ISO 21905:2020
(Main)Gas turbine exhaust systems with or without waste heat recovery
Gas turbine exhaust systems with or without waste heat recovery
This document specifies requirements and gives recommendations for the design, materials of construction, modelling, controlling, fabrication, inspection, testing, installation, start-up and operation of industrial gas turbine (GT) exhaust systems with or without waste heat recovery unit (WHRU). Gas turbines can be on-shore or off-shore for such sectors as oil and gas, chemical and process industries, utilities, or other intensive energy users. For this document, the exhaust system means all items in the turbine exhaust gas stream between the GT exhaust gas collector outlet flange and the termination/s to the atmosphere. The following items are not covered by this document: — heat recovery steam generator equipment (HRSG); — supplementary fired systems; — auxiliary fired systems; — exhaust gas collector (also known as exhaust plenum); — fire detection and extinguishing systems; — emissions controls equipment intended to modify the gaseous composition of the exhaust gas; — WHRUs that are of the firetube type, where the turbine exhaust gas (TEG) passes through the tubes.
Systèmes d’échappement des turbines à gaz avec ou sans récupération de la chaleur résiduelle
General Information
Standards Content (Sample)
INTERNATIONAL ISO
STANDARD 21905
First edition
2020-03
Gas turbine exhaust systems with or
without waste heat recovery
Systèmes d’échappement des turbines à gaz avec ou sans récupération
de la chaleur résiduelle
Reference number
©
ISO 2020
© ISO 2020
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ii © ISO 2020 – All rights reserved
Contents Page
Foreword .v
Introduction .vi
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 2
4 Abbreviated terms . 3
5 Proposals . 5
5.1 Purchaser’s responsibilities . 5
5.2 Supplier’s responsibilities . 5
6 Basic exhaust system design . 5
6.1 General . 5
6.2 Exhaust system configuration . 6
6.3 Service life . 6
6.4 Supply responsibility . 6
6.5 GT characteristic data . 6
6.6 Required operating envelope . 6
6.7 Equipment specification . 6
6.8 WHRU equipment specification . 6
6.9 Operating conditions . 7
6.10 Operating environment . 7
6.11 Equipment arrangement . 7
6.12 Provision for future addition of WHRU . 7
6.13 Electrical equipment . 7
6.14 Field assembly and disassembly . 8
6.15 Special tools and fixtures . 8
6.16 Spare parts . 8
6.17 Deviations . 8
7 Documentation . 8
7.1 General . 8
7.2 Data sheets . 8
7.3 Supplier document requirements . 8
8 Exhaust system engineering and design .10
8.1 Overview .10
8.2 Typical WHRU configurations .10
8.3 General .10
8.4 TEG flow-induced vibrations .11
8.5 Exhaust system casing and ducting .11
8.5.1 General.11
8.5.2 Hot casing design and materials .13
8.5.3 Cold casing design material .14
8.5.4 Flange bolts .14
8.5.5 Surface preparation and treatment .16
8.6 Mechanical and thermal analysis .17
8.7 Insulation and refractory .17
8.7.1 Exhaust system casing and ducting external insulation (hot casing design) .18
8.7.2 Exhaust system casing and ducting internal insulation (cold case design) .18
8.8 Noise emission and silencing .21
8.9 Stacks.21
8.10 Expansion joints.22
8.11 Steel structures, stairs, ladders and platforms .23
8.12 Preservation, handling, packing and storage .24
8.12.1 Handling and storage of materials .24
8.12.2 Handling and storage of construction material and subcomponents at
suppers works .24
8.13 Inspection and testing .25
8.13.1 General inspection .25
8.13.2 Specific inspection requirements .25
9 WHRU engineering and design .26
9.1 WHRU process design .26
9.2 WHRU tube bundle mechanical design .28
9.2.1 General.28
9.2.2 Pressure part design .29
9.2.3 Corrosion allowances.30
