Professional Documents
Culture Documents
Chapter 1
Chapter 1
Chapter 1
Introduction
1.1 History and Background:
CG Industrial Park(CGIP) is Nepals first ultramodern industrial village situated
at Nawalparasi district, 185 km by road from Kathmandu and 23 km west
of Narayanghat.CUG spans over 137 acres of strategically located land adjacent
to Mahendra Highway.
In 1965, CG established its first Modern Hosiery Industry in Birgunj. Next development
was by establishing a Biscuit Factory and Maida Mill in Duhabi, one of the very first
industries in the area. Today it is the largest industrial area in Nepal.While establishing
CGFP(CG Food Park) at Sainbu, it was realized that every time the same infrastructure
was needed to establish an industry.This was when the Group decided to
build an
integrated world class industrial village fledged infrastructural facilities to smoothen the
progress of the establishment of industries in a short period decreasing the cost, time and
efforts required to establish an industry.
The land was acquired in 1993 and the commercial production started in 1995. It was
formally named as Ganga Devi Chaudhary Udyog Gram on 9th March 2003. Today CGIP
has been producing a variety of products such as instant noodles, beverages, potato
chips, brewery, cheese balls, chocolate wafers, cracker sticks, packaging cartoons,
chyawanprash, cooking powder and many other products are still planned for the future.
1.2 Mission Statement
Vision:
To provide a self-contained, integrated and eco-friendly infrastructure to be able to
compete with any south Asian standards.
Objectives:
1. Understand consumer insights and meet their needs with safe, effective and world
class products.
2. Enhancing the value we deliver to our customers.
3. Develop a lasting relationship with our customers.
4. Recruit, develop, motivate and retain the best talents within the country; recruit if
need be from abroad and provide them a challenging and demanding
environment.
5. Become globally competitive.
6. Become the most admired company in Nepal.
President
Vice President
General Manager
Administration
Department
Production
Head/Brew
Master
System Officer
R&D
QC Department
Shift Brewer
QC Officer
Production
Supervisor
Process Control
Operator/
Workers
Process Control
Coworkers
Engineering
Department
Commercial
& R/A
R&M
In charge
Operator
RM & PM
Analysis Supervisors
Store
Department
Organization Name
Factory name
Address
Nature of ownership
Standard Obtained
: Chaudhary Group
: Chaudhary Group Industrial Park(CGIP)
: Dumkauli, Nawalparasi, Nepal
: Private
: ISO 9001 2008 Certified
S.N
1.
2.
3.
4.
5.
6.
Chapter 2
CGBN
4
2.1 Introduction:
CG Brewery (Nepal) Pvt. Ltd. (CGBN) formerly known as Sun gold Brewery (Nepal)
Pvt. Ltd. (SBN) was established in 1997 as the brewery arm of Chaudhary Group and has
a current capacity of producing 250,000 cartons of beer per month. It has its own popular
brands like Nepal Ice, Real Gold and Mustang which are also exported to Hongkong,
Japan, Australia, UK and the USA besides domestic sales. It has also tied up with
international brewer InBev International, Netherlands. CGBN is an ISO 9001:2008
certified company and it is recently awarded NS: 23 by Nepal Bureau of Standards and
Metrology, Govt. of Nepal for quality production.
2.2 Production Machineries
The plant consists of milling machine, malt equipment, mash filter, centrifugal pumps,
plate type heat exchanger, air compressor, washing machine, filler machine, packaging
machine.
2.3 Production Process
Various steps are involved in the production of brewery which are described below:
2.3.1 Malting
Malting is the process where a barley grain is partially germinate, making seeds
resource available to the brewer. Malting begins by soaking the raw barley. It is dumped
in steeping tanks where it spends a couple of days soaking up water. The barley is then
transferred to a huge room where it is aerated and held at around 60 degrees Fahrenheit.
It is also regularly turned This is all done to encourage the grain to sprout without putting
down roots which it does in around five days. It is now called green malt. The maltsters
then kiln or dry the green malt by slowly raising the temperature to over 120 degrees
Fahrenheit. The final temperatures vary depending on what kind of malt they want in the
end. The result, however, is the same, regardless of the final temperature the growth of
the sprouts is stopped. Malted barley is the source of the sugars (principally maltose)
which are fermented into beer.
