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A detailed centrifugal electropump SEMI ANNUALLY preventive maintenance checklist

General Inspection

Inspect the overall condition of the pump.

Look for any visible signs of wear or damage.
Assess the general cleanliness of the pump.
Ensure all components are securely fastened.
Check for any loose or missing parts.

Check for any visible leaks around seals and joints.

Examine seals for moisture or residue.
Inspect joints for wetness or corrosion.
Use a flashlight to illuminate hard-to-see areas.
Monitor for any fluid pooling around the pump base.

Examine the pump housing for signs of wear or damage.

Look for cracks, dents, or corrosion.
Inspect paint for peeling or bubbling.
Check for any abnormal vibrations indicating structural issues.
Ensure all fasteners are tight and secure.

Verify that all labels and identification tags are intact and legible.

Check for fading or damage to labels.
Ensure critical information is visible and readable.
Replace any missing or illegible tags.
Confirm that tags are securely attached.

Here are some additional steps that could be included in the General Inspection section of the centrifugal electropump SEMI ANNUALLY preventive maintenance checklist

Inspect the pump base and mounting bolts for tightness and signs of corrosion

Tighten any loose mounting bolts.
Look for rust or corrosion on the base.
Check that the base is level and stable.
Assess the condition of vibration isolators.

Check for any unusual noises during operation, which may indicate mechanical issues

Listen for grinding, rattling, or whining sounds.
Run the pump at normal operating conditions.
Document any irregular sounds for further analysis.
Investigate sources of noise for potential repair.

Examine the alignment of the pump with the driver (motor) to ensure proper operation

Use a dial indicator to check alignment.
Adjust the alignment if misaligned.
Inspect coupling for wear or damage.
Ensure secure attachment to both pump and motor.

Inspect the piping and connections for signs of stress or corrosion

Look for cracks or leaks in pipes.
Inspect joints and fittings for rust.
Check for proper support and alignment.
Assess the condition of any gaskets used.

Verify that the venting and drainage ports are clear and functional

Remove any blockages from ports.
Test drainage functionality using water.
Inspect venting for proper airflow.
Ensure no obstructions around ports.

Check the condition of the vibration isolators or pads, if applicable

Look for cracks or degradation in isolators.
Ensure that pads are securely mounted.
Assess for proper cushioning and support.
Replace any worn or damaged isolators.

Inspect the condition of any protective covers or guards for signs of damage

Look for cracks, bends, or rust.
Ensure covers are securely fastened.
Check that guards are properly aligned.
Replace any damaged protective coverings.

Ensure that the area around the pump is clean and free of debris that could affect operation

Remove any dust, dirt, or spills.
Check for any obstructions around the pump.
Ensure clear access to maintenance points.
Dispose of waste materials properly.

Review and assess the condition of any accessories, such as strainers or filters, connected to the pump

Inspect strainers and filters for clogs.
Clean or replace accessories as necessary.
Check for any signs of wear on connections.
Ensure accessories are properly secured.

Look for signs of cavitation, such as pitting or erosion on the impeller or casing

Examine impeller and casing for surface damage.
Check for unusual performance issues.
Document any findings for further investigation.
Consider adjusting pump operation parameters.

Inspect the foundation or support structure for stability and integrity

Look for cracks or shifting in the foundation.
Ensure support structures are sound and stable.
Check for water pooling or erosion around supports.
Assess load-bearing capacity of support elements.

Confirm that all safety devices, such as pressure relief valves, are functioning properly

Test operation of safety devices.
Inspect for signs of wear or damage.
Verify that relief valves are not stuck.
Document any issues for immediate attention.

Electrical Components

Inspect electrical connections for corrosion or wear.

Examine all terminal connections for signs of corrosion.
Look for frayed wires or damaged insulation.
Ensure connections are tight and secure.
Clean any corrosion using appropriate cleaning agents.

Check motor alignment and mounting for stability.

Inspect motor mounts and brackets for tightness.
Use a straight edge to check motor alignment.
Look for signs of vibration or misalignment.
Adjust mounts as necessary to ensure proper alignment.

Test the insulation resistance of the motor windings.

Use a megohmmeter to measure insulation resistance.
Record readings and compare to manufacturer specifications.
Inspect for any signs of moisture or damage.
Replace or repair as necessary if readings are below acceptable levels.