9.3 WHRU tube bundle design .30
9.3.1 Tube and bend materials .30
9.3.2 Tube bundle design conditions .30
9.3.3 TEG flow-induced vibrations .32
9.3.4 Tube supports .33
9.3.5 Tube fins .34
9.3.6 Tube bundle headers .35
10 Dampers .36
10.1 General .36
10.2 WHRU dampers .36
10.2.1 Damper and isolator types and functions .36
10.2.2 Damper and isolator design .40
10.2.3 Damper and isolator TEG leakage performance .41
10.2.4 Seal air isolation system .42
10.2.5 Damper casing and insulation .43
10.2.6 Blades, shaft and operating gear .43
10.2.7 Requirements specific to damper types .44
11 WHRU system control .45
11.1 General .45
11.2 Guidance notes .45
11.2.1 WHRU control philosophy .45
11.2.2 WHRU control philosophy — Standby units .46
11.2.3 Signals .46
11.2.4 Wiring, junction boxes and protection .46
11.2.5 Control, instrumentation and protection equipment .47
11.2.6 HTM process side valves and piping .49
12 Access, inspection and maintenance .50
12.1 TEG path access .50
12.2 WHRU .51
13 Installation .52
14 Pre-commissioning and commissioning .53
15 Performance test .55
Annex A (informative) Application of computational fluid dynamics to exhaust system design .56
Annex B (informative) Application of thermal and structural analytical techniques to
exhaust system design .65
Annex C (informative) Information to be provided by purchaser .71
Annex D (informative) Fabrication and welding .84
Annex E (informative) Data sheets .94
Bibliography .95
iv © ISO 2020 – All rights reserved
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/ patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to
the World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see
www .iso .org/ iso/ foreword .html.
This document was prepared by Technical Committee ISO/TC 192, Gas turbines.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/ members .html.
Introduction
This document has been developed in response to the international market need for a specification
relating to the exhaust and heat recovery systems for gas turbines. Purchasers and suppliers will
benefit from a standard against which equipment can be purchased, designed and constructed -
especially given the challenging nature of the turbulent exhaust gas flow and associated complexity of
mechanical design. Equipment is frequently installed in remote and challenging locations both onshore
and offshore where maintenance and repair can be prohibitively expensive.
A waste heat recovery unit recovers thermal energy from the waste heat available in gas turbine exhaust
gases, exchanged into various heat transfer media such as water, water/glycol mixtures, thermal oils
and hydrocarbon gases.
The application of heat recovery devices to gas turbines results in significant thermal efficiency gains
and resultant environmental benefit from reduction in CO emissions. Gas turbine exhaust is one of
many sources of waste heat energy and can be classed as medium grade within a typical temperature
range between 400 °C and 600 °C suitable for Rankine cycle applications.
vi © ISO 2020 – All rights reserved
INTERNATIONAL STANDARD ISO 21905:2020(E)
Gas turbine exhaust systems with or without waste heat
recovery
1 Scope
This document specifies requirements and gives recommendations for the design, materials of
construction, modelling, controlling, fabrication, inspection, testing, installation, start-up and operation
of industrial gas turbine (GT) exhaust systems with or without waste heat recovery unit (WHRU). Gas
turbines can be on-shore or off-shore for such sectors as oil and gas, chemical and process industries,
utilities, or other intensive energy users.
For this document, the exhaust system means all items in the turbine exhaust gas stream between the
GT exhaust gas collector outlet flange and the termination/s to the atmosphere.
