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INTRODUCTION
Since the inception of the first compressor plant by Austrian engineer Viktor
Popp, air compressors have emerged as a transformative force in modern industry.
Compressed air, often referred to as the 'fourth utility' alongside electricity, water,
and gas, has become indispensable across a myriad of sectors. This report aims to
explore the significance, functionality, and diverse applications of piston
compressors within the broader context of industrial operations.
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applications like tire inflation. These compressors play a vital role in
manufacturing processes, ranging from automotive production to metal fabrication
and beyond. Moreover, they are crucial components in safety systems, powering
air brakes and ensuring timely deployment of airbags in vehicles.
Compressed air usage, storage, leakage, and efficiency are several factors
that influence the efficiency of a compressed air system. Usually for those
industrial plants having multiple types and sizes of air compressors, the efficiency
of each one is quite different, even for those of the same type and size. It greatly
influences overall system performance when demand is matched with the air
compressor or group operated at or near maximum efficiency levels. The air
compressor provides not only the required pressure air for the cooling equipment
and refrigeration plant, but also the raw material required for the air separation
plant.
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pipeline systems. In aircraft design, ACs are integral for functions like fuel
injection
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and metal finishing. They are also essential for quality control systems, particularly
in evaluating tolerable pressure for different aircraft components during transit,
ensuring operational success. Aircraft manufacturers rely heavily on high-quality
compressors at every production phase to maintain operational efficiency.
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Figure 1.1 A Brief Overview on Common Faults that occurs in Air Compressor
Flywheel Dysfunction: The flywheel serves as the primary storage unit for
kinetic energy within a machine. When wear and tear affect the flywheel, it
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may spin faster but store less kinetic energy. Consequently, an increase in
spinning speed may elevate the frequency of noise emitted.
Inlet Valve Leakage: When leakage occurs in the compressor's inlet valve, it
results in a significant reduction in cylinder pressure, compromising the
compressor's efficiency. As a consequence, noise levels decrease due to
reduced piston speed and frequency.
Rider Belt Faults: Rider belts, integral in transmitting power within the
compressor, require vigilant monitoring. Signs of faults, such as slippage,
wear, or improper tension, necessitate immediate attention. A healthy rider
belt maintains optimal tension, remains free from visible wear, and operates
silently, ensuring seamless power transmission.
As discussed by Chao Cui, once a fault happened, the economy and security
of pneumatic production will be negatively affected. In the aspect of economy, the
faults of air compressor may lead the production equipment lose power, thus
resulting in halting production and then a big decrease of corporate profits.
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Meanwhile, the faults of air compressor will add an extra cost for companies
because of high repair cost. In the aspect of security, air compressor is a kind of
mechanical equipment with high-speed spinning motors, its gas tank has high
pressure for storing large quantities of compressed air. The faults of air compressor
will result in serious security accidents such as parts flying out at high speed or
cylinder explosion and so on, which are seen as serious threats to the safety of field
workers.
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supervised, unsupervised, and reinforcement learning, handling vast datasets and
dynamic environments across various domains.
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Deep Learning (DL), a subset of ML, mimics human brain decision-making
using multi-layered neural networks. DL algorithms automate feature extraction,
expanding data analysis possibilities. Convolutional Neural Networks (CNNs)
excel in image recognition, while Recurrent Neural Networks (RNNs) process
sequential data like natural language.
DL's impact spans industries like finance, healthcare, and customer service.
In finance, DL powers algorithmic trading and risk assessment, while in healthcare,
it aids medical image analysis and disease diagnosis. DL-driven chatbots enhance
customer service experiences, and in cybersecurity, DL algorithms detect
anomalies to safeguard networks.
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CHAPTER 2
LITERATURE SURVEY
Verma N.K et al in year 2011 were discussed about data from reciprocating
air compressors, representing various operating conditions and potential faults, is
compiled into a tabulated dataset. Support Vector Machine (SVM) is a machine
learning algorithm commonly employed for classification tasks. In this study, four
SVM-based methods - one-against-one (OAO), one-against-all (OAA), fuzzy
decision function (FDF), and decision directed acyclic graph (DDAG) - are
compared alongside the proposed SVM method. SVMs classify data points by
identifying the optimal hyperplane that maximally separates different classes. The
proposed method focuses on parameter selection, particularly the radial basis
function (RBF) parameter σ, which significantly influences kernel computations.
