ML20238F036
| ML20238F036 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 09/08/1987 |
| From: | Beck J, Counsil W, Streeter J TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC) |
| To: | |
| Shared Package | |
| ML20238F024 | List: |
| References | |
| NQA-3.07-1.01, NUDOCS 8709150350 | |
| Download: ML20238F036 (20) | |
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l NEO QUALITY ASSURANCE DEPARTMENT-PROCEDURE ~-
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-NOAr3.07 - 1.01 TECHNICAL' AUDIT PROGRAM t
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REVISION:
0 ISSUE DATE:
9/8/87
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.i EFFECTIVE DATE:
9/8/87-o APPROVED:
"k.[Fl1TWrnn_-
Directg, Quality Assurance APPROVED:
Mk we DA.QhY Vite President, Nuclear Eng.
APPROVED:
&&Ma Executive Vice President,NEO i
8709150350 870908 i
PDR-ADOCK 05000445 A
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l NE0' QUALITY ASSURANCE DEPARTMENT PROCEDURE.
1 NQA 3.07-l'.01 LTECHNICAL AUDIT PROGRAM
.g 1.O PURPOSE'
'The p'rpose'of this procedure.is.to describe the Technichl Audit
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Program. "The' objectives of this program are (1).to assure the K
technical and programmatic effectiveness of the Corrective Action Program (CPRT), and (2) to provide oversight of project actions in-
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response to actions recommended to the Project by 'the Comanche Peak Response Team and' commitments made by the Project.to the CPRT as a result of:the conduct of the Issue' Specific Action Plans (ISAP).
The Technical' Audit Program is constituted to achieve'these objectives.by.means of a comprehensive series of technical. audits using'TU Electric NEO Quality Assurance procedures and processes, and using personnel technically qualified in'the areas being evaluated.-
2.0 APPLICABILITY.
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' :t 2.1 This program is applicable to the Quality Assurance Section of the.TU Electric NEO Quality Assurance Department.
Contractors whose activities are subject to technical' audit via this program are provided with controlled distribution copies of this procedure.
2.2 The Technical Audit Program covers.two specific activities,.one directed at the design-related Corrective Action Program and the
.l i other directed at Project' actions related to the results of the CPRT ISAP's.
The portion of the program'that performs design-related
,j audits is referred to as the Corrective Action' Program audit program, whereas the portion that performs' audits related to Project activities related to ISAP results is referred'to as the ISAP audit f
program.
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3.0 REFERENCES
l 3.1 TU Electric Generating Division, Corporate Quality Assurance Program 3.2 Comanche Peak Steam Electric Station, Quality Assurance Plan 1
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f 3,3 NEO-3.01 - Corrective Action a
-324' DQP-QA Indoctrination, Training and Certification of Dallas QA Personnel d
3.5 DQP-QA Quality Assurance Records Program 3.6 DQP-QA TU Electric QA Audit Program 3.7 DQP-VC Conduct of External Audits
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3.8 DQP AG-2 %
Conduct of Internal Audits tn-74 lU pi
.3. 9 DQF-AS -Internal Audit Deficiency Followup / Closeout
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3.10 DQP-QE 7 - Quality Engineering Surveillance of Engineering nucl<rittee 4.0 DEFINITIONS 4.1 Lead Design Contractors:
Stone and Webster Engineering Corporation-Corrective Action Program (SWEC-CAP), Stone and Webster Engineering Corporation Piping Systems and Supports (SWEC-PSAS), EBASCO Services, Impell Corporation.
For the purposes of this procedure TU Electric CPE is. considered a Lead Design Contractor where they assume responsibilities for portions of the CAP.
5.0 RESPONSIBILITIES 5.1 Executive Vice President, NE0; Vice President, Nuclear Engineering; Directort, Quality Assurance The Executive Vice President, NE0; Vice President, Nuclear
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Engineering; and Director, Quality Assurance are responsible for
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the' approval of this procedure end any revisions thereto.
5.2 Mananen Quality Assurance
't 5.,2.1 The Manager, Quality Assurance is responsible for the management of the Technical Audit Program. He has assigned the dut'ies for implementation of that program to the Supervisor, Technical Audits.