2.2.4 Lautering
The next step in the brewing process is the take the mash, and separate out the spent
grain from the sugary liquid known as wort (pronounced wert). This process is called
lautering.
To begin the lautering process, the mash is transferred to vessel with a false-bottom
called a lauter tun. Here the clear wort is drained away from the hulls and barley grist.
Water is also added during lautering, in order to extract even more of the fermentable
sugars from the grain. This is known as sparging. Sparging must be done very gradually
as to not disrupt the grain bed that acts as a natural filter for the wort. Brewers typically
add sparge water at the same rate as the wort is being drained below, although some
English brewing methods call for completely draining the wort, then adding water and
doing it all over again. This second go-round of lautering is called second runnings, and
was historically made for small beers.
Brewers must be careful not the sparge for too long, as eventually the bitter tannins from
the grain will also be stripped away.
2.2.5 Boiling
Once the sweet wort has been separated from the grains, it is brought to a strong,
prolonged boil for one to two hours. Boiling does more than sterilize the brew, however.
Hops introduced to boiling water will begin to break down, or isomerize, molecularly
altering the composition of the acids within the hops and releasing bitterness into the
beer. The longer the hops are boiled, the more of their alpha acids will be isomerized in
order to lend bitterness to the brew. Hops added to the boil to lend bitterness are called
early hop additions, and are generally allowed to boil in the beer for an hour or more.
Hops added later in the boil dont bitter the beer all that much, but instead lend flavor
and aroma. This is because in addition to alpha acids, hops also contain highly volatile,
and very pungent oils, which break down quickly in boiling water. However if only
exposed to the boiling wort for a short period of time, or at lower temperatures, hops will
release these oils and lend aromatics and flavor to the beer. To extract flavor, brewers
typically add hops about 10-15 minutes before the end of the boil. For aroma, hops are
added even later, no more than 2 minutes before the end of the boil. Often aromatic hop
additions even occur just after the boil ends.
2.2.6 Wort separation and cooling
Once the boil is completed it is sent to a whirlpool to collect any hop matter and
coagulated proteins that have accumulated. Then it is immediately cooled. Cooling the
beer quickly is important, since the beer will begin to oxidize and produce off flavors
almost immediately at these temperatures. The plate type heat exchanger is used for
cooling of wort.
2.2.7 Fermentation
Fermentation is the process by which yeast converts the glucose in the wort to ethyl
alcohol and carbon dioxide gas giving the beer both its alcohol content and its
carbonation. To begin the fermentation process, the cooled wort is transferred into a
fermentation vessel to which the yeast has already been added. If the beer being made is
an ale, the wort will be maintained at a constant temperature of 68 F (20 C) for about two
weeks. If the beer is a lager, the temperature will be maintained at 48 F (9 C) for about
six weeks. Since fermentation produces a substantial amount of heat, the tanks must be
cooled constantly to maintain the proper temperature.
These fermentation tanks hold more than 2,400 gallons (9,085 L), which means that it
takes four batches of wort to fill one tank. Since fermentation takes at least two weeks,
the capacity of the brewery is limited by how many tanks they have.
When the wort is first added to the yeast, the specific gravity of the mixture is measured.
Later, the specific gravity may be measured again to determine how much alcohol is in
the beer, and to know when to stop the fermentation.
The fermenter is sealed off from the air except for a long narrow vent pipe, which allows
carbon dioxide to escape from the fermenter. Since there is a constant flow of CO2
through the pipe, outside air is prevented from entering the fermenter, which reduces the
threat of contamination by stray yeasts.
When fermentation is nearly complete, most of the yeast will settle to the bottom of the
fermenter. The bottom of the fermenter is cone shaped, which makes it easy to capture
and remove the yeast, which is saved and used in the next batch of beer. The yeast can be
reused a number of times before it needs to be replaced. It is replaced when it has
mutated and produces a different taste remember, commercial brewing is all about
consistency.
10
11
6) The crowned bottle is ready for packing and is packed in the cartons. The cartons of
beer are sent to the store room and then it is distributed to the market through the dealer.
Malting
Barley
Milling
Hot Water
Mashing
Lautering
Boiling
Chockers
Whirlpool
Yeast
Fermentation
Conditioning
Filtering
Bottles
Packaging
Cans
13
Chapter 3
Refrigeration
3.1 Introduction
Refrigeration refers to the use of mechanical devices or heat activated devices for
producing and maintaining the temperature in a region less than that of surroundings.