The results obtained through implementation of all five techniques are thus
compared as per their accuracy rate in percentages and the performance of the
proposed method with 98.03 percent accuracy rate was found to be better than all
other classification methods. SVMs exhibit robustness against overfitting and are
adept at handling complex datasets. They demonstrate the ability to accurately
classify unseen data beyond the training set. However, their major drawback lies in
their high time complexity, making them less efficient for large datasets or real-
time applications. Additionally, proper tuning of SVM parameters and selection of
appropriate kernel functions can be challenging, requiring careful optimization.
Moreover, SVM performance may exhibit sensitivity to the choice of parameters,
such as the RBF parameter σ, necessitating meticulous adjustment for optimal
results. Due to the diverse nature of faults, the vibration signals indicating the
condition of air compressor components are inherently complex. Conventional
time-
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frequency analysis and multi-resolution analysis often fail to capture a
comprehensive range of fault features, thus limiting their effectiveness.
In year 2015, Verma N.K et al explained about acoustic signals serve as the
foundation for fault diagnosis in reciprocating air compressors, recorded via
strategically positioned sensors on the compressor. The data undergoes meticulous
analysis to identify the most sensitive sensor placement locations, ensuring optimal
signal capture for fault diagnosis. Subsequently, the raw acoustic signals are
cleaned and prepared to eliminate noise and irrelevant data, facilitating further
analysis. Relevant features indicative of various fault conditions in the air
compressor are then identified and extracted from the pre-processed signals. A
classification model, employing machine learning techniques, categorizes the
extracted features to diagnose different fault states of the air compressor, enabling
early fault detection and mitigating costly breakdowns while minimizing
downtime. Remarkably, faults are accurately detected using acoustic signals from
just a single sensor, streamlining the monitoring process and reducing equipment
costs. Successfully implemented in real-time on an air compressor, the approach
showcases its practical applicability and reliability in industrial settings. However,
identifying the most sensitive sensor placement locations may require expertise
and experimentation, adding complexity to the implementation process. Currently
focused on diagnosing individual faults, adapting it to recognize multiple faults
simultaneously may demand additional research and development efforts. Further
optimization may also be necessary to ensure efficient online fault recognition,
potentially increasing the complexity of the model and implementation process.
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the
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characterization of unique fault patterns. To classify the vibration signals into
different fault conditions, a random forest classifier is employed. Random forest, a
machine learning algorithm, constructs numerous decision trees during training and
outputs the mode of the classes for classification tasks. The developed model
undergoes testing using a 10-fold cross-validation technique to evaluate its
performance in accurately categorizing fault conditions. This data modelling
approach holds promise for application across various machinery and industrial
equipment for fault diagnosis, with the potential for expansion beyond air
compressors through meticulous parameter tuning. Despite achieving high
accuracy, interpreting the underlying patterns and features identified by the random
forest classifier may pose challenges, diminishing the transparency of the diagnosis
process. Continuous monitoring and periodic updates may thus become necessary
to uphold the model's effectiveness over time, thereby increasing overall
maintenance overheads. Additionally, while the model demonstrates adaptability to
different compressor setups, fine-tuning of initial parameters may prove essential,
potentially requiring additional effort and resources.
The method described by Cui .C et al, in year 2019 explained about real-
time data from the air compressor's operation are collected and pre-processed to
eliminate outliers and dynamic operating points. The model is constructed using
Principal Component Analysis (PCA) and Back Propagation (BP) methods, which
are useful for selecting important parameters from the pre-processed dataset.
Additionally, a Multivariate State Estimation Technique (MSET) is employed to
develop a fault early warning model under normal conditions. For fault detection,
the deviation between observed and estimated values is calculated using a
deviation function. A sliding window statistical method is utilized to establish a
fault warning threshold. When the deviation exceeds this threshold, it triggers a
fault warning, indicating a potential fault in the air compressor. The advantages of
this approach include timely detection, increased safety, automation, and
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adaptability. However, its drawbacks
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include dependence on real-time data, complexity, high initial setup costs,
sensitivity to the threshold, limited scalability, and potential challenges in
integrating with existing systems.