5.2.2 The Manager, Quality Assurance is ruponsible for maintaining this procedure current.
l 5.3 Supervisor, Technical Audits i
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5.3.1 The Supervisor, Technical Audits is a temporary position j
created especially for this program. The incumbent is responsible for planning, scheduling, and executing a technical audir, program. He is responsible for interfacing l
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with the Supervisors of QA Audits and Vendor Compliance as well as with.the contractors' supervisors of audits regarding the scheduling and performance of technical
-audits.
He will' identify to those supervisors any concerns identified during the implementation of the Technical Audit Program which he judges to have an impact on their programs.
5.3.2
.The Supervisor, Technical Audits is dedicated full-time to management of the Technical Audit Program and has no other assigned duties to detract from this effort.
Figure 7.1 shows the organizational structure for the Technical Audit
' Program Unit.
The Technical Audit Program Unit reports through the normal TU Electric Quality Assurance management and is independent of the parties having responsibilities for corrective action activities.
The balance of personnel shown.on Figure 7.1 reporting to the Supervisor, Technical Audits are similarly dedicated full-time to execution of the Technical Audit Program. The Supervisor,' Technical Audits has two, full-time senior advisory consultants reporting to him to provide recommendations and assistance in managing the Technical Audit Program.
5.4 Audit Team Leader Each audit 'is managed by an Audit Team Leader qualified per Reference 3.4 and experienced in nuclear power plant design and construction. The' Audit Team Leader functions as a " Project
-Manager".for each audit assignment r.nd is responsible.and accountable for audit planning, execution, reporting and closeout.
The Audit Team Leader is also responsible for identifying personnel resources required for performance of the audit, for assuring a
-proper mix of technical skills to conduct the audit, and for assurin5.that the team provides technically supportable audit results.
5.5 Technical Specialist A team of technical specialists has been assembled to provide the requisite engineering skills needed for accomplishment of the audit function. The team is comprised of experienced, senior, degreed engineers with demonstrated expertise in technical disciplines such as seismic and stress analyses; fluid systems design; equipment qualification; hazards analyses; instrumentation and control logic; circuitry design; electrical power systems analyses; nuclear construction; and startup testing. Although the selection of audit team specialists is principally based on their recognized expertise in a particular technical discipline or function, the ability to operate independently and effectively, capacity to analyze and assess complex engineering, construction and test data, and the capability to communicate effectively are other important considerations for selection of audit specialists. A team of I
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' full-time techr.ical specialists are located at CPSES to support Ithe.
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Teihnical Audit Program. This cadre of full (time specialists is I
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suyoEtedby!otherengineeringspecialistsavailableonan"as need0 " basis.. Technical specialists'are independent-of the
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5'.6/SupervirAr(s'ofQAAuditsandVendorCompliance-p
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i The TU Elec..tric Supervisors of QA Audits and Vendor Comp 1!.ance pr'o'ri'de scheduling information to the Supervisor,.Tachnica Audits.
5.7 Contractor Supervisors The Supervisor'of Engineering Assurance / Quality Assurance for sach I
lead design contractor (EBASCO, SWEC-CAP, SWEC PSAS, and Impell)
.provides scheduling information to the Superviser, Technical Audits.
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[3 6.0 INSTRUCTIONS 3
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.s 61' General
,y 6.1.1 Techni(IU Audit Program act!'rities are performed in 1
conformande with existing TU F.lectric Quality Assurance J
Program requirements asid proesdures. Qualifications and certification of audit' personnel, conduct of audtts, reporting.and followup of audit findings, and reciords are consiste9c with existing TU: Electric NEO Quality Assurance procedures and practices. TReference 3.4 through 3.10) 6.1.2 The results of surveilicdess perforsed by TU Electric Quality Engineering (QA), in accordance with References 5-3.10, may be ut.tlized ta supplement or reduce the scope of
,/'t technical audits, i
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/ f/2 Corrective Action Program Audi,t,,Progre.m l
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6.2.1 Programihp3 y j j
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The6Technihal Audit Program has been developed and
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1 strdetured to provide continuing, in depth t.c.chnie-L ' /
oversight"of the CPSES Corrective Action Program. The '
effort has been structured to' focus on (1) the effchti*ieness i
of the design val.idation process, and (2) technical'accepta-g bility of the validated design product and supporting documentation. The effort will consist of a series of
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comprehensive technical audits concentrating on each of th<e I
eleven Corrective (Action Program elements and selected subelements listr..'d in Attachment 8.A.