The following items are not covered by this document:
— heat recovery steam generator equipment (HRSG);
— supplementary fired systems;
— auxiliary fired systems;
— exhaust gas collector (also known as exhaust plenum);
— fire detection and extinguishing systems;
— emissions controls equipment intended to modify the gaseous composition of the exhaust gas;
— WHRUs that are of the firetube type, where the turbine exhaust gas (TEG) passes through the tubes.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 3744, Acoustics — Determination of sound power levels and sound energy levels of noise sources using
sound pressure — Engineering methods for an essentially free field over a reflecting plane
ISO 9614, Acoustics — Determination of sound power levels of noise sources using sound intensity
ISO 10494, Turbines and turbine sets — Measurement of emitted airborne noise — Engineering/survey
method
ISO 10474, Steel and steel products — Inspection documents
ISO 12241, Thermal insulation for building equipment and industrial installations — Calculation rules
ISO 13704, Petroleum, petrochemical and natural gas industries — Calculation of heater-tube thickness in
petroleum refineries
ISO 13705:2012, Petroleum, petrochemical and natural gas industries — Fired heaters for general
refinery service
ISO 13916, Welding — Measurement of preheating temperature, interpass temperature and preheat
maintenance temperature
ISO 14122, Safety of machinery — Permanent means of access to machinery
ISO 14555, Welding — Arc stud welding of metallic materials
ISO 15612, Specification and qualification of welding procedures for metallic materials — Qualification by
adoption of a standard welding procedure specification
ISO 15613, Specification and qualification of welding procedures for metallic materials — Qualification
based on pre-production welding test
ISO 15614-1, Specification and qualification of welding procedures for metallic materials — Welding
procedure test — Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys
ISO 19902, Petroleum and natural gas industries — Fixed steel offshore structures
ASME B16.9, Wrought steel butt-welding short radius elbows and returns
ASME B31.3, Petroleum Refinery Piping
ASTM C680-10, Standard Practice for Estimate of the Heat Gain or Loss and the Surface Temperatures of
Insulated Flat, Cylindrical, and Spherical Systems by Use of Computer Programs
EN 287-1, Qualification test of welders — Fusion welding — Steels
EN 1011-2, Welding — Recommendations for welding of metallic materials — Part 2: Arc Welding of
Ferritic Steels
EN 1991-1-4, Eurocode 1: Actions on structures — Part 1-4: General actions — Wind actions
EN 10025-2, Hot rolled products of structural steels — Technical delivery conditions for non-alloy
structural steels
EN 10025-3, Hot rolled products of structural steels — Technical delivery conditions for normalized/
normalized rolled weldable fine grain structural steels
EN 10253-2, Butt-welding pipe fittings. Non alloy and ferritic alloy steels with specific inspection
requirements
EN 13445-3:2014, Unfired pressure vessels — Part 3: Design
EN 13480, Metallic Industrial piping
EN 15614, Specification and qualification of welding procedures for metallic materials
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at http:// www .electropedia .org/
3.1
analogue control signal
control or digital signal that represents a continuous range of values
EXAMPLE A traditional 4-20 mA current loop.
2 © ISO 2020 – All rights reserved
3.2
commissioning
action whereby dynamic checks and tests where the GT is running, the exhaust system is subject to
TEG flow and the WHRU is filled with circulating HTMs, progressively loaded with control systems and
functioning
3.3
data sheet
formal document containing process and/or mechanical data
3.4
insulation
material applied to either the inside or outside of the exhaust system component casings (e.g. WHRU,
ducting, stacks, dampers) in order to reduce the casing material or outer cladding temperature,
respectively
3.5
pre-commissioning
static checks and tests where the exhaust system is cold and the WHRU is not filled with HTM and the
controls are energized
3.6
purchaser
party that enters into contract with the supplier (3.8) for the supply of the exhaust system
Note 1 to entry: The purchaser is the party who specifies the technical requirements. The purchaser can also
instruct a contractor (3.7), an agent or consultant, authorized to act for, and on his behalf. The purchaser can in
some cases also be the GT supplier.
