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M.

Nakamura
Associate Professor of Systems
Control Laboratory.

N. Egashira Digital Control of Working Fluid


Postgraduate student of Systems
Control Laboratory. Flow Rate for an OTEC Plant
Department of Electrical Engineering, The role of control in operating an OTEC plant efficiently is of great importance.
Saga University,
This paper describes digital control of working fluid rate based on an adaptive con-
Honjomachi, Saga 840, Japan
trol theory for the "Imari 2" OTEC plant at Saga University. Provisions have been
made for linkage between the software of the adaptive control theory and the hard-
H. Uehara ware of the OTEC plant. We can obtain satisfactory control performance using this
Director of OTEC Laboratory,
digital control system.
Department of Mechanical Engineering,
Saga University,
Honjomachi, Saga 840, Japan

1 Introduction
The purpose of ocean thermal energy conversion (OTEC) is trol for the real pilot OTEC plant. In the construction of the
to extract power from temperature differences existing in the system, a provision has been made for linkage between the
oceans. The principle of OTEC was first proposed by D'Ar- software of control theories and the hardware of the OTEC
sonval [1] in 1881. Since the oil-shock of 1974, there has been plant. We obtained satisfactory control performance using
considerable interest in producing a feasible OTEC system, this digital control system.
and a good deal of research has been devoted to the subject.
One of the authors has designed an OTEC plant, was the first 2 OTEC Plant and Control Objective
to succeed in extracting power using the OTEC plant [2], and
has improved the design of the OTEC plant based on steady- The closed cycle OTEC plant, shown in Fig. 1, consists of
state operating conditions [3]. The next phase of OTEC an evaporator, condenser, turbine-generator, and pumps,
research is the control of OTEC plants under varying condi- which are interconnected by pipe lines. Warm surface water is
tions. Owens [4] studied two types of control problems of used to evaporate a working fluid, such as Freon 22 (R-22), in
OTEC plants, which were modelled by nonlinear differential the evaporator. The dry Freon 22 vapor then expands in a tur-
equations; response and control of the OTEC plants were bine to produce power. Finally, cold subsurface water is used
analyzed by computer simulation. Because the thermal effi- to condense the Freon 22 vapor in the condenser.
ciency in OTEC plants is generally low, on the order of 3 per- The ultimate purpose of OTEC plant control is to provide
cent, and the operating conditions, such as seawater stable power efficiently by appropriately regulating the
temperatures, are constantly changing, the role of control is of seawater flow rates and the working fluid flow rate under con-
great importance in operating an OTEC plant effectively. ditions of continually changing seawater temperatures.
Among the many control theories, adaptive control is the most The control objective is to find a process input signal which
promising for this purpose. The adaptive control theory gives will produce an appropriate working fluid flow rate from the
a control algorithm which tunes its parameter on-line for the Turbine Generator
plant. Recently, adaptive control theories have been greatly
improved [5, 6], and digital controls, using adaptive control
theories programmed in computers, have been successfully ap-
plied to industrial processes such as paper machine control,
ore crusher control, and so on [5], But to our knowledge, there
has not been any attempt to utilize digital control at OTEC
plants.
In this paper, we explain the digital control of working fluid
flow rate for the "Imari 2 " OTEC plant [7] at Saga Universi-
ty. The innovative feature of this study is the construction of a
digital control system and the implementation of digital con-
Warm surface
water
Contributed by the Solar Energy Division for publication in the JOURNAL OF Cold subsurface
SOLAR ENERGY ENGINEERING. Manuscript received by the Solar Energy Division, water
February, 1985. Fig. 1 Scheme for closed cycle OTEC plant

Journal of Solar Energy Engineering MAY 1986, Vol. 1 0 8 / 1 1 1


Copyright © 1986 by ASME
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DIGITAL CONTROL SIDE ! OTEC PLANT SIDE
desired [~ ' Input signal part ' ' Controlled process '
Adaptive control ' ' Input signal '
value I
part ) [characteristics part)
QD U Vu Vu'VUi Vu
identification a ll
u/v evapo 9e
control algorithms chara chara [ j * ® ^ amp v/u pump rator "]"'H t u r b i n e M ? .tor
n?
iu J I j