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.l i 6 J',!. 2 Audit Methodology Where appropriate, audits are planned to provide a vertical and a horizontal examination of the design validation r
process.
For example, audits of SWEC Large Bore Pipe Supports includes a vertical examination of a total piping package covering both piping stress analysis and analysis of individual supports contained within the package.
In this
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phase of the audit, emphasis is placed on verification of.
design inputs, information flow and exchanges between SWEC disciplines, calculation adequacy, and processing /
transmittal of outputs to interfacing design organizations.
.In parallel with the vertical examination, technical audit specialists examine and assess horizontally SWEC resolution 3
of specific Generic Technical Issues common to a number of large bore piping packages (e.g., modeling of flexible valves, damping of piping systems containing active valves, f
, implementation of ASME Code Case N-411).
The Corrective Action Program audit program functions are, in general, coordinated with other TU Electric audit activities and, in particular, with the SWEC-managed Engineering Functional Svaluation effort. The purpose of
- 1 such coordination is to avoid duplication of effort and unnecessary overlap and to provide, where appropriate, the sharing of results and findings.
Technical audits are planned and scheduled to cover discrete elements or phases of each lead design contractor's design validation activities from design criteria validation through as-built reconciliation of the physical plant with the final validated design. Each Corrective Action Program component is audited as the work progresses and at the t
location or locations where the work fs being accomplished.
". hlection of specific audit activities (i.e., Design Validation Packagen) is based on the status of the ongoing
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effort, significance of previously identified design 3
rdoquacy issues, and the degree of interface activities 9
associated with the particular element of design.
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f For each Corrective Action Pro 5 ram component, or selected subcomponent, validation package, the audits are designed to 1,
' address the fellowing:
A 1.
availability and adequacy of CPSES-specitte design validation procedures, instructions and guidance documents.
2.
development of Design Basis Documents and reconciliation with licensing commitments.
Design bases include functional and performance Rev..
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l requirements under applicable operating / accident conditions as well as requirements (loads) imposed by interfacing systems or structures.
3.
reflection of Generic Technical Issues in Design Validation Packages and, where appropriate, incorporation of resolutions into applicable design manuals, procedures and/or criteria documents.
4 validation of existing CPSES design documentation (i.e., calculations / analyses, engineering drawings and design specifications sufficient to demonstrate-compliance with specified design criteria).
Calculations are examined for validity and 1
traceability of inputs, reasonableness of l
assumptions, design interface considerations, correctness of calculations / analyses (including applicability and qualification of computer programs or.
models utilized in the analysis), reasonableness of results and adequacy of supporting documentation.
If, as a result of the validation process, supplemental or replacement calculations are to be generated by the lead design contractor, these calculations are examined in the same manner.
5.
resolution of Third-Party Discrepancy Issue Reports.
6.
consideration of the "as-built" or "as-installed" status of CPSES in the validation of design drawings, specifications and calculations.
7.
identification, preparation and implementation of design modifications and changes required as a result of the design validation effort.
The impact of such modification / changes on interfacing design activities (i.e., synergistic effects) are addressed during the audit.
8.
implementation of the Post Construction Hardware Validation Program intended to demonstrate complier.;3 of existing CPSES systems, structures and c>mpon.nts with revised installation design requir.9 ente.
9.
final reconciliation of CPSES systems, structures and components, with the final approved design.
1 Many of the design validation element.s cited above are accomplished over a period of time and in varying locations.
For example, the SWEC PSAS Large Bore Pipe Support design i
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1 validation function was initiated in early 1986 and-is j
continuing in'1987 in several locations (New York, NY,'
Cherry Hill,.NJ, and CPSES). Audits are planned to examine specific elements or phases of the work as the work progresses and at the location where principal portions of the work.are being accomplished.
Consequently, initial audit efforts, involving SWEC-CAP design validation are
' focused on preparation of Design Basis Documents and the I
identification and reconciliation of referenced. design criteria.
Later ardits examine' calculation validation, design and specif3 cation validation, as-built reconciliation
-and design modification activity.
In essence, the. technical audit effort is structured to follow and assess the design validation effort on.a continuing'"real time" basis. As substantial portions of the work are completed, the audit effort is refocused to provide an in-depth review and assessment.of the total (integrated) design validation process for preselected areas of design.
