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Fouzi Harrou
King Abdullah University of Science and Technology
Computer, Electrical and Mathematical Sciences and Engineering (CEMSE) Division
Thuwal, Saudi Arabia
Ying Sun
King Abdullah University of Science and Technology
Computer, Electrical and Mathematical Sciences and Engineering (CEMSE) Division
Thuwal, Saudi Arabia
Amanda S. Hering
Baylor University, Dept of Statistical Science
Waco, TX, United States
Muddu Madakyaru
Department of Chemical Engineering, Manipal Institute of Technology
Manipal Academy of Higher Education
Manipal, India
Abdelkader Dairi
University of Science and Technology of Oran-Mohamed Boudiaf
Computer Science Department, Signal, Image and Speech Laboratory
Oran, Algeria
Elsevier
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The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom
50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States
Copyright © 2021 Elsevier Inc. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying, recording, or any information storage and
retrieval system, without permission in writing from the publisher. Details on how to seek
permission, further information about the Publisher’s permissions policies and our arrangements
with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency,
can be found at our website: www.elsevier.com/permissions.
This book and the individual contributions contained in it are protected under copyright by the
Publisher (other than as may be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research and
experience broaden our understanding, changes in research methods, professional practices, or
medical treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge in
evaluating and using any information, methods, compounds, or experiments described herein. In
using such information or methods they should be mindful of their own safety and the safety of
others, including parties for whom they have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors,
assume any liability for any injury and/or damage to persons or property as a matter of products
liability, negligence or otherwise, or from any use or operation of any methods, products,
instructions, or ideas contained in the material herein.
ISBN: 978-0-12-819365-5
Preface ix
Acknowledgments xi
1. Introduction
1.1 Introduction 1
1.1.1 Motivation: why process monitoring 1
1.1.2 Types of faults 2
1.1.3 Process monitoring 4
1.1.4 Physical redundancy vs analytical redundancy 5
1.2 Process monitoring methods 6
1.2.1 Model-based methods 7
1.2.2 Knowledge-based methods 9
1.2.3 Data-based monitoring methods 9
1.3 Fault detection metrics 13
1.4 Conclusion 14
References 15
v
vi Contents
3. Fault isolation
3.1 Introduction 71
3.1.1 Pitfalls of standardizing data 72
3.1.2 Shortcomings of contribution plots/scores 77
3.2 Fault isolation 79
3.2.1 Variable thinning 79
3.2.2 Iterative traditional isolation 80
3.2.3 Variable selection methods 83
3.3 Fault classification 99
3.4 Fault isolation metrics 100
3.4.1 Fault isolation errors 101
3.4.2 Precision and recall 102
3.4.3 Phase I FI metrics 102
3.4.4 Discussion 103
3.5 Case studies 103
3.5.1 Retrospective fault isolation 104
3.5.2 Real-time fault isolation 108
3.6 Further reading 111
References 112
8. Case studies
8.1 Introduction 255
8.2 Stereovision 258
8.2.1 Deep stacked autoencoder-based KNN approach 261
8.2.2 Data description 266
8.2.3 Results and discussion 266
8.2.4 Model trained using data with no obstacles 267
8.2.5 Evaluation of performance for busy scenes 269
8.2.6 Obstacle detection using the Bahnhof dataset 271
8.3 Detecting abnormal ozone measurements using deep learning 274
8.3.1 Introduction 274
8.3.2 Data description 276
8.3.3 Ozone monitoring based on deep learning approaches 278
8.3.4 Detection results 284
8.4 Monitoring of a wastewater treatment plant using deep learning 288
8.4.1 Introduction 288
8.4.2 Proposed DBN-based kNN, OCSVM, and k-means
algorithms 290
8.4.3 Real data application: monitoring a decentralized
wastewater treatment plant in Golden, CO, USA 291
8.4.4 Conclusion 297
References 297
Index 311
Preface
Anomaly detection and isolation have a vital role in modern industrial processes
to enhance productivity, efficiency, and safety, as well as to avoid expensive
maintenance. Therefore, it is important to be able to detect and identify any
possible anomalies or failures in the system as early as possible. Generally,
anomalies in modern automatic processes are difficult to avoid and may result
in serious process degradations. The role of detection is to identify any anomaly
event and indicate a distance from the system behavior compared to its nominal
behavior. Furthermore, anomaly isolation determines the probable source of the
detected anomaly. To illustrate, an accidental or even deliberate contamination
of a drinking water distribution network can lead to financial losses, as well as to
serious health risks. Therefore, early detection of anomalies is crucial not only to
maintain proper process operation but also for the sake of people’s health. Today
engineered and environmental processes have become far more complex due to
advances in technology. Multiple key variables need to be monitored simulta-
neously, and data may have both temporal and spatial aspects. New features of
these processes require new and better statistical tools for process monitoring.