QF QF
rriF
<e
heat
rate
thermo-
equation
couple
chara
I Detection characteristics part i

Fig. 2 Digital control system for working fluid flow rate

working fluid pump, so that the heat rate of the working fluid working fluid flow rate and the working fluid temperatures.
QF at the evaporator will behave according to a desired value. The working fluid flow rate is detected by an electro-
The controlled process consists of the plate type evaporator oscillation type flow meter and an amplifier. The
and the working fluid pump. The plant must also be equipped characteristics of the amplifier are expressed as
with an input signal part and a detection part. The digital con-
trol part consists of a computer (TOSBAC 600) programmed V„ = V*„,(V) (1)
with adaptive control theories and equipped with analog- and the relation between the flow rate mF and the voltage Vm
digital (A/D) converters and a digital-analog (D/A) converter. is given by
mF = 0.833 F,„(kg/s). (2)
3 Digital Control System
The working fluid liquid temperature TFI at the inlet and the
The digital control system for working fluid flow rate, working fluid vapor temperature Tvo at the outlet of the
depicted in Fig. 2, consists of the OTEC plant side and the evaporator are detected by thermocouples and amplifiers. The
digital control side. The two sides are connected by A / D con- amplification factor is 5000, and the characteristics of the
verters and a D/A converter, and they have a symmetric rela- amplifiers are written
tionship at the converters in Fig. 2 between a real and a mirror
image. Amplifiers in the OTEC plant side are used to stand- VT = 0.200 V*r(mV). (3)
ardize each of the analog values to the restriction of the A / D The thermocouples are characterized by the following
converters (0-10.24 V) and to that of the D/A converter polynomial equations of VT based on the least squares
(0~ 10.24 V), respectively. The digital control side consists of method:
the following blocks: a detection characteristics part, an adap-
7>/ = 2 . 1 1 6 x l 0 - 2 + 2.506xl0 1 K 7 F + 6..151xl0- 1 K 7 y 2
tive control part, and an input signal characteristics part. The
components of each part, programmed in the computer, are - 8.173 x lO" 1 VTI? + 1.805 x 1 0 ' 1 * V ( ° C ) , (4)
described below in detail. 3 1 2 2
Tvo = -6.700X 10" +2.539X 10 VTV-2.065 x\Q- VTV
3
3.1 Detection Characteristics Part. The heat rate of the -4.520x 1 0 - ' VTV + 1.114 x 1 0 - ' VTV* (°C). (5)
working fluid given at the evaporator is determined by the The heat rate of working fluid QF in the evaporator is deter-

Nomenclature

unknown parameter
of process
«i ( * ) estimated parameter Q = heat rate (kW)
of process r2, r3 = parameter of Superscripts
b0, bl = unknown parameter observer-and- * = standard value for
of process (kJ/kg) regulator the restriction of
b0(k),bx(k) estimated parameter T = temperature (°C) A / D D/A converters
of process (kJ/kg) U(k) = process input (kg/s) i = power
C(k) estimation matrix V = voltage (V, mV) T = transposition
specific heat W(k) = process disturbance
(kJ/kgK) (kW) Subscripts
m mass flow rate (kg/s) x(k) = estimated state of C — cold water
h specific enthalpy observer (kW) D = desired value
(kJ/kg) z~x = backwards shift F = working fluid liquid
I identity matrix operator m = mass flow rate
K(k) gain matrix z(k) = input-output vector H = hot water
k control stage \ , , X2 = pole of regulator I = inlet
N number of control /* = pole of observer O = outlet
stages p = index of exponential S = condensed liquid
p(k) = estimated parameter weighted least T = temperature
vector squares method V = working fluid vapor

112/Vol. 108, MAY 1986 Transactions of the ASME

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1 1 1 1 | , , i i | , , , ,
1 ' ' ' ' .