3.7
contractor
party that carries out all or part of the design, engineering, procurement, construction, commissioning
(3.2) or management of a project or operation of a facility
Note 1 to entry: The purchaser (3.6) can choose to undertake all or part of the duties of the contractor
3.8
supplier
party that manufactures or supplies equipment and services to perform the duties specified by the
purchaser (3.6)
3.9
WHRU tube bundle
hairpin tube bundle arrangement contained within a rectangular casing, or a nested helical coiled tube
arrangement contained within a cylindrical casing
4 Abbreviated terms
ALS Absolute limit state
CFD Computational fluid dynamics
CHT Conjugate heat transfer
CSCC Chloride stress corrosion cracking
COTS Commercial off the shelf
DES Detached eddy simulation
DFF Design fatigue factor
DLE Dry low emission
DNS Direct numerical simulation
FAT Factory acceptance test
FEM Finite element method
FPSO Floating production storage and offloading
FLS Fatigue limit state
FSI Fluid structure interaction
GT Gas turbine
HART Highway addressable remote transducer
HCF High cycle fatigue
HTM Heat transfer medium
ITP Inspection and test plan
LES Large eddy simulation
LCF Low cycle fatigue
MLD Multi louvre damper
NDT Non-destructive test
P&ID Piping and instrument diagram
PMI Positive material identification
PQR Procedure qualification record
PT Penetrant test
RANS Reynolds averaged Navier-Stokes CFD modelling (generally referring to modelling
steady flow behaviour)
RFQ Request for quotation
SDRL Supplier document requirement list
TEG Turbine exhaust gas
ULS Ultimate limit state
URANS Unsteady Reynolds averaged Navier-Stokes CFD modelling
WHRU Waste heat recovery unit
WPQ Welding procedure qualification
WPS Welding procedure specification
4 © ISO 2020 – All rights reserved
5 Proposals
5.1 Purchaser’s responsibilities
The purchaser’s enquiry should include data sheets, checklist and other applicable information outlined
in this document. This information should include any special requirements or exceptions to this
document (see Annex C).
The purchaser is responsible for the correct process specification to enable the supplier to carry out the
exhaust system design and manufacture.
The purchaser is responsible to clearly state the supplier’s scope of supply.
The purchaser’s enquiry should specify the number of copies of drawings, data sheets, specifications,
data reports, operating manuals, installation instructions, spare parts lists and other data to be
provided by the supplier.
5.2 Supplier’s responsibilities
The supplier’s proposal should include:
a) data sheets for each exhaust system and the associated equipment;
b) an outline drawing showing as a minimum, layout and clearances, arrangement of tube bundles,
platforms, ducting, damper systems and stack;
c) a definition of the extent of shop assembly, including the number, size and weight of prefabricated
parts and the number of field welds;
d) a detailed description of any exceptions to the specified requirements including this document;
e) a completed noise data sheet if specified by the purchaser;
f) a time schedule for submission of all required drawings, data and documents;
g) a program for scheduling the work after receipt of an order; this should include a specified period
of time for the purchaser to review and return drawings, procurement of materials, manufacture
and the required date of supply;
h) a list of utilities and quantities required;
i) if specified by the purchaser, a list of proposed sub-suppliers for major components and items,
which can include steel plate, insulation materials, expansion joints, tubes and extended surfaces on
tubes, fittings, tube bundle fabrication, dampers, castings, steel fabrication, ladders and platforms
and other auxiliary equipment.
The supplier shall identify all parts and components with a shorter estimated lifetime than that specified
for the complete system or which will need maintenance and/or removal for service. Expansion joints,
damper, actuators and seals are examples of such components.
6 Basic exhaust system design
6.1 General
GT exhaust systems can be with or without a WHRU and damper system which recovers heat from the
exhaust of a GT and exchanges this heat into HTM to supplement the thermal requirements of another
process. The WHRU enhances the thermal efficiency of the cycle with minimal impact on the operation
of the GT itself.
6.2 Exhaust system configuration
Each exhaust system should normally be connected to its own GT. In the event that more than one GT
is connected to an exhaust system, then special considerations would apply which are not covered in
detail in this document.