Verify that the control panel is functioning correctly and all indicators are operational.

Check that all indicator lights are illuminated as expected.
Test functionality of switches and buttons.
Inspect for loose connections or damaged components.
Document any malfunctions for further investigation.

Here are some additional steps that could be included in the Electrical Components section of the centrifugal electropump SEMI ANNUAL preventive maintenance checklist

Inspect and clean electrical contacts to ensure proper conductivity

Remove covers to access electrical contacts.
Clean contacts using an appropriate contact cleaner.
Check for pitting or excessive wear.
Replace contacts if they show significant damage.

Verify proper operation of overload protection devices

Test the trip mechanism to ensure it activates properly.
Inspect wiring and connections for any damage.
Check reset functions to ensure they work smoothly.
Document any issues for immediate attention.

Check the power supply voltage and phase balance to ensure it meets specifications

Use a multimeter to measure voltage across phases.
Check that voltage levels match manufacturer specifications.
Look for signs of phase imbalance.
Report any discrepancies for corrective action.

Test the functionality of emergency shutoff switches and safety interlocks

Activate emergency shutoff switches to ensure they function.
Inspect interlocks for proper operation.
Ensure all safety devices engage and disengage correctly.
Document any issues found during testing.

Inspect and secure all conduit and wiring for wear or damage

Examine conduits for cracks or breaks.
Check for loose or exposed wiring.
Secure any loose wires to prevent hazards.
Replace damaged conduits or wires as necessary.

Ensure that all fuses and circuit breakers are in good condition and functioning properly

Inspect fuses for signs of blowing or damage.
Test circuit breakers to ensure they trip correctly.
Replace any faulty fuses or breakers.
Document the condition of all protective devices.

Check for signs of overheating in electrical components, including the motor and control panel

Look for discoloration or burnt areas on components.
Use an infrared thermometer to measure temperature.
Ensure adequate ventilation around electrical components.
Address any overheating issues immediately.

Test the operation of variable frequency drives (VFDs) if applicable, looking for error codes or malfunctions

Access the VFD display to check for error codes.
Run a functional test to observe performance.
Inspect wiring and connections for integrity.
Document any errors or irregularities for further analysis.

Review and update electrical schematics as necessary to reflect any changes or repairs made

Compare existing schematics with current configurations.
Update diagrams to reflect any modifications.
Ensure all changes are documented and saved.
Distribute updated schematics to relevant personnel.

Inspect grounding connections to ensure proper grounding of the electrical system

Check all grounding connections for tightness.
Inspect ground wires for signs of corrosion or damage.
Ensure grounding system meets local electrical codes.
Repair or replace any faulty grounding connections.

Evaluate the condition and function of any sensors or feedback devices associated with the electric motor operation

Inspect sensors for proper installation and alignment.
Test signal output from each sensor.
Check for any physical damage or wear.
Replace faulty sensors as needed.

Test the operation of any remote start/stop controls to ensure they are functioning correctly

Activate remote controls to check responsiveness.
Inspect wiring and connections for damage.
Ensure signals are transmitted without delays.
Document any malfunctions for correction.

Mechanical Components

Inspect the bearings for wear and proper lubrication.

Remove protective covers if necessary.
Check for any signs of discoloration or overheating.
Ensure lubricant is at recommended levels.
Apply grease or oil as per manufacturer guidelines.
Rotate bearings to confirm smooth operation.

Check the impeller for damage or excessive wear.

Remove the impeller from the assembly.
Inspect for nicks, cracks, or pitting.
Measure wear using a caliper against specifications.
Clean debris from the impeller surface.
Replace if damage exceeds allowable limits.

Examine the volute casing for cracks or erosion.

Inspect the exterior and interior surfaces.
Look for visible cracks or signs of erosion.
Use a flashlight to enhance visibility.
Note any observations for further evaluation.
Document findings and replace if necessary.

Ensure that all fasteners are tightened to the manufacturer’s specifications.

Refer to the service manual for torque values.
Use a torque wrench for accuracy.
Check all accessible bolts and screws.
Inspect for any missing fasteners.
Retighten any loose connections as needed.