The refrigeration process continuously extracts heat from a
body that needs to be stored at relatively low temperatures and keeps it
away from being
damaged.
Refrigeration happens to be the chief part of the brewery industry as
almost all the products
needs to be kept at lower temperature. The refrigeration system is used
to cool the cold
stores. In addition, the refrigeration is also used in the supply of chilled
water in the chilling processes in the plant.
3.2 Types of Refrigeration
Two types of refrigeration are used in CGBN which are given below.
3.2.1 Vapour Absorption Refrigeration
Specifications:
Company: Thermax
Cooling capacity: 247 kW
Operating weight: 5T
Heat source: Steam
Inlet Pressure: 8 bar
Power Supply 3 Phase Voltage: 415 V
Refrigerant: Lithium Bromide
Working Principle of Vapour absorption refrigeration:
In a water-lithium bromide vapor absorption refrigeration system, water is used as the
refrigerant while lithium bromide (Li Br) is used as the absorbent. In the absorber, the
lithium bromide absorbs the water refrigerant, creating a solution of water and lithium
bromide. This solution is pumped by the pump to the generator where the solution is
heated. The water refrigerant gets vaporized and moves to the condenser where it is
cooled while the lithium bromide flows back to the absorber where it further absorbs
water coming from the evaporator. The cooled or chilled water is collected in the chiller
water tank and is used in the whirlpool for the cooling of wort.
14
15
Condenser
Generator
Heat
exchanger
Expansion valve
Evaporator
Absorber
16
Condenser
Condenser
Expansion Valve
Evaporator
Compressor
Evaporator
17
3.2.3 Compressor
The compressor is known as the heart of the refrigeration system. It pumps the
refrigerant vapour in refrigeration cycle as the heart pumps blood in the body. The low
temperature, pressure, superheated vapour from the evaporator is conveyed through
suction line and compressed by the compressor to a high pressure, without any change of
gaseous state and the same is discharge into condenser. During this process heat is added
to the refrigerant and known as heat of compression ratio to raise the pressure of
refrigerant to such a level that the saturation temperature of the discharge refrigerant is
higher than the temperature of the available cooling medium, to enable the super-heated
refrigerant to condense at normal ambient condition.
In the refrigeration plant the compressor is of reciprocating type.
Ammonia compressor Specifications
Compressor Type: Double acting reciprocating; V-type
No. of cylinders: 4
No. of strokes: 2
Bore diameter: 160
Stroke length: 110
RPM: 400/1000
Max. delivery pressure: 21 kg/cm2
Power input(Motor power): 75 kw
Sets of compressor: 3 Set
18
20
Chapter 4
Boiler
4.1 Introduction
Boiler, also called steam generator is the engineering device which generates steam at
constant pressure. It is a closed vessel, generally made of steel in which vaporization of
water takes place. Heat required for vaporization may be provided by the combustion of
fuel in furnace, electricity, nuclear reactor, hot exhaust gases, solar radiations etc. The
boiler used in the CGIP is for heating purpose.
4.2 Types of Boiler
In CGIP two types of boiler is used.
4.2.1 Horizontal fire tube boiler
Specification
Company: Thermax
Capacity: 5 TPH
Fuel: Furnace oil
Working principle of fire tube boiler
The basic working principle of boiler is, heat is exchanged between water and the hot
gases running in tube after firing in furnace. Due to heat exchange water is converted
into steam by convection.
The boiler consist of a step up transformer in which the current provided in the primary
windings is 220V. The voltage obtained in the secondary windings is 14000V. Hence
14KV is present in the spark rod whose two ends are separated by 5mm.
As current passes in the solenoid valve (initially at 180 V and later after resistance it drop
down to 80 V), magnetic field is developed and hence it opens the valve for the oil. As
the solenoid valve is open oil is blown off to the spark rod where 14000 V is present. As
oil reaches the spark rod firing happens in furnace and the hot gases passes to the tube
which is surrounded by water and steam is generated.
Photocell is present which acts as sensor to cut off the voltage provided at spark rod. The
photocell senses the light of firing and it cut off the supply of high voltage to spark rod.