6.3 Service life
Unless otherwise stated by the purchaser, the design, selection of equipment and materials and
corrosion protection shall be based on a design lifetime of 20 years with 30 starts/stops from cold to
full load per year. The supplier should supply the service life and minimum uninterrupted operation
interval based on each specific application. The maintenance procedure necessary to achieve these
intervals should also be supplied.
NOTE For highly cyclic GT applications, e.g. in single cycle mode, where the start/stop cycles are significantly
more frequent, the risk of fatigue on various parts of the WHRU increases.
6.4 Supply responsibility
Supply responsibility for the exhaust system should be either with the GT supplier or contracted
directly between the purchaser and the exhaust system supplier.
6.5 GT characteristic data
If the exhaust system is purchased under the GT supplier responsibility then the GT supplier is
responsible to provide the required dimensional, acoustic, thermal, flow characteristics (steady state
and transient) and mechanical information to the exhaust system supplier as specified in this document.
In the event that the purchaser contracts directly with the exhaust system supplier then it becomes the
purchaser’s responsibility to obtain this data from the GT supplier and pass it on the exhaust system
supplier.
6.6 Required operating envelope
The purchaser is responsible to define the equipment’s required operating envelope which should be
shown on the data sheets including any dry run requirements as defined in 9.3.2.
The supplier is responsible for ensuring that all items of equipment and components provided are
designed for the specified operating conditions.
The supplier shall ensure that the equipment takes account of all potential applied loads (typically
seismic, transportation, wind loads, etc.).
6.7 Equipment specification
The exhaust system should be proven in practice, robust, reliable, safe, operable and maintainable.
The exhaust system should be based on the least number of factory-built modules consistent with
transport and site erection dimensional and weight restrictions.
The exhaust system shall be designed and constructed to meet all operational cases specified in the RFQ.
6.8 WHRU equipment specification
Materials of construction for the tube bundle pressure parts shall be selected from internationally
recognized material codes. The supplier’s data sheets shall clearly state the location(s) of each material.
6 © ISO 2020 – All rights reserved
The WHRU shall be designed to provide the required performance with no negative tolerance. The
design shall consider the selected fouling factor and required degree of over-surface to ensure that
these requirements are met.
NOTE The HTM can typically be the following:
(i) a water/glycol solution;
(ii) hot oil/thermal oil;
(iii) water;
(iv) hydrocarbons, liquid or gaseous.
In the final selection of the HTM, due consideration should be given to operating temperatures and
pressures, the degradation limits, surface tension, toxicity, flammability and corrosiveness of the HTM.
6.9 Operating conditions
Each component of the exhaust system (e.g. WHRU tube bundle and supports, casings and linings,
ductwork, dampers, etc.) shall be capable of withstanding the most severe temperature specified plus
a margin as defined in Clause 8.
6.10 Operating environment
The equipment, including all auxiliaries, shall be designed for operation under the environmental
conditions specified by the purchaser. These conditions should include whether the installation
is indoors (heated or unheated) or outdoors, maximum and minimum temperatures, unusual
humidity, and dusty or corrosive conditions, wind, earthquake and/or sea motions during operation
and transport. The unit and its auxiliaries shall be designed for shipment and installation under the
specified conditions.
If sub-zero ambient temperatures are specified by the purchaser, then appropriate materials and test
procedures should be applied.
6.11 Equipment arrangement
The arrangement of the equipment, including piping and auxiliaries, should be developed jointly by the
purchaser and the supplier. It is the purchaser’s responsibility to identify dimensional limitations for
the location of the exhaust system including space required for tube bundle and/or tube removal as well
as any handling weight limitations that apply. The arrangement should be submitted by the supplier to
the purchaser for review and agreement during the proposal phase.
The purchaser is responsible for specifying any weight limitations (e.g. maximum total equipment
weight, maximum lifted weight). If no such limitations exist, at least the total equipment weight with
applicable margin (e.g. ±10 %) should be included in the supplier's proposal.
6.12 Provision for future addition of WHRU
Where specified by the purchaser, the exhaust system shall include provision for future installation of a
WHRU. This should include the bolted panel sized for the full exhaust flow to which a future WHRU can
be connected. It should also include bolted duct section which can be replaced with a future damper or
diverted system.