4UU h(Tvo) ~
300 -_

200 h(TFi) ~

100

I , , , , 1 , , , , I I I , , "
0 10 20 30 40
o 0.5 1.0 1.5 2.0 2.5
Temperature T [°CI
Working Fluid Flow Rate U ikg/si
Fig. 3 Characteristic curves of specific enthalpy for Freon 22
Fig. 4 Characteristic curve of working fluid pump input

mined by the working fluid flow rate mF and the specific en-
thalpy difference between h(Tvo) and h{TFI) as follows: The index p is in the range 0 < p ts 1, and / is the identity
matrix.
QF = mF{h(Tvo)-h(TFr)}(kW). (6)
The characteristics of the specific enthalpies are formulated by (b) Control Algorithm. We adopt the observer-and-
polynomial equations based on the least squares method for regulator using an extended model [10] as the control
the data in the Freon 22 Table [8] as algorithm. Arranging the control algorithm, we obtain a
process input for the next stage k + 1 as
h{TV0) = 4.047 x 102 +3.592x \0"lTvo k

-1.429xl0-37Vo2 U(k+l) = rl(k)x(k+l) + r2(k) X) {QF(')-QD(')}. (14)


5 3
-1.788xl0- 7Vo (kJ/kg), (7)
The value QD(i) represents a desired output value, and the
2 3 2
h{ TFl) = 2.000 Xl0 + 1.158 Xl0°7> 7 + 1.519 X l O " r w variable x(k+ 1) is calculated by the observer as follows:
+ 9.895 x 10- 6 7> 7 3 (kJ/kg). (8) x(k + 1)= - o j (k)x(k) + {hi (k)-d1 (k)b0(k)} U(k)
These curves are illustrated in Fig. 3. -r,(k){QF(k)-x(k)-b0(k)U(k)}. (15)
3.2 Adaptive Control Part. The controlled process, which The parameters (rx(k), r2(k), ri(k)) of the observer-and-
consists of the evaporator and the working fluid pump, is regulator in the above equations are
assumed to be formulated by a pulse transfer function of the /-,(/:) = (X, +X 2 + a, (k) - 1
first order as
QF(k) = {(b0 + blz-l)/(l + alz-i)}U(k) + W(k) (9) -b0(k)r2(k))/{bl(k)-al(k)bQ(k)}, (16)
where the process input U(k) is the input signal for the work- /• 2 (*) = (X,+X 2 + X 1 X 2 - 1 ) / { S 0 ( * ) - S 1 ( * ) ) , (17)
ing fluid pump, and the process output QF(k) is the heat rate r3(k)=n + di(k) (18)
of working fluid; W{k) represents a process disturbance, k
the kth stage of the sampling period, z" 1 a backwards shift where Xj and X2 are poles of the regulator, and n is a pole of
operator, and {ql ,b0,bx) unknown parameters of the process. the observer. These poles must be selected appropriately by
The adaptive control algorithm comprises combinations of a the designer beforehand. Since the controller parameters
recursive identification algorithm and an easy-to-control r\(k), r2(k), and r3(k) are calculated using the estimated
algorithm as follows: the unknown parameters of the process parameters of the process p(k), the control algorithm can
are estimated on-line by use of the identification algorithm, adapt properly to the process even under varying conditions.
and an appropriate process input U(k) is determined by the (c) Initial Condition. The initial value of the estimated
control algorithm using the estimated parameters (<J,, b0, bx) parameter vector is necessary as the initial condition for the
thus obtained. identification algorithm. Before digital control commences,
the initial value is calculated using input and output data
(a) Identification Algorithm. We adopt the exponential based on the exponential weighted least squares of batched
weighted least squares (EWLS) method [9] as the identifica- type as follows:
tion algorithm. The estimated parameters of the process are o o
given by
P= E p-'z(i)QF(i)/ £ p-'z(i)zU)T. (19)
r
p(k) = [dl(k)b0(k) £,W] 1 = 1-N i=l-N
This algorithm is equivalent to the algorithm of an on-line
= {I-K(k) z(k) }p(k- \) + K(k) QF(k), (10)
type, equations (10-12).
C(k) = {I-K(k) z(k)}C(k- l)/p, (11) 3.3 Input Signal Characteristics Part. The relation be-
T tween the pump input voltage Vv and the working fluid flow
K(k) = C{k- \)z(k)/{z{k) C{k- \)z(k) + p) (12)
rate U (the process input) is determined by a polynomial equa-
where p(k) is the estimated parameter vector. Both the
tion based on the least squares method as
estimated parameter vector p(k- 1) and the estimation matrix
Vy= - 6.000 X 10~2 + 6.286 x 10° U-l. 606 X 10~' t/2 (V).
C(k- 1) on the right side of the above equations have already
been determined in the previous stage k-l. The input-output (20)
vector z(k) is the column vector whose elements are the pro- This curve is illustrated in Fig. 4. The characteristics of the
cess input and the process outputs as amplifier used here are expressed as
z(k) = [QF(k- 1) U(k) U(k~ l)]7". (13) Vf, = 0.667 VV(V). (21)