Certainly! Here are some additional steps that could be included in the Mechanical Components section of the centrifugal electropump SEMI ANNUALLY preventive maintenance checklist

Inspect the shaft for signs of wear, corrosion, or misalignment

Remove any covers or guards to access the shaft.
Check for rust or wear patterns.
Ensure the shaft is aligned with the motor.
Rotate the shaft manually to feel for resistance.
Replace if significant wear or misalignment is found.

Check the wear rings for excessive wear and proper clearance

Remove the volute or casing for access.
Measure the clearance between the wear rings.
Inspect for grooves or excessive wear.
Replace wear rings if clearance exceeds specifications.
Reassemble components carefully post-inspection.

Verify that the mechanical seal is intact and functioning properly

Inspect the seal for leaks or wear.
Check alignment with the shaft.
Ensure springs are intact and not corroded.
Test for proper sealing under operational conditions.
Replace if any damage or malfunction is detected.

Inspect the coupling for any signs of damage or misalignment

Check for cracks or wear on the coupling.
Ensure alignment with the motor and pump shaft.
Look for excessive play or noise during operation.
Tighten fasteners to manufacturer specifications.
Replace if any damage is observed.

Check for any unusual noises during manual rotation of the pump

Manually rotate the pump shaft.
Listen for grinding, scraping, or rattling sounds.
Document any unusual noises for further analysis.
Inspect components if any noise is detected.
Address issues immediately to prevent failure.

Ensure that vibration levels are within acceptable limits using a vibration analyzer

Attach the vibration analyzer to the pump.
Collect baseline vibration data during operation.
Compare readings against manufacturer specifications.
Identify and address any anomalies.
Document results for future reference.

Inspect the pump base for any signs of movement or deterioration

Check for cracks or corrosion on the base.
Ensure the base is securely fastened to the foundation.
Look for any signs of shifting or settling.
Address any issues promptly to ensure stability.
Document findings and remedial actions taken.

Verify that the pump is level and properly secured to its foundation

Use a level tool to check the pump's position.
Adjust as necessary to maintain proper alignment.
Inspect securing bolts for tightness.
Ensure no movement occurs during operation.
Document any adjustments made.

Clean any debris or buildup from the pump exterior and surrounding area

Use a soft brush or vacuum to remove debris.
Avoid using harsh chemicals that can damage surfaces.
Inspect for signs of leaks or corrosion during cleaning.
Ensure surrounding area is clear for maintenance access.
Document cleaning activities for records.

Check the condition of any protective coatings or paint on the pump components

Inspect surfaces for peeling or rust.
Look for areas where the coating is worn away.
Touch up with appropriate paint if necessary.
Ensure coatings are intact to prevent corrosion.
Document any maintenance performed.

These steps will help ensure the mechanical integrity and reliability of the centrifugal electropump during its operation

Seals and Gaskets

Inspect all seals and gaskets for signs of deterioration.

Look for cracks, tears, or hardening.
Check for discoloration or swelling.
Assess the overall integrity of each seal.
Note any unusual wear patterns.

Replace any worn or damaged seals as necessary.

Select appropriate replacement seals.
Use proper tools to remove old seals.
Install new seals carefully to avoid damage.
Ensure a snug fit to prevent leaks.

Check the condition of the O-rings and gaskets at connection points.

Examine for signs of wear or breakage.
Ensure O-rings are properly seated.
Replace any compromised gaskets immediately.
Verify compatibility with the fluids.

Ensure that all sealing surfaces are clean and free from debris.

Use a lint-free cloth to wipe surfaces.
Remove old sealant or residues carefully.
Inspect for scratches or imperfections.
Confirm surfaces are smooth and dry.

Here are some additional steps you can include in the Seals and Gaskets section of the centrifugal electropump SEMI ANNUALLY preventive maintenance checklist

Verify the correct type and size of seals and gaskets used for compatibility with the fluid being pumped

Consult manufacturer's specifications.
Check material compatibility with fluids.
Measure dimensions accurately before replacement.
Ensure seals meet pressure requirements.

Inspect for any signs of leakage around seals and gaskets during operation

Observe the area visually during operation.
Look for wet spots or dripping fluid.
Check for unusual sounds indicating leaks.
Monitor pressure readings for irregularities.

Check for proper installation and seating of all seals and gaskets

Verify alignment of components.
Ensure seals are not pinched or twisted.
Confirm that gaskets are uniformly compressed.
Test for ease of assembly without force.