6.13 Electrical equipment
Motors, electrical components, and electrical installations shall be certified for the area classification
specified (class, group, and division or zone).
6.14 Field assembly and disassembly
The supplier shall state in the proposal the proposed method for the disassembly required for repair
or replacement of exhaust system parts such as expansion joints, WHRU, dampers or silencers. While
tube failures are rare, if specified by the purchaser, the design shall include provision for tube bundle
pressure part repair or replacement.
6.15 Special tools and fixtures
If special tools and fixtures are required to disassemble, assemble or maintain the unit, they shall be
included in the supplier’s proposal and furnished as part of the initial supply of the equipment. For
multi-unit installations, the requirements for quantities of special tools and fixtures should be agreed
between the purchaser and the supplier.
6.16 Spare parts
Spare parts supplied with the main equipment delivery shall be identical to the fitted parts.
6.17 Deviations
All proposed deviations of the supplier’s equipment from this document shall be listed by the supplier
with the bid.
7 Documentation
7.1 General
The supplier should provide all drawings, design details, calculations, and analysis, operation and
maintenance manuals, and other information necessary for the design assessment, erection, operation
and maintenance of the exhaust system installation. All information should be clear and not open to
misinterpretation and shall apply specifically to the installation supplied.
The purchaser should specify which documentation is required to be provided in a local language.
The purchaser should specify the format and number of copies of documentation required from the
supplier.
Unless otherwise specified and agreed by the purchaser all documentation should be submitted in
electronic format.
All calculations and documentation shall be prepared using the agreed unit system for the project.
7.2 Data sheets
Data sheets should be used for the exchange of specification related information between the purchaser
and the supplier. The purchaser is responsible for providing the GT data and corresponding WHRU
thermal loads for the required duty envelope. The supplier shall provide completed data sheets with
confirmation that performance requirements are met.
The recommended data sheet format for WHRUs is available for download using the link given in
Annex E.
7.3 Supplier document requirements
The purchaser should provide a SDRL for the exhaust system.
The supplier shall provide the documents listed in Table 1 for review unless otherwise specified by the
purchaser.
8 © ISO 2020 – All rights reserved
The purchaser should specify which documents are subject to his approval.
Table 1 — Documentation to be provided by the supplier and reviewed by the purchaser
Document Remark
Calculations demonstrating compliance with specification
requirements, including any pressure part and structural
design codes
Detailing process design and performance data at
all specified operating cases. Mechanical, materi-
Data sheets
als and construction data
Key dimensions and weight
Suppliers manufacturing data report
FAT procedure
Site performance acceptance test procedure
Showing locations of all interfaces and major
General arrangement drawings
dimensions
Hazardous area and ingress protection certification for all
electrical components.
Welding and NDT data, including
— WPS and PQR
— WPQ
— Weld map
— ITP
— NDT procedures
— NDT personnel qualifications
— Procedure for storage and handling of filler metals
Material certificates in accordance with
a
ISO 10474 , type 3.1 for all pressure parts and type
Inspection certificates for all metallic materials of con-
2 for materials of exhaust gas ducts/casings.
struction.
The certificates shall satisfy the applicable code
requirements.
Installation, operating and maintenance instructions
Commissioning and operational and strategic
Spare parts list
spare parts lists
Pre-commissioning and commissioning instructions
Pressure and capacity test certificates for any pressure
relief valves
Pressure test certificates for any fabricated pressure parts
Quality plan
To include:
— sound power levels and sound pressure levels
Fan and motor curves and data sheets for all fans.
— test reports
Sound power levels and sound pressure levels of the
equipment.
P&IDs and controls description including alarm and trip In accordance with appropriate ISO code and shall
points and cause and effect. be complete, comprehensive and consistent
a
Reference can also be made to EN 10204 with regards to material certificates.
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