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to decompose intricate signals into a series of intrinsic mode functions (IMFs),
each
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representing distinct oscillatory modes or trends within the signal. The proposed
EMDM method specifically addresses the challenge of mode mixing inherent in
EMD, wherein decomposed modes contain residual noise, by employing a noise-
assisted approach to bolster fault diagnosis. EMDM nonlinearly and adaptively
integrates fault-related modes harboring various noise sources via a manifold
learning algorithm, preserving genuine fault-related transients while suppressing
non-fault-related components and residual noise. Moreover, a novel criterion,
termed the TESK criterion, is introduced to automatically identify sensitive modes
among the IMFs generated by the EMD method. The method's efficacy is validated
through experimental studies conducted on gearbox and bearing faults, showcasing
superior performance compared to traditional noise-assisted EMD methodologies.
EMDM effectively segregates fault-related transients from noise, thereby
enhancing the accuracy of fault diagnosis in rotating machines. It achieves this by
adaptively fusing fault-related modes, facilitating nonlinear integration of diverse
noise sources while preserving authentic fault-related components. Additionally,
EMDM adjusts the local data distribution of the high-dimensional matrix using
random noise, ensuring satisfactory symmetry of the EMDM feature and
augmenting its reliability. However, the iterative process involving the
construction of high-dimensional matrices and adjustment of data distribution
using random noise may demand substantial computational resources, potentially
hindering real-time application or necessitating efficient optimization techniques.
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across various
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time scales and frequency ranges. Initially, the envelope spectrum derived from the
vibration signal using the Hilbert transform serves as input to the DCNN for fault
feature extraction. These extracted fault features are then combined with an SVM,
serving as the classifier for diagnosing multiple faults in bearings and rotors.
Furthermore, two time-domain features, handcrafted by human experts, are
incorporated into the model, resulting in the semi-DCNN method, which
amalgamates machine-derived insights with human experience in fault feature
design. The method demonstrates high diagnostic accuracy rates, with the semi-
DCNN method outperforming both DCNN and SVM individually, particularly in
diagnosing compound faults in bearings and rotors. Advantages of the approach
include the integration of human expertise in designing time-domain features,
which reduces preprocessing requirements. Moreover, fault feature extraction is
automated and adaptable to complex signals. However, drawbacks encompass the
complexity of the model and potential overfitting, which may lead to poor
generalization and reduced performance on unseen data.
The method described by Wang et al in the year 2020 deal with Data
Collection involves gathering vibration acceleration and pressure signals from the
reciprocating compressor air valve, while Signal Processing includes wavelet noise
reduction and decomposition of the vibration acceleration signal to eliminate
unwanted components. Time-Varying Singular Spectrum introduces time
information into the analysis, constructing a spectrum that offers insights into the
vibration signal over time. Fault Feature Extraction captures parameters indicating
specific fault types, used to construct fault feature vectors for Fault Diagnosis
using an SVM classifier, enabling accurate diagnosis. Advantages include Detailed
Analysis aiding in identifying specific fault types and Effective Fault Diagnosis
with high accuracy. However, Complexity in mathematical analysis and Signal
Processing, along with Data Collection Requirements, may pose challenges.
Additionally, Parameter Optimization and the method's Limited Applicability to air
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valve faults may require extensive resources and limit direct adaptation to other
faults.
The method described in the Kim. W et al, in year 2021 considered the
methodology involves utilizing virtual sensors, which are software-based
algorithms simulating the behaviour of physical sensors, to identify and diagnose
faults in air conditioners. These virtual sensors analyze data collected from a
limited number of physical sensors installed in the air conditioner, offering insights
into the system's performance and potential faults. One of the main advantages is
cost-effectiveness, as virtual sensors eliminate the need for additional physical
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sensors, thereby
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reducing initial setup costs. Moreover, they enhance fault detection by being able
to identify and isolate specific faults, even when multiple faults occur
simultaneously. Additionally, virtual sensors offer adaptability, as they can be
easily adjusted or reconfigured to accommodate different operating conditions and
fault scenarios. Furthermore, the fault detection and diagnostics process can be
automated, allowing for timely identification and resolution of issues without
human intervention. However, virtual sensors may face challenges accurately
detecting faults under certain conditions, such as condenser fouling, potentially
affecting the reliability of fault diagnosis. Moreover, there is a risk of false alarms,
as inaccurate estimations by virtual sensors may trigger unnecessary maintenance
or downtime.