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= 500

400 400

300 300

200 200

a 100 100

0 100 200 300 400 0 100 300 200400


Time isi Time is]
Fig. 5 Input and output data fo the controlled process for off-line Fig. 7 The process input and output in the first control experiment
identification (constant conditions)

500 - 0. 300
" I , MM,
'"' "|l" I " " I " "

„ 400 o- "i - 200 c?"

-0.1 - 100
300 3 3 °i
-0.2 " -
Bo
200
M M
-0.3, I I M I M N I ; I I I I I M I I I I M I M M I M I
-100
^ 0 100 200 300 400
100
Time Isi
Fig. 8 The estimated parameters in the first control experiment (cons-
LnJn I tant conditions)
0 100 200 300 400
Time is)
Fig. 6 Model output for the process
flow rate was 20 t/h (5.56 kg/s). Other conditions for the ex-
periment were as follows:
4 Experimental Results • warm water temperature TH, 30 °C
We investigate an off-line identification result and three on- • cold water flow rate mc, 80 t/h (22.22 kg/s)
line digital control results for the "Imari 2 " OTEC plant. In • cold water temperature Tc, 10 °C
the experiments, warm fresh water heated by a boiler and cold • sampling period, 5 s
fresh water cooled by a refrigerating machine were used in- • number of control stages N, 90
stead of warm surface seawater and cold subsurface seawater. • poles of the regulator \i X2, 0.7 0.7
The turbine-generator was disconnected from the OTEC plant • pole of the observer JX, 0.5
for the purpose of the experiments. • index of EWLS p, 0.95
• initial value p(l), [-0.115 -39.11 252.20] T
(a) Off-Line Identification Result. Figure 5 illustrates the » initial value C(l), diag (0.0100, 1752, 1752) (diag:
input and output data of the controlled process for the off-line diagonal matrix)
identification. The sampling period was 5 s and the sample • initial value x(l), 160 Mcal/h (186 kW)
number was 90. The process inputs U(k) were given by ran-
dom numbers drawn from Gaussian distribution with a mean • initial condition ^ (Q F (/) - QD (/)), 250 Mcal/h
of 1.53 having a variance of 0.28. The estimated parameters / = — oo

using the input and output data based on the exponential


(291 kW)
weighted least squares method (equation 19) are calculated as
r Figure 7 shows the input U(k) and the output QF(k) of the
p= [-0.115 -39.11 252.20] . (22)
digital control. As seen from Fig. 7, the output QF(k) ap-
To verify the validity of the model (equation 9), one-step- proached the desired output value QD(k) in 80 s and main-
ahead model output was used tained its value. The estimated parameters p(k) are shown in
QF(k) = -a1QP(k-l) + b0U(K) + blU(k-l). (23) Fig. 8; they keep almost constant values for the whole control
interval.
As seen from QF(k) in Fig. 6, the model output was approx-
imately equal to the true output QF(k) in Fig. 5, which allows (c) Control Result (Variable Desired Output Value). In the
us to prove the validity of the model (equation 9). We adopted second control experiment, the desired output value QD(k)
the estimated parameter vectorp as for the initial valuep(\) of was changed from 250 Mcal/h (291 kW) to 300 Mcal/h (349
the on-line identification algorithm in the following kW) at a time of 250 s. Other conditions were the same as
experiments. those adopted for the previous experiment. Figure 9 shows the
input U(k) and the output QF(k), and Fig. 10 illustrates the
(b) Control Result {Constant Conditions). In the first con- estimated parameters p(k). It may be seen that the process
trol experiment, we investigated the digital control of working output QF(k) behaves appropriately according to the variable
fluid flow rate under constant conditions; the desired output desired output value Qo(k), and that the estimated
value QD(k) was 250 Mcal/h (291 kW) and the warm water parameters adapt to the system under the changed conditions.