If high voltage is not cut then it will destroy the spark rod.
As it is fire tube boiler, hot gases flows in tube surrounded by water.
As it is horizontal type of boiler its pressure is controlled by itself. As more steam is
generated pressure of closed system increases and convectional flow of water is
constrained and rate of steam production become slower. Again if more steam is taken
out, convectional flow of water becomes faster and rate of production of steam increases
Initially when the current is provided to the motor of the blower its blows air and at the
same time oil pump also starts working, so the oil pressure is generated with the help of
oil pump.
21
small particles stacked in bag are removed by giving vibrating motion on bag with help
of compressed air controlled by solenoid valve. Solenoid valve contain solenoid wire
which converts the electrical energy into mechanical pulse. There are 12 solenoid valve
fitted into the pipe where compressed air is passed through the pipe. The ashes, dust and
very small particle are delivered to ash room through the rotatory valve. The flue gas
with low temperature and less polluted air is passed to chimney.
The husk consumption in 24 hours is about 57000 kg.
4.3 Boilers mountings
Boiler mounting are different fitting and devices that are necessary for operation and
safety of boiler. They are as follows:
4.3.1 Saftey Valve
Safety valve is mainly installed in boiler for preventing the pressure vessels from
exploding or damaging. In CGIP, spring loaded safety valves are used at the top to
protect the boiler against excessive high pressure of steam. These safety valves are
regulated with help of spring force created by pressure of steam. There is each safety
valve located in 5 TPH and 10 TPH boilers. The cutoff pressure for water tube boiler is
17.5 kg/cm2 and for fire tube boiler it is 15 kg/cm2.
4.3.2 Water level indicator:
The function of water level indicator is to indicate the level of water in boiler constantly.
The level of water in a steam boiler must be carefully controlled, to ensure good quality
steam is produced safely, efficiently and at the correct pressure. If the boiler operates
with insufficient water, severe damage could occur and there is ultimately the risk of
explosion.
For this reason, controls are required which will:
1. Monitor and control the water level.
2. Detect if a low water level point is reached, and take appropriate action.
4.3.3 Mobrey:
Mobrey helps to control the flow of water inside the boiler by controlling the rate of feed
pump during steam production. There is a Mobrey in each boiler. It is basically a
magnetic switch. When the water level is decreased to certain level, the feed pump
operates and pumps water into the boiler. As the water level reaches the maximum level,
the pump automatically stops.
4.3.4 Pressure gauge:
The function of pressure gauge is to indicate the pressure of steam inside the boiler. In
CGIP, the pressure gauge used is of bourdon tube type which has a dial indicating the
pressure of steam at kg/cm2.
23
Boiler:10 TPH
Power: 15 KW
Speed:2930 RPM
Discharge: 14.5m3/h
24
In a boiler arrangement, a forced draft fan draw in air and force it into the combustion
chamber of the boiler, where it mixes with the fuel being supplied. FD fans are typically
used to regulate the proper amount of air-to-fuel ratios in an effort to maximize fuel
efficiency. It operates at positive pressure because outside air is drawn into the fan and
forced into the system. Forced draft handles atmospheric air (relatively high density)
hence are of smaller capacities. The speed of motor used in FD is controlled by VFD
(Variable Frequency Drive) according to working condition.
There are 2 FD in 10TPH Boiler and 1 FD in 5TPH Boiler. FD fan is a centrifugal type
fan.
Specification of FD:
Boiler: 5 TPH
No of FD: 1
Speed: 2900 R.P.M.
Power: 11KW
Boiler: 10 TPH
No of FD: 2
Speed: 2900 RPM
Power: 22 KW
Belt: C82
Boiler: 10TPH
No of ID: 1
Speed: 1470 RPM
Power: 37 KW
25
Chapter 5
Maintenance
5.1 Introduction
Maintenance involves keeping the workplace, its structures, equipment, machines,
furniture and facilities in good repair and operating efficiently and safely. It includes
many tasks including repairing, replacing, servicing, inspecting and testing. The
objective of plant maintenance is to achieve minimum breakdown and to keep the plant
in good working conditions at the lowest possible cost. Machines and other facilities
should be kept in such a condition which permits them to be used at their optimum
capacity without any interruption or hindrance.