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Improvements that can be
Title of the paper Methodology used done
CHAPTER 3
EXISTING METHOD
Oil Analysis: Oil analysis involves sampling and analysing the lubricating oil
used in the compressor to assess its condition and detect any contaminants,
wear particles, or degradation products. Maintenance technicians collect oil
samples at regular intervals and send them to a laboratory for analysis. Oil
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analysis can provide valuable insights into the condition of internal
components such as bearings, pistons, and cylinders.
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limits their ability to continuously monitor and track changes in performance or
detect early warning signs of faults. Consequently, maintenance efforts may
become reactive rather than proactive, resulting in increased downtime, repair
costs, and safety risks for industrial operations.
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CHAPTER 4
PROPOSED METHODOLOGY
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Rider belt 255
Flywheel 255
Bearing 255
Healthy 255
Total Recording 1980
Table 4.1 contains a list of eight states, one of which is healthy while the
other seven are faulty. The recordings are stored in separate folders for each faulty
and healthy condition.
Figure 4.1 shows that the dataset is divided into subfolders, each of which
contains 225 recordings, for a total of 1980 acoustic recordings. The recordings are
in waveform file format, which the software can readily process. Figure 4.2 shows
the waveforms of numerous faults, from which we can see the different variations
accessible in each method of fault recording.
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Figure 4.2 Time Domain Waveform of Various Faults
The waveform analysis provides critical insights, yet the intricate details
within the graphs are beyond the resolution of the human eye, making it
challenging to identify errors manually. Deep learning models have revolutionized
this process by offering an automated and highly effective solution for detecting a
wide range of issues in reciprocating air compressors. The dataset is divided as
described in Figure
4.3 for further processing.
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4.2 GENERAL WORKING OF MACHINE LEARNING MODEL
The general working of the machine learning model can be well understood
from Figure 4.4.
In the workflow of a machine learning model, the process begins with the
retrieval of data, where relevant data is collected from various sources to form a
comprehensive dataset. This stage is crucial as the quality and quantity of data
directly impact the performance of the model. Following data retrieval, the next
step involves cleaning and exploring the data. This includes handling missing
values, removing outliers, and conducting exploratory data analysis (EDA) to
understand the patterns, correlations, and distributions within the data. These initial
steps set a strong foundation for building effective machine learning models.
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Once the data is clean and well-understood, the next phase is preparation and
transformation. Here, the data is formatted and engineered to better suit the
algorithms, for instance normalizing or scaling numerical inputs and encoding
categorical variables. After the data is prepared, the development and training of
the model commence. Algorithms are selected based on the problem type (e.g.,
regression, classification) and trained using the processed data. Following the
training, the model is validated and evaluated using metrics such as accuracy,
precision, and recall to ensure it meets the desired performance criteria. If the
model performs satisfactorily, it is then deployed into a production environment
where it can make predictions on new data. Post-deployment, continuous
monitoring and updates are essential to maintain its relevance and accuracy over
time, adjusting to new data and feedback to refine and improve the model's
performance.
Deep learning is a subset of machine learning that uses neural networks with
multiple layers to process large and complex datasets effectively. These networks
mimic the human brain's structure, allowing deep learning models to perform
advanced tasks. For fault diagnosis of air compressor, two different models are
trained and tested in order to find the most suitable model. Figure 4.5 shows the
workflow of the methodology implemented.
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Figure 4.5 Block Diagram of Proposed Model Workflow
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features are then either padded or truncated to a fixed length to match the
expected input requirements of the LSTM model, ensuring that all input data
has uniform dimensions. The librosa library has a function that converts
audio signals to MFCC features, internally using the following formula:
𝑚 = 2595𝑙𝑜𝑔 𝑓
10(1+ ) (4.1)
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Where,
m = frequency in Mels
f = frequency in Hertz
After the audio data is processed, the next step involves handling the
labels associated with each audio file, which denote the type of fault or
condition the compressor audio represents. The directory structure is used to
determine these labels, with each subdirectory name serving as the label for
all files within it. These labels are then encoded using a `LabelEncoder`
from the scikit-learn library, transforming them from textual descriptions
into a numerical format suitable for modeling. The encoded labels are
further converted into a one-hot encoded format using `to_categorical`,
which is necessary for the classification model to predict the probability of
each class as output. Lastly, the dataset is split into training and testing sets,
allowing for the validation of the model on unseen data, which is a crucial
step for assessing the model’s ability to generalize beyond the data it was
trained on.