Assess the torque specifications for bolts and fasteners associated with sealing surfaces to ensure proper compression

Refer to the maintenance manual for torque values.
Use a calibrated torque wrench.
Tighten bolts in a crisscross pattern.
Recheck torque after initial installation.

Monitor for any signs of excessive wear or misalignment that could affect seal performance

Conduct regular visual inspections.
Check for vibrations or unusual noises.
Evaluate alignment of pump components.
Address any misalignments promptly.

Document any seal and gasket replacements in maintenance records for future reference

Record the date of replacement.
Include details of materials used.
Note any observed issues during replacement.
Store records electronically or in a logbook.

Evaluate the environmental conditions surrounding seals and gaskets, such as temperature and chemical exposure, to ensure they are suitable for optimal performance

Measure operating temperature regularly.
Assess chemical compatibility with seals.
Monitor humidity and other environmental factors.
Adjust operating conditions if necessary.

Lubricate O-rings and gaskets as necessary to facilitate proper sealing and prevent damage during assembly

Use compatible lubricant as recommended.
Apply a thin, even layer to O-rings.
Avoid excess lubricant that may attract dirt.
Reapply lubricant during assembly as needed.

Review manufacturer's recommendations for the specific seals and gaskets used in the pump for any maintenance or replacement guidelines

Obtain the latest manufacturer documentation.
Follow specified maintenance intervals.
Stay updated on any product recalls.
Implement any special handling instructions.

Hydraulic System

Check the inlet and outlet piping for blockages or leaks.

Inspect for visible blockages.
Look for any signs of leakage.
Ensure connections are secure.
Use appropriate tools to clear any obstructions.
Document any issues found.

Inspect the strainer or filter for clogs and clean as necessary.

Remove strainer or filter from the system.
Examine for debris and clogs.
Clean using suitable cleaning agents.
Replace if damaged or excessively worn.
Reinstall ensuring proper sealing.

Verify proper functioning of any flow meters or pressure gauges.

Check calibration of flow meters and gauges.
Look for any physical damage.
Test readings against expected values.
Replace faulty meters or gauges.
Document the verification results.

Test for adequate pressure and flow rates.

Measure pressure at designated points.
Record flow rates using flow meters.
Compare readings to manufacturer specifications.
Adjust system settings if necessary.
Note any discrepancies for follow-up.

Certainly! Here are some additional steps that could be included in the Hydraulic System section of the centrifugal electropump semi-annual preventive maintenance checklist

Inspect all hydraulic hoses for wear, cracks, or leaks and replace as necessary

Examine hoses for visible damage.
Check for leaks at connections.
Ensure hoses are secure and properly routed.
Replace any damaged hoses.
Document replaced hoses in maintenance records.

Check all hydraulic connections for tightness and integrity

Inspect each connection point visually.
Use a torque wrench to verify tightness.
Look for any signs of fluid seepage.
Tighten connections as necessary.
Record any adjustments made.

Verify that the hydraulic fluid is at the proper level and condition; replace or top off as needed

Check fluid level against the gauge.
Inspect fluid for color and clarity.
Top off or replace fluid as needed.
Use manufacturer-recommended fluid only.
Document fluid condition and any changes.

Monitor for any unusual noises during pump operation that may indicate hydraulic issues

Listen for grinding or rattling sounds.
Pay attention to changes in normal operation.
Identify the source of any unusual noises.
Investigate potential issues as needed.
Document findings for further review.

Test the operation of any hydraulic valves to ensure they open and close properly

Manually operate each valve for testing.
Check for smooth operation without resistance.
Inspect seals for wear or damage.
Replace valves that do not function correctly.
Document testing results and any actions taken.

Assess the condition of the hydraulic reservoir for signs of contamination or wear

Inspect reservoir for rust or scratches.
Check fluid for contaminants or particulates.
Clean the reservoir if contamination is found.
Ensure proper sealing of the reservoir.
Document any findings and maintenance performed.

Inspect the hydraulic actuator mechanisms for signs of wear or malfunction

Examine actuators for physical damage.
Check for fluid leaks around actuators.
Test actuator movement for responsiveness.
Replace any malfunctioning actuators.
Record the inspection findings.

