOP STRAP
\ \ YRiNG OUTER SUPPQ
.COLUMN AODLE FIGURE 3-2 ELEVATlON VlEW TORUS SHELL AND HOOP STRAPS
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M p R ASSOCIATES. INC.
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Section 4 REFERENCES
- I ' 1. GPU Nuclear Corporati on Materi a1 Nonconformance Report Number 86-285 dated June 17, 1986.
MPR report MPR-718, "Oyster Creek Nuclear Generating S t a t i o n - Mark I Contaiment Long-Term Program - Analysfs o f Torus Shell" dated August 1982.
MPR report MPR-722, Oyster Creek Nuclear Generating Station Mark I Containment Long-Term Program PI ant Unique Analysis Supplemental Report
dated July 1983.
- 4. American Society o f Mechanical Engineers, ASFIE Boiler and Pressure Vessel Code, Section 111, Rules f o r Construction o f Nuc7ear Power P l a n t Components, I Division 1. 1977 Edition w i t h Addenda through Summer 1977.
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1 Section 5 AP P ENOX CES Appendix A - Stress Margin Appendix B - Other Sources o f Margin Appendix C - ,1983 Inspection Reports
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I M PR ASSOCIATES. INC.
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I APPENDIX A Stress Margin I PURPOSE t The purpose o f t h i s appendix i s t o determine the thickness margin i n the Oyster Creek torus shell based an stress.
I DISCUSSION I Torus shell stresses were evaluated as part o f the Mark I Containment Long-term Program f o r Oyster Creek (Reference (1)). These stresses were calculated for many 1 p l a n t unique load combinatSons as defined i n Reference ( 2 ) . The results o f t h e stress analyses are contained in References ( 3 ) and (4) and are summarized i n E Table A-I. The approach t o determining whether a stress margin on thickness exists i n the 0.385" [nominal) thick she11 is as follows:
I (A) Membrane Stresses I Membrane stresses vary inversely w i t h thfckness. Therefore a ratio o f calculated membrane stress to allowable s t r e s s can be used t o determine the I minimum required wall thickness as follows:
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Calculated Mernbr ane Stress Allowable Membrane Stress I = (
Minimum Required Wall Thickness 0.3a~
1 1 Wall thickness margin based on membrane stress i s therefore calculated as follows: .
1 Margin = 0,385" - Minimum Required Wall Thickness I I A-1 I
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.(B) . Bending Stresses Bending stresses vary inversely w i t h t h e square o f the thickness. Therefore, a ratio of calculated bending stress t o allowable stress can be used t o determine the minimum required wall thickness as follows:
Calculated Bending Stress Minimum Required Ma71 Thickness 2
( I = ( 1 A I 7 owabl e Stress 0.385" Wall thickness margin based on bending stress i s also calculated by subtract-ing the minimum required wall thickness from t h e 0.385" nominal H a l l t h i c k -
ness.
T a b l e A - 1 sumnarizes the calculated stresses and allowable stresses f o r primary membrane stress (Pm), local primary membrane stress (Pl), and primary membrane plus bending stress (Pm + Q o r PI j . Q ) , for each region o f t h e torus shell. These calculated and allowable stresses were obtained from the results o f the Mark 1 Containment Long-term Program (Reference (1)), Also tabulated i n Table A-1 are the torus shell margins based on stress calculated using the equations shown above. (Note t h a t membrane p l u s bending stresses are listed i n Table A-1. For simplicity, the membrane portion o f these stresses was conservatively assumed t o be pure bending stress.
As shown in Table A-1, t h e thickness margin i n several she77 regions (described below') i s much smaller than i n other regions, The remainder of t h i s appendix documents calculations performed t o reanalyze the stress calculations from Reference (1) t o determlne if stresses i n these regions were calculated conser-vatively, and if so, then stresses were recalculated more realistically. Torus shell thickness margins are t h e n determined based on these more r e a l i s t i c calculated stresses.
A-2
07/10/06 11:41:19 The particular areas which were reanalyzed i n t h i s task are listed below, along w i t h a description of the reanalysis effort:
0 She 11 Between Straps The o r i g i n a l calculations o f the general primary membrane stress in-tensity i n the shell between straps was reviewed t o determine any sources of conservatism which could be removed t o reduce the stress.