Model Building:
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In the architecture of the neural network designed using Keras Sequential
model, each layer is constructed to perform distinct and critical roles,
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processing the input data linearly from one layer to the next. This model is
particularly effective due to its simplicity and versatility, making it suitable
for both simple and complex neural network tasks.
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This pre-processing phase also involves translating the categorical labels,
indicative of the air compressor's operational state, from text to a numerical
form using one-hot encoding. Such encoding is essential for the subsequent
classification process within the CNN model. This meticulous preparation of
features and labels sets the stage for effective model training and accurate
fault detection. Ensuring the balance of classes within training batches is
critical to avoid biases in the model's predictions, necessitating techniques
like stratified sampling or synthetic data generation to manage unbalanced
datasets effectively.
Model Building
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Accuracy: This metric measures the overall correctness of the model and is defined
as the ratio of correctly predicted observations to the total observations. The
formula is,
Precision: Precision assesses the accuracy of the positive predictions made by the
model, i.e., the proportion of positive identifications that were actually correct.
Specificity: Specificity measures the proportion of actual negatives that are correctly
identified and is crucial for tests that need to rule out diseases.
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CHAPTER 5
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Table 5.2 Optimal Parameters Tested in CNN Model Development
5.1 RESULTS
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31 for the LIV and NRV faults.
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By scrutinizing these matrices, stakeholders can gain insights into the models'
strengths and weaknesses in classifying specific fault types. This nuanced
understanding facilitates targeted enhancements to the models' predictive
capabilities, thereby fostering more reliable fault detection mechanisms.
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Figure 5.2 Confusion Matrix of LSTM Model
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Figure 5.3 Accuracy vs Epochs Plot for CNN
In our project, both LSTM and CNN models have demonstrated remarkable
strengths in predicting faults within air compressor systems, underscoring their
critical importance. The LSTM model excels in capturing long-term dependencies
in sequential data, making it particularly adept at analyzing time-series data
common in fault prediction scenarios. Its ability to retain memory over time
enables it to effectively learn complex patterns within the operational data of air
compressors, thereby enhancing fault detection accuracy. On the other hand, the
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CNN model
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showcases exceptional feature extraction capabilities, leveraging convolutional
layers to identify spatial patterns within sensor data. This spatial awareness is
invaluable for detecting spatially distributed faults, such as anomalies in
compressor components.
Figure 5.5 shows the results obtained for LSTM model. The LSTM
model demonstrated outstanding performance with a test loss of 0.0020 and
an accuracy of 99.68%. It achieved a precision of 99.67%, a recall of
99.35%, and a specificity of 99.93%, indicating its high reliability and
accuracy in fault detection for air compressors, which underscores its
potential as a predictive maintenance tool.
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Figure 5.6 Test Results of LSTM Model
Figure 5.6 shows the results obtained of CNN model. The CNN model
showcased excellent results with perfect test accuracy and specificity, both
achieving a score of 1.0000. The model also recorded high precision of 1.0000 and
a recall of 0.9957, alongside a test loss of 0.0749. These metrics indicate the
model's exceptional capability in accurately identifying and classifying faults in air
compressors, affirming its effectiveness for use in predictive maintenance
scenarios.
The integration of both LSTM and CNN models in our project holds
significant promise for future improvements. One potential avenue for
enhancement is the utilization of real-time acoustic signals for fault detection. By
incorporating audio data from the compressor system, we can leverage the models'
strengths in sequential and spatial data analysis to detect anomalous sounds
indicative of potential faults. This expansion into multi-modal data fusion could
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greatly enhance
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the robustness and accuracy of fault prediction systems, providing early warnings
for maintenance interventions.
CHAPTER 6
CONCLUSION
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