Review hydraulic system schematics to confirm that all components are correctly configured

Obtain the latest hydraulic schematics.
Cross-reference physical components with schematics.
Look for any discrepancies or misconfigurations.
Correct any identified issues.
Document the review process.

Check for signs of cavitation or aeration in the hydraulic system during operation

Observe for abnormal noise or vibration.
Monitor pressure fluctuations during operation.
Inspect fluid for foaming or bubbles.
Address potential cavitation sources immediately.
Document any occurrences and corrective actions.

Ensure that all safety devices (such as pressure relief valves) are functioning correctly

Test the operation of safety devices.
Inspect for visible damage or wear.
Confirm calibration and settings are accurate.
Replace any non-functional safety devices.
Document testing and maintenance performed.

Feel free to modify or expand upon these suggestions based on the specific requirements and operational conditions of your centrifugal electropump system

Cooling System

Inspect the cooling water supply for obstructions.

Check inlet screens for debris.
Verify pipe connections and fittings.
Flush system if necessary.
Ensure flow is unobstructed.
Document findings and actions taken.

Check heat exchanger for scale buildup or corrosion.

Inspect exterior for visible damage.
Open access panels if necessary.
Use appropriate cleaning solutions.
Check for effective heat transfer.
Record any signs of deterioration.

Clean cooling fins and ensure unobstructed airflow.

Use compressed air to remove dust.
Inspect for bent or broken fins.
Ensure surrounding area is clear.
Verify airflow direction is correct.
Document cleaning results.

Verify that temperature sensors are functioning correctly.

Check calibration against standards.
Test at various temperature points.
Inspect wiring for integrity.
Replace faulty sensors as needed.
Log all tests and replacements.

Here are some additional steps that could be included in the Cooling System section of the centrifugal electropump SEMI ANNUAL preventive maintenance checklist

Inspect all cooling system hoses and connections for leaks or signs of wear

Look for cracks or bulges.
Check clamps and fittings for tightness.
Perform a pressure test if necessary.
Replace any damaged components.
Record inspection results.

Check the coolant level and top off as necessary with the appropriate fluid

Determine the correct coolant type.
Inspect reservoir for minimum/maximum levels.
Add fluid as needed to reach optimal levels.
Check for leaks during filling.
Document the coolant level after adjustment.

Test the operation of the cooling system valves to ensure they are opening and closing properly

Manually operate each valve.
Listen for unusual sounds during operation.
Verify full range of motion.
Check seals for integrity.
Record valve performance.

Inspect the pump's cooling jacket for any signs of damage or corrosion

Examine for cracks or leaks.
Check for corrosion on surfaces.
Ensure proper mounting and alignment.
Use appropriate cleaning methods.
Document any findings.

Monitor the coolant flow rate to ensure it is within the manufacturer's specified range

Use flow meter for measurement.
Compare with manufacturer specifications.
Check for obstructions in the system.
Adjust flow if necessary.
Log flow rates and adjustments.

Check for any unusual noises or vibrations from the cooling system components

Listen closely during operation.
Use vibration analysis tools if available.
Inspect mounts and supports for wear.
Identify sources of noise or vibration.
Document any issues found.

Assess the condition of the coolant for contamination or degradation, and replace if necessary

Check for discoloration or debris.
Test for pH and chemical balance.
Replace coolant if tests indicate degradation.
Clean the system before refilling.
Record coolant condition findings.

Ensure that all cooling system components are securely mounted and free from excessive movement

Inspect all mounting hardware.
Tighten loose components.
Check for signs of fatigue or wear.
Ensure alignment of connected parts.
Document any adjustments made.

Inspect and clean any strainers or filters in the cooling system to prevent blockages

Remove strainers/filters according to procedures.
Clean with suitable solvents.
Inspect for damage and replace if necessary.
Reinstall ensuring proper sealing.
Document cleaning actions.

Evaluate the overall temperature performance of the cooling system during operational testing

Monitor temperatures during operation.
Compare to baseline performance metrics.
Look for fluctuations or anomalies.
Adjust system settings if needed.
Record performance data for analysis.

Operational Testing

Perform a functional test of the pump under normal operating conditions.

Ensure the pump is connected to the power supply.
Start the pump and allow it to reach stable operating conditions.
Observe the pump's operation for any irregularities.
Verify that the pump operates smoothly without interruptions.