One source o f conservatism (Reference ( 4 ) , p. 20) found i n the original calculation was the use o f safe shutdown earthquake loads t o envelope both operating basis earthquake and safe shutdown earthquake. A second source o f conservatism was the algebraic sumnation o f the earthquake results with the tfme dependent loss of coolant accident (LOCA) results (Reference f4), p. A-16) whlch implies the loads are i n phase. A less conservative square root-sum o f squares sumnati an of these dynamic loads i n acceptable, A t h i r d source of conservatism i s the use of an enveloping stress extrapolation factor (Reference (5)).
Additional torus stress analyses performed to remove the conservatisms discussed above are documented i n Reference (61, Section 1 o f t h i s appendix, 5ased on these calculations, the shell between the straps has a thickness margin of 0.060".
Shell a t Saddle Flange Edge Two sources of conservatism found i n the original evaluation are the use o f a conservative stress extrapolation factor and the absolute summing of LOCA and seismic stresses. Reference (7), Section 2 o f this appendix, contains further evaluations o f stresses in the she'll a t t h e saddle flange I n which these conservatisms were removed. Based on these calculations, the torus shell adjacent t o the saddle flange has a margin o f a t least U.06Ol1 within one inch of t h e saddle flange. Between 1 inch and 8 inches away from the saddle flange the margin is 0.151".
Shell a t Rins Girder One source o f conservatism i n the original evaluatlon is the use of conservat 5 ve s bress extrapol a t ion factors. Reference ( 8 ) , Sect i on 3 of t h i s appendix, contains further evaluations o f these stress extrapola-t i o n factors at the r i n g girder. Based on these calculations, the tarus shell has a margin of 0.06Ii1w i t h i n one inch adjacent t o ring girders w i t h Safety Relief Valve (SRV) attached p i p i n g , and 0.079" within one inch o f r i n g girders without attached SRV piping. Between 1 inch and 8 inches away from the ring girder the margin i s 0.103".
A-3
II . REFERENCES II i
{ I ) MPR-718, "Oyster Creek Nuclear Generating Station Mark I Containment Long-Term Program, Analysis of Torus She1 1," August 1982.
1 (2) MPR Calculation, "Calcu7ation o f Overall Stresses i n Torus Shell and Comparisons to Allowed Stress," By R.C. Trench, Dated 7/29/82.
(3) MPR Calculation, Yknrnary o f Stresses i n She'll Monftor Elements," By E R C. Trench, Dated 7/15/82,
( 4 ) MPR Calculation, "Load Combinations for Evaluation of Torus Shell Using I (5)
Program TORSHST," by B.R. Bernier, Dated 6/3/82, MPR Calculations, "SEF f o r Membrane Stress Intensity i n S h e l l Between I (6)
Straps," by T.E. Greene, Dated 6/17/82.
MPR Calculation, "Torus Shell Thickness Margin i n Shell 5etween Straps,'#
by M.J. Kennedy, Dated 9/26/86.
I ( 7 ) MPR Calculation, "Torus Shell Thickness Margin a t Saddle Flange," by M. J, Kennedy, Dated 9/25/86.
I ( 8 ) MPR Calculation, "Torus Shell Thickness Margin a t Ring Girder," by M.3.
Kennedy, Dated 9/19/86.
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07/10/06 11:41:19 TABLE A-l Torus Shell Thqckness Margin Calculated Based on Stress L/
Calculated ASME Calculated Allowable Torus Shell Type o f Service Stress Stress Thickness Margin Location Stress Level (Ksi) (Ksi) (in)
Clean She'll Pm A/B 14.3 19,3 0.100 c 14.4 .35.6 0.229 She1 1 Between Pm A/B 19-1 19.3 0.004 Straps C 19.1 35.6 0.178 Shell at Edge Pm+Q A/B 50-3 69.5 0.057 o f Straps Shell at T i p Pt A/B 22-2 29.0 0.090 of Straps c 22.2 53.4 0.225 Shell at Saddle Fl A/B 17.6 . 29-0 0.151 F1 ange C 30.9 53,4 0.162 Pl+Q A/B 57.4 69-5 0,035 Shell at Saddle PI 1 A/B 15.0 29-0 0.186 Flange Tips C . 15.1 53.4 0.276 Pl+Q A/B 24.2 69.5 0.158 Shell at Ring PI A/B 24.2. 29.0 0.064 Girder c 31.7 53.4 0. I56 Pl+Q A/B 67 ,7 69.5 0.005 Shell at Column PI A/B 15.5 29.0 0.179 Connection C 23.1 53.4 0,218 PI+Q AI8 25.4 69.5 0.171 Shell a t Vent PI A/B 8-4 29.0 0.273 Penetration C 8.4 53.4 0.324 Pl+Q A/B 10-7 69.5 0.234
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Notes 1
' Calculated and allowable stresses for each shell region are obtained from Reference 1.