Maintenance department of the factory ensures the availability of the machines and
services required by other sections of the factory for performance of their functions at
optimum return on investment whether this investment be in material, machinery or
personnel.
A system of scheduled, planned and preventive maintenance tries to minimize the
problems of breakdown maintenance. It locates weak spots (such as bearing surfaces,
parts under excessive vibrations, etc.) in all equipments, provides them regular
inspection and minor repairs thereby reducing the danger of unanticipated breakdown.
The underlying principle of preventive maintenance is that prevention is better than cure.
5.2 Preventive maintenance
CGIP has used preventive maintenance so that losses are minimized. If there is
occurrence of break down in any machinery during the working condition then there is
quick replacement or maintenance of the machine by replacing another new repaired
machine. In the CGIP plant there is schedule of preventive maintenance at the every
week of Saturday. Under the supervision of R&M incharge repair and maintenance is
done. Machinery maintenance workers do basic maintenance and repairs on machines.
They clean and lubricate machinery, perform basic diagnostic tests, check the
performance of the machine, and test damaged machine parts to determine whether
major repairs are necessary.
Machinery maintenance workers must follow machine specifications and adhere to
maintenance schedules. They perform minor repairs, generally leaving major repairs to
machinery mechanics.
All maintenance workers use a variety of tools to do repairs and preventive maintenance.
For example, they may use a screwdriver or socket wrenches to adjust a motors
alignment, or they might use a hoist to lift a heavy printing press off the ground.
26
Chapter 6
Work Assigned
During the course of industrial attachment work assigned was to calculate the efficiency
of the water tube boiler and observe and measure cooling tower temperature, glycol
temperature, head and flow rate of the glycol pump, compressor inlet ant outlet pressure
chilled water inlet and out let temperature.
6.1 Calculation of efficiency of the vertical water tube boiler
Followings observevations and data were taken to calculate the efficiency of the boiler:
Capacity of boiler: 10TPH
Steam pressure: 11 kg/cm2 =11*9.8*104=10.78 bar
Enthalpy at 10.78 bar: 2780.41 KJ/Kg
Feed water flow rate: 10400 Kg/hrs.
Husk consumption per hours: Total Husk consumption/24 = 57000/24 = 2375 Kg/hrs.
Feed Water Temperature: 50oC
Enthalpy at 50oC: 209.3 KJ/Kg
Mass of steam produced per Kg of husk consumed i.e. m s: Feed water flow rate / Husk
consumption per hours: 10400/2375 = 4.378 kg
Calculation:
Efficiency of 10 TPH Boiler= ms *(h s- hf) *100%/Gross Calorific Value
= 4.378*(2780.41-209.3) *100/15217.2
= 73.97 %
Ratted efficiency: 802%
6.2 Measuremnet of compressor inlet and outlet pressure and secondary refrigerant
glycol temperature of vapour compression refrigeration system
Observations:
Primary Refrigerant: Ammonia(NH3)
Secondary Refrigerant: Glycol
Table 6.2.1 Compressor inlet and outlet and secondary refrigerant glycol temperature
S.N
Compressor
High pressure
Low Pressure
Oil Pressure
Glycol
2
2
2
No.
(kg/cm )
(kg/cm )
(kg/cm )
Temp C
1.
1
210
30
70
-2.1
2.
2
210
30
70
-2.5
3.
210
25
27
75
-1.9
Temperature
Inlet C
Outlet C
6.3
1.
32
29
2.
31
28
3.
34
31
Measurement of cooling tower inlet and outlet temperature
Table 6.3.1 Cooling tower inlet and outlet temperature
S.N
Table 6.4.1 Chilled water inlet and outlet and mass of steam used
Time
Chilled Water Temperature
Mass of Steam
hrs
Used
Inlet C
Outlet C
kg
1.
29
12.6
4.5
2.
29
10.2
5.5
3.
29
12.1
5.5
6.5 Findings
1. The calculated efficiency of boiler is found to be 73.97% which is less than rated
efficiency of the boiler.
2. There is variation in the temperature of secondary refrigerant glycol, chilled water and
cooling tower water temperature.
3. Unusal sound coming out from the compressor.
6.6 Remedies
6.6.1 Remedies for boiler to increase efficiency
1. Increasing Feed Water Temperature
28
To improve any systems efficiency, it is important to maintain the standard of all the
inputs of that system. In boiler system, it is the feed water which plays an important role
in deciding the overall efficiency. For this, the feed water temperature must be
maintained at approx. 80- 85 deg C to ensure boiler is operated at high efficiency.