114/Vol. 108, MAY 1986 Transactions of the ASME

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500

400

300

o 200

V 100-

0,
100 200 300 400
Time is)
Fig. 9 The process input and output in the second control experiment
(variable desired output value)

a ° MM|MM| ill nil | i i ii H I ,M i | i i i i | i i n 300 o 100 200 300 400


Time ts)
Fig. 13 The temperatures around the evaporator (a) and around the
o- "i
200
condenser (b)
-
s -o.i 100
"i
I i n i|ii n |i i u | i in III 30
V. -0.2 " b0 - 0 2

11111111111 111111 11111 ,,,,1,1, mc


^ -0.3, I M l l l M l l 100
0 100 200 300 400 ms m?
/\ - 20
Time isi
Fig. 10 The estimated parameters in the second experiment (variable U
desired output value) -

500 mn

400
,,,!,, IMIIIIIIII I I I H I I I M Illll
100 200 300 400
300 Time is)
Fig. 14 The mass flow rates
200

600 ~ r . i i | i l l , I I M | M , | i n , M I | I M I , I Ml III

- 500 Qc
- QH -
200 300 /
u. 400 ^ - V N V A -
Time isi ^y^<.
Fig. 11 The process input and output in the third experiment (variable 300 r QF

warm water flow rate)

3 0.1 300
200

100
j jps -

0 200
CD
b_ _l_Lllll IIIMMIII IIIMM! ,,!,,,,! I l l l l l l
CD
100 200 300 400
| -o.i 100 „ Time Isi
a
o_ Fig. 15 The heat rates
"a -n P 2 - o •e.
b0 =
o
E constant at 300 Mcal/h (349 kW). Other conditions were the
LLJ U 100 200 300 400 -100 same as those for the previous experiment. Figure 11 shows
the input U(k) and the output QF(k), and Fig. 12 illustrates
Time is)
the estimated parameters p (k). It may be seen that the process
Fig. 12 The estimated parameters in the third experiment (variable
output QF(k) can maintain the desired value shortly after the
warm water flow rate)
conditions have been changed.
(d) Control Result (Variable Warm Water Flow Rate). In (e) Related Values. Related values for the third control ex-
the third control experiment, the warm water flow rate value periment are shown in Figs. 13-15. Figure 13 shows the
mH was changed from 40 t/h (11.11 kg/s) to 20 t/h (5.56 kg/s) temperatures around the evaporator and the condenser. The
at a time of 250 s, and the desired output value QD(k) kept mass flow rates mH, mc, mF, ms for the water and the work-