The planning for each audit begins with a. review of pertinent Discrepancy Issue Reports and Issue Resolution Reports developed under the Design Adequacy Program to assure proper understanding of design-related issues and problems associated with each particular element of design.
Generic Issue Reports prepared by the cognizant lead design contractor describe the method, scope and responsibility for resolvin5 design adequacy issues. Although Generic Issue Reports are not required to be maintained as living documents, they are examined during the planning phase to assure the lead design contractor's validation program is consistent with the substance of Design Adequacy Program findings.
In each instance, the nature and substance of the lead design contractor's validation program and its relevance to previously identified problems and design adequacy issues is addressed in the audit team's plans and checklists.
The planning function is further enhanced by means of information exchanges and periodic meetings with the lead design contractor personnel.
The purpose of these exchanges and meetings is to provide designated Audit Team Leaders, technical audit specialists and TU Electric QA management with an understanding of the techniques, methodologies and work procedures used in the design validation process and to confirm the status of the ongoing work scheduled for audit.
The information gained through this process is fed into the planning and scopin5 of each audit.
Each audit is preceded by an audit team planning session under the direction of the Audit Team Leader to detail the approach and scope of the upcoming effort.
These sessions are usually held the week i
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preceding the audit. At that time, work packages available for audit are identified by the auditors and arrangements made to have such packages available to the: team upon its arrival at the contractors design facility.
The audits focus on both " completed".and "in-process" design validation activities.
For purpose of the audits, "in-process" work.is
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. defined as elements of design validation accomplished by the 4
assigned engineers or analysts, but which are subject to l
further contractor review and checking.
Checklists are developed in these pre-audit sessions.
1 Audits involve documentation review and interviews with cognizant design engineers and analysts. Access to the design engineer or analyst responsible for specific work products is considered a prerequisite to the conduct of the audit.
Such access to the responsible engineer,is the most-effective rans for assuring understanding of the methodology nd rationale used in the validation process.
As approprj 3,
documentation reviews and personal interviews are further supplemented by individual auditor calculation checks which provide independent verification of the acceptability and reasonableness of the results of specific validation tasks.
Emphasis during the audit is focused on an assessment of the cognizant design engineer's understanding of the specific design issue or problem and on the reasonableness of the approach in carrying out the specific design validation function. Calculation packages are examined for adequacy of documentation of design inputs, justification of assumptions, identification of open or unconfirmed items, and references to specific computer models used in the analysis. The methods and techniques used to. factor the as-built configuration of the plant into the design validation process receive particular attention and focus in the audit. As an example, the audit of HVAC System Design Validation loads, lighting heat loads and HVAC component perfortnance data accurately reflect as-built or as-installed conditions; and similarly, that calculated heat losses and flow rates utilized in the design validation process are based on design inputs validated either by walkdowns or tests or other appropriate means.
The process used to reflect and reconcile as-built status in the design validation process is addressed in the course of audits of each Corrective Action Program component.
Equal attention is directed on each lead design contractor's sensitivity to and understanding of design interfaces.
These include internal or interdisciplinary interfaces l
within the designer's organization as well as interfaces with other design contractors, equipment suppliers and the Rev.:
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l NSSS vendor.. The impact'of design changes / modifications j
upon interfacing design activities is addressed during the
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audit process. Where appropriate,. audit specialists are 1
encouraged to cross organizational boundaries to verify proper interface impact assessments.
For example,'the audit will, where appropriate, excmine and assess'the impact of s.
SWEC CAP-initiated change'in amplified response spectra for a given building area or elevation upon SWEC (and/or Westinghouse) piping design analyses and Impell (and/or i
Westinghouse) seismic equipment' qualification. functions.
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As a general principle, the audit team is directed to assure that full.and technically satisfactory consideration of design interfaces is being provided in all aspects of the design validation process.
6.3 ISAP Audit Program i
i 6.3.1 Program Scope l
l Actions recommended to the Project by the CPRT and commitments made by the Project to the.CPRT as a result of the conduct of the Issue Specific Action Plans are in two categories.
In the first category ars recommendation /
commitments which-the CPRT considers to be mandatory in the sense that either the recommendation / commitment or an alternative acceptable to the CPRT must be accomplished by the Project.
In the second estegory are those which the CPRT considers to be nonmandatory in the sense that they are enhancements for which the Project can exercise discretion in addressing.