2. Supply of air/steam to burner
Air/steam is required to ensure adequate fire is generated inside the furnace through good
combustion. It is therefore important to know the percentage of air/steam for efficient
combustion. For fuel oil fired marine boiler with register type burner, 15-20 % by weight
of air is required for efficient combustion.
Controlling excess air within the required range will lead to decrease in the flue gas
losses. Every 1% reduction in the excess air supplied to the furnace results in approx
0.6% increase in the boiler overall efficiency.
4. Blow down control
It is normally observed that boiler blow down is not performed regularly by operators.
Blow down is only performed when the water test results are high in chloride or when
high conductivity alarm occurs. This leads to uncontrolled continuous blowdown which
is actually waste of boiler heat and efficiency. This reduces prominent amount of high
temperature water inside the boiler and addition of moderate temperature water from hot
well.
The boiler burner will now fire for longer period to maintain the steam pressure hence
fuel combustion will increase reducing the efficiency. It is recommended to perform
regular blowdowns for short period which not only maintains the chloride level but also
reduces the thermal stresses within the boiler.
5. Boiler insulation
It seems obvious, but industrial boilers need to be insulated to minimize heat loss.
Because industrial boilers are so big, they have massive surface areas that are vulnerable
to significant heat loss if not insulated properly. The primary type of insulation used for
industrial boilers is the refractory material that lines them. When replacing refractory
materials, make sure to do a structural analysis to determine how much weight your
boiler can support.
6. Soot blowers
Byproducts of combustion such as soot and ash inevitably build up on heat transfer
surfaces in a boiler, even if it is run flawlessly within operating parameters. Installing an
intelligent soot blowing system (ISS) can keep this buildup in check with periodic jets of
compressed air or steam triggered by undesirable conditions. Of course, soot blowing
and deslagging can also be performed manually.
7. Regular maintenance
The best way to keep industrial boiler system running efficiently is to have a regular
boiler maintenance program. A good maintenance program will slow equipment
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Chapter 7
7.1 Conclusion
The period of industrial attachment at CGIP was an immeasurably
valuable
experience. Skills have been gained technically, professionally and
socially. This training was helpful to gain technical knowledge and
insightful experiences in a real
working environment.
During the attachment, the production process of brewery was gone
through and
knowledge was gained about the mechanisms of the machines. The
different parts of the
machines were analyzed. Throughout the attachment period,different plants like
refrigeration plant, boiler plant were visited and became familiar with various systems,
its working principles components of an engine and analyzed the reasons of its failure
and also the methodologies used in maintaining it.
The technical knowledge related to mechanical engineering as well as
learnt the social behavior and the various managerial skills that an
engineer needs to have. The working skills and behavior with the coworkers and various other staffs was also learnt.
Thus, in this entire 15 days of industrial attachment period the basic idea of how
engineers decide and work under various working circumstances were known.
7.2 Recommendations
During the industrial attachment period, various aspects of the CGIP were learnt
Followings are the some recommendations that factory need to consider.
1. The employee working in the company, especially the lower level staffs seem to
be unsatisfied with the salary, incentives, facilities they got. The company need
to bring out schemes that will satisfy the workers so the efficiency of the work,
production will be increased.
2. The safety adaption during the work is to low. The workers seem to be neglecting
the safety measures. The factory needs to be strict on safety adaption in order to
avoid the accidents
3. The factory has been using the tools and technology that was install quite a long
ago except brewery production plant. The factory needs to use latest and modern
technology to increase the production process to gain high profit.
4. Frequent training programme for all engineering staffs.
5. More interaction between supervisors and co-workers
6. Technicians should be introduced with the manual of equipments they are going
to use.
7. Newer and more advance machines in mechanical work shop.
31
REFERENCES
1.Singh, Onkar, 2003, Applied Thermodynamics, New Age International (P) Ltd.,
Publishers, Third Edition, New Delhi, ISBN (13) : 978-81-224-2916-9
2. Rajput, R.K., 2013, Thermal Engineering, Laxmi Publications (P) Ltd.,
New Dehli
3. http://www.chaudharygroup.com.np
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