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ing fluid are shown in Fig. 14, and the heat rates QH, Qc, QF, ponential weighted least squares method as an identification
Qs are illustrated in Fig. 15. The heat rates were calculated by algorithm and the observer-and-regulator as a control
the following formula: algorithm. Other adaptive control theories, such as the
Q„ = CpmH(THI-THO), (24) MRACS (Model Reference Adaptive Control System) [6],
could also be applied simply by changing the program of the
Qc = Cpmc(Tco-TCI), (25) adaptive control part.
QF = mF{h(Tvo)-h(TFI)}, (26) (c) Future Problems
Qs = ms{h(TVI)-h(TFo)}. (27) (i) Remarks described in the previous subsection will be
considered in order to achieve the more precise digital control
The specific heat Cp is 4.186 kJ/kgK. The specific enthalpies of working fluid flow rate.
of working fluid vapor h (TVI ),h( Tv0) were calculated by the (ii) The "Imari 2 " OTEC plant has been designed based
polynomial (equation 7), and those of working fluid liquid on steady-state analysis. By using dynamic characteristics,
h(TFI), h(TF0) were calculated by the polynomial (equation such as the curves shown in Figs. 13-15, the hardware designs
8). These curves in Figs. 13-15 can hopefully provide some of the OTEC plant will be reconsidered in order to achieve
useful information for hardware designs of the OTEC plant in more efficient performance.
the future. (Hi) Using adaptive control theory for multi-input and
multi-output systems, the control of the seawater flow rates as
5 Discussion well as the working fluid flow rate will be accomplished.
(a) Significance. The innovative feature of this study was (iv) The total system control of the OTEC plant will be
the construction of a digital control system and the implemen- established to provide generating power at a desired value.
tation of the digital control of working fluid flow rate for the (v) The OTEC plant in Imari is now planned to be con-
real pilot OTEC plant. The process output of the digital con- trolled by microcomputer from Saga University, approximate-
trol behaved appropriately according to a desired output value ly 40 km away, using ordinary public telephone lines.
under changing conditions by use of an adaptive control
algorithm of the digital control side programmed in the com- Acknowledgments
puter. The advantages of using digital control in general are The authors are grateful to Mr. T. Nakaoka (research assis-
summarized as follows: tant), Mr. S. Nishida (research assistant), and Mr. Oishi
(/) Any adaptive control algorithm can be selected by (postgraduate student, now with Mitzubishi Heavy Industry)
changing the program of the adaptive control part, whereas of Saga University for their useful comments and help in the
for analog type control, such as the PID controller, this is experiments, and to Dr. G. Jember of Saga University for
rather difficult to do once the controller has been attached to revising the English in this paper.
the plant.
(//) Linearity for detection characteristics and for input References
signal characteristics is not necessarily requisite. The
polynomial equations for the characteristics, determined by 1 D'Arsonval, J. A., "Utilization des forces naturelles: Avenir de l'elec-
tricite," La Revenue Scientifique, Sept. 17, 1881, pp. 370-372.
the least squares method, need only be programmed in the 2 Uehara, H., Kusuda, H., Monde, M., Nakaoka, T., Masuda, T., and
computer. Nakahara, M., "Model of Ocean Thermal Energy Plant—Shiranui 3 , " Proc.
5th OTECConf., 1978, pp. V 117-146.
(b) Remarks 3 Uehara, H., Kusuda, H., Monde, M., Nakaoka, T., and Sumitomo, H.,
"Shell-and-Plate-Type Heat Exchangers for OTEC Plants," ASME JOURNAL OF
(i) The heat rate of working fluid at the evaporator was SOLAR ENERGY ENGINEERING, Vol. 106, Aug. 1984, pp. 286-290.
calculated by equation (6). A more reliable calculation might 4 Owens, W. L., "OTEC Plant Response and Control Analysis," ASME
be possible by using mv (working fluid vapor flow rate) in- JOURNAL OF SOLAR ENERGY ENGINEERING, Vol. 104, Aug. 1982, pp. 208-215.
stead of mF (working fluid liquid flow rate) adopted here. 5 Astrom, K. J., Borisson, V., Ljung, L., and Wittenmark, B., "Theory
and Applications of Self-Tuning Regulators," Automatica, Vol. 13, 1977, pp.
(ii) The process model (equation 9) used here had the 457-476.
structure of the first order. A more appropriate order of the 6 Landau, I. D., " A Survey of Model Reference Adaptive Techni-
process model might be found by using another technique, ques—Theory and Applications," Automatica, Vol. 10, 1974, pp. 353-379.
such as AIC (Akaike's Information Criterion) [11]. 7 Uehara, H., "Introduction to OTEC," Ohm, (in Japanese), 1982.
8 JAR., "Thermophysical Properties of Refrigerants (R22)," (in Japanese),
(Hi) The values of the poles A,, X2, \i in the control 1982.
algorithm and the value of the index p in the identification 9 Nakamura, M., "Relationship Between Steady State Kalman Filter Gain
algorithm were selected a priori by computer simulation and Noise Variances," Int. J. Systems Sci., Vol. 13, No. 10, 1982, pp.
before the control experiments. More appropriate values 1153-1163.
might be determined through further experimental 10 Furuta, K., "Digital Control and Control Theory," Computwl, (in
Japanese), No. 2, 1983, pp. 16-25.
investigation. 11 Akaike, H., "A New Look at the Statistical Model Identification," IEEE
(iv) For an adaptive control theory, we adopted the ex- Trans. Autom. Control, Vol. AC-19, No. 6, 1974, pp. 716-723.

116/Vol. 108, MAY 1986 Transactions of the ASME

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