2/ Calculated stresses shown for the shell 'at r i n g girders are for the shell at ring girders without attached piping. Stresses i n the shell near r i n g girders w i t h attached p i p i n g are considered.separate1y i n Section 3 o f this appendix-
m APPENDIX A Section I MPR Calculation Entitled "Torus Shell Thickness Margin in Shell Between Straps,"
by M, J, Kennedy dated September 26, 1986.
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NE3213.10 Locd Primary Membrane Stress. Cas- sn es arise in which a membrane stress produced by pressure or otter mechanical loading and associated wit!! a primary or discontinuity effect produces excessive distortion in the transfer of load to other portions of the structure. Conservatism requires that such a stress be classified as a local primary mem-brane stress even though it has some characteristics of r -
the minimum miburface radius of curvature and t is the minimum thickness in the region considered.
Regions of local primary stress integsy involving axisymmetric membrane stress distributions which exceed 1.1 Sw shall not be closer in the m e n m f T E Z i i a a n 2.5 Rt, where R is defined as (RI +
R2)i2.andr is de med as ( r l +r2)/2, where and f Z are the minimum thicknesses at each of the regions considered and R,and Ro are the minimum midsur-face radii of curvature at these region; where the membrane stress intensity exceeds 1.1 S,. Discrete regions of local p n m q membrane stress intensity, such as those resulting from concentrated loads acting on brackets, where the membrane stress intensity exceeds 1.1 ,S shall be spaced so that there is no overlappingof the areas in which *e membrane stress intensity exceeds 1.1.
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I 1 APPENDIX A Section 3 MPR Calculation Entitled "Torus Shell Thickness Margin a t Ring Girder," by M, 3, Kennedy dated September 19, 1986.
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I I APPENDIX B I Other Sources o f f.,drgi n Contents
!I MPR Calculation Entitled "Other Sources o f Margin," by M. J. Kennedy dated I September 26, 1986.
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I NE2W Material Size Ranges and Tolerances (a) Materid outside the limits of size br thickness I given in any specification in Section 11 may be used if the material is in compliance with the other requirements of the specification and no size iimita-I tion is given in this Subsection.In those specifications in which chemical composition or mechanical proper-I ties are indicated to vary with size or thickness, any material outside the specification range sMl be required to conform to the composition and rnechani-kI-. caI properties shown for the nearest specified range
[NA-3766.6(a)(I)J.
(b) Plate material shallbe ordered not thinner than io the design thickness. Vessels, except for piping, made I of plate furnished with an undertolerance of not more
-ban the lesser value of 0.01 in. (0.25 mm)or 6% of the.
,06(35A) = 4023fA lordered thickness may be used at the f u U design pres-I *surefor the thickness ordered. If the specillcation to which the plate is ordered allows a greater undertoler-ance, the ordered thickness of the material shall be
' 0 ,v7;&4* KY&&7M = .d/&
I sufficiently greater than the design thickness so that the thickness of the material furnished is not more than the lesser of 0.01 in. (0.25 mm) or 6% under the design thickness.
1 (c) If pipe or tube is ordered by its nominal wall thickness, the manufacturing undertolerance on wall thickness shd1 be taken into account. The manufac-f turing undertolerances are given in the several pipe and tube specificationsIisted in the applicable Tabks in Appendix I. After the minimum wdl thickness is I determined (NE-3641.1), it shall be increased by an amount sufficient to provide for the manufacturing undertolerance dlowed in the pipe or tube spec-I ification.
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APPENDIX C 1983 Inspection Results GPU Nuclear Corporation f iel d Change Request Number c-015357 dated November 12, 1983 i
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