Monitor vibration levels and compare with baseline readings.

Use a vibration analyzer to measure current vibration levels.
Compare the readings to previously recorded baseline data.
Identify any significant deviations from baseline values.
Report any irregularities for further investigation.

Listen for unusual noises during operation.

Stand near the pump during operation.
Pay attention to any grinding, rattling, or unusual sounds.
Document any noises that are out of the ordinary.
Investigate sources of unusual sounds if detected.

Record operational parameters (flow rate, pressure, etc.) for comparison.

Use calibrated instruments to measure flow rate and pressure.
Document the readings in a maintenance log.
Compare current readings with historical data.
Identify any discrepancies that may require attention.

Here are some additional steps that could be included in the Operational Testing section of the centrifugal electropump SEMI ANNUALLY preventive maintenance checklist

Verify the alignment of the pump and motor shafts during operation

Observe the pump and motor during operation.
Check for any misalignment signs such as vibrations.
Use alignment tools if necessary to verify shaft alignment.
Correct any misalignment issues immediately.

Check the temperature of the pump casing and motor to ensure they are within acceptable limits

Use an infrared thermometer to measure temperatures.
Compare the readings to the manufacturer's specifications.
Document any readings that exceed acceptable limits.
Take corrective actions if overheating is observed.

Assess the performance of the pump in terms of efficiency by comparing the input power to the output flow rate

Measure the electrical input power using a wattmeter.
Calculate the flow rate using a flow meter.
Determine the pump efficiency using the formula.
Document and analyze the efficiency for anomalies.

Inspect the discharge pressure to confirm it is within the specified range for the application

Use a pressure gauge to measure discharge pressure.
Compare the measured pressure to the specifications.
Document any readings that are outside the acceptable range.
Investigate and rectify pressure issues immediately.

Evaluate the suction pressure to ensure there are no signs of cavitation or air leaks

Measure the suction pressure using a pressure gauge.
Look for fluctuations indicating cavitation or air leaks.
Document and investigate any anomalies in suction pressure.
Ensure all seals and connections are secure.

Test the operation of any control systems or automation features associated with the pump

Activate control systems and observe their responses.
Test any automated features to ensure proper operation.
Document the performance of control systems.
Identify and troubleshoot any issues found.

Check for proper fluid levels in the pump and associated reservoirs during operation

Observe fluid levels in the pump and reservoir tanks.
Verify that levels are within acceptable operating ranges.
Document any low fluid levels or leaks.
Refill or repair as needed to maintain proper levels.

Ensure that all valves in the system are functioning correctly and are in the proper positions

Inspect all valves visually for proper operation.
Manually operate valves to ensure they are not stuck.
Document any valves that require maintenance or adjustment.
Confirm that all valves are in the correct positions.

Review any alarms or fault indicators for any abnormal readings or alerts during operation

Monitor the control panel for alarms and alerts.
Document any abnormal readings or indicators.
Investigate and address any faults immediately.
Reset alarms post-correction and ensure normal operation.

Conduct a flow rate test to ensure it meets the design specifications

Use a calibrated flow meter to measure flow rate.
Compare the measured flow rate to design specifications.
Document any discrepancies and take corrective actions.
Ensure consistent flow rate during testing.

Verify the response time of the pump to changes in operational parameters, such as flow or pressure adjustments

Make a sudden change to flow or pressure settings.
Time the pump's response to the change.
Document the response time and compare to specifications.
Investigate any delays in response.

Perform a surge test if applicable, to check pump response under varying loads

Gradually increase and decrease the load on the pump.
Observe the pump's response to load changes.
Document the performance during the surge test.
Identify any issues related to load fluctuations.

Documentation

Update maintenance logs with findings and actions taken.

Record any parts replaced or repairs made.

Schedule next maintenance date and follow-up actions.

Ensure all documentation is stored appropriately for future reference.

This checklist will help ensure that centrifugal electropumps are maintained efficiently and effectively, reducing downtime and prolonging the lifespan of the equipment.

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A detailed centrifugal electropump SEMI ANNUALLY preventive maintenance checklist

General Inspection

Electrical Components

Mechanical Components

Seals and Gaskets

Hydraulic System

Cooling System

Operational Testing

Documentation

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