The CPRT provides a list of all such recommendations / commitments and categorizes each item as mandatory or nonmandatory. The objective of the ISAP audit program is to assure that the mandatory recommendations /
commitments are effectively implemented by the Project, and
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that the nonmandatory recommendations are addressed by the Proj ect.
This is accomplished by audit coverage of each mandatory item and selected audit coverage of nonmandatory items.
6.3.2 Audit Methodology The scope of a ISAP audit generally consists of one or more recommendations / commitments arising from a particular ISAP Results Report. Although a given ISAP audit is normally limited to recommendations / commitments originating from one ISAP, there may be occardons when it is more effective to examine in a single audte an activity set which contains elements from several ISAPs.
The audits include documenta-tion review, personnel interviews, and direct observation of l
Rev.: 0 NQA 3.07 - 1.01 Date: 9/8/87 Page: 9 of 11
g hardware,las appropriate.For each recommendation /
commitment, the audit is planned to:
.1.
assure lthat the responsible party has captured the item in a formal control system.
2.
assure'that the' resolution actions as approved by.the CPRT are effectively implemented.
3, assure that the corrective' actions have been completed and documented.
For each recommendation / commitment identified by CPRT, the ISAP audit program maintains verification status. Upon completion of an audit, the Audit Team Leader completes a Validation Summary Status Sheet which summarizes the extent to which each recommendation./ commitment within the audit scope 'is validated by the audit.
Each item is designated-unverified,-partially verified, verified. or not to be verified.. Verified indicates that the ISAP audit program has audited the item sufficiently to have met.the three objectives listed above as applicable to the particular item.
Items.not completely validated by a given audit are
're-audited at a later date.
Information is also maintained to allow correlation between the item and the ISAP audit documentation which documents the verification. 'At the conclusion of the ISAP audit program, all mandatory items will be designated as verified and all nonmandatory items will be designated as verified or not be verified.
In some cases, recommendations / commitments arising from ISAPs may be design-related and may fall within.the scope of the Corrective Action Program.. In those instances, audit of the corrective action may be included in a Corrective Action Program audit, rather than.in a ISAP audit.
Factors considered in ISAP audit scheduling are status of recommendation / commitment action implementation for the ISAP, impact on the audited; organization, overall project schedule, and audit schedules of other auditing organizations (such as the TU Electric QA Audit and Vendor Compliance units). More than one audit is normally required on a ISAP in order to completely verify recommendation /
commitment action implementation, depending on the complexity of the issues, the number of organizations involved, and the schedule for completion.
6.4 Audit Completion. Reporting and Followup 6.4.1 Audit start dates are pre-scheduled, however, completion dates are not.
Audit Team Leaders may request additional resources or extend the audit duration as necessary to Rev.: 0 NQA 3.07 - 1.01 Dato: 9/8/87 Page: 10 of 11 L
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accomplish the audit objectives.
Checklists are developed as part of an audit plan and are approved prior to the start of the audit.
Information generated by auditors during conduct of the audits is documented on the Checklists and form the basis for the audit reports.
6.4.2 In most instances, TU Electric QA management is present at the conclusion of each audit to assess the team in developing an overall assessment and perspective of the audit results and in assuring that needed improvements and corrective actions are adequately communicated to the responsible management at the time of the audit conclusion.
The need for prompt (within 15 days) and meaningful response to identified audit findings is emphasized at these exit meetings.
6.4.3 The results of the audit are reviewed with the management of the organization responsible for the work and is reflected in an audit report issued within 15 calendar days after completion of the audit.
Emphasis is placed on providing l
both TU Electric and contractor management with an overall assessment of the quality and acceptability of the work activity examined.
Both positive and negative findings are addressed and an effort is made te judge the impact of negative findings upon overall work quality and acceptability. All audit reports are approved by TU QA management and are so distributed to appropriate levels of management and to SRT representatives.
l 6.4.4 kesponses to audit findings are evaluated for acceptability by the audit team.
Corrective actions to all audit findings f
are verified prior to closure.
i 6 4,5 A monthly raport to the Executive Vice President, NEO is prepared which provides a management summary of the results of technical audits completed during each month.
i 7.0 FIGURES 7.1 Technical Audit Program Organization 8.0 ATTACHMENTS 8.A Corrective Action Program Components and Responsibility l
9.0 RECORDS None Rev.:
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