Early detection and isolation of potential faults in complex engineering
and environmental processes have proven to be particularly challenging. In the
absence of a physics-based process model, data-driven statistical techniques
for process monitoring have proved themselves in practice over the past four
decades. These approaches use information derived directly from input data and
require no explicit models for which development is usually costly or time-
consuming. This book is intended to report recent developments in statistical
process monitoring using advanced data-driven and deep learning techniques.
The book is divided into nine chapters, and they are grouped into two parts.
The objective of the first part is to tackle multivariate challenges in process
monitoring by merging the advantages of univariate and traditional multivariate
techniques to enhance their performance and widen their practical applicabil-
ity. The second part aims to merge the desirable properties of shallow learning
approaches, such as a one-class support vector machine, k-nearest neighbors,
and unsupervised deep learning approaches to develop more sophisticated and
efficient monitoring techniques. Throughout the book, the presented approaches
are demonstrated using experimental data from many processes including waste-
water treatment plants at KAUST and Golden, CO, USA, ozone air quality data,
ix
x Preface
and stereovision data for obstacle detection in driving environments. Thus, the
reader will find illustrative examples from a range of environmental and engi-
neering processes.
The book should be of interest to engineering and academic readers from
process chemometrics and data analytics, process monitoring and control, data
scientists, applied statistics, and industrial statisticians. In fact, this book can be
assimilated by advanced undergraduates and graduate students having knowl-
edge of basic multivariate statistical analysis and machine learning.
Acknowledgments
xi
xii Acknowledgments
Introduction
1.1 Introduction
1.1.1 Motivation: why process monitoring
Recent decades have witnessed a huge growth in new technologies and advance-
ments in instrumentation, industrial systems, and environmental processes,
which are becoming increasingly complex. Diagnostic operation has become
an essential element of these processes and systems to ensure their operational
reliability and availability. In an environment where productivity and safety are
paramount, failing to detect anomalies in a process can lead to harmful effects
to a plant’s productivity, profitability, and safety. Several serious accidents have
happened in the past few decades in various industrial plants across the world,
including the Bhopal gas tragedy [1,2], the Piper Alpha explosion [3,4], the acci-
dents at the Mina al-Ahmadi Kuwait refinery [5] and two photovoltaic plants in
the US burned in 2009 and 2011 (a 383 KWp PV array in Bakersfield, CA and a
1.208 MWp power plant in Mount Holly, NC, respectively) [6]. The Bhopal ac-
cident, also referred to as the Bhopal gas disaster, was a gas leak accident at the
Union Carbide pesticide plant in India in 1984 that resulted in over 3000 deaths
and over 400,000 others gravely injured in the local area around the plant [1,2].
The explosion of the Piper Alpha oil production platform, which is located in
the North Sea and managed by Occidental Petroleum, caused 167 deaths and
a financial loss of around $3.4 billion [3,4]. In 2000, an explosion occurred in
the Mina Al-Ahmadi oil refinery in Kuwait, killing five people and causing seri-
ous damage to the plant. The explosion was caused by a defect in a condensate
line in a refinery. Nimmo [7] has estimated that the petrochemical industry in
the USA can avoid losing up to $20 billion per year if anomalies in inspected
processes could be discovered in time. In safety-critical systems such as nu-
clear reactors and aircrafts, undetected faults may lead to catastrophic accidents.
For example, the pilot of the American Airlines DC10 that crashed at Chicago
O’Hare International Airport was notified of a fault only 15 seconds before the
accident happened, giving the pilot too little time to react; this crash could easily
have been avoided according to [8]. Recently, the Fukushima accident of 2011
in Japan highlighted the importance of developing accurate and efficient moni-
toring systems for nuclear plants. Essentially, monitoring of industrial processes
represents the backbone for ensuring the safe operation of these processes and
to ensure that the process is always functioning properly.
Statistical Process Monitoring using Advanced Data-Driven and Deep Learning Approaches 1
https://doi.org/10.1016/B978-0-12-819365-5.00007-3
Copyright © 2021 Elsevier Inc. All rights reserved.
2 Statistical Process Monitoring
“Wait till I get home from Germany!” repeated Jim, when he had
explained that he was sailing in ten days, and Betty had explained
that getting ready to be married takes ages and ages. “Never mind a
trousseau! Never mind a linen chest! Never mind even a wedding
dress! Let’s just be married. That’s the best way, I think, no matter
how much time you’ve got. We can run over to Paris—we shall
probably have to anyway—and you can shop there while I work. You
can do anything you like all the rest of your life, if you’ll only marry
me some day next week. Honestly now, Betty, do you care about the
fuss of weddings?”
“N-o,” confessed Betty hesitatingly. “I guess not. I’m rather tired just
now of all kinds of fuss and complications and crowds.”
“Then will you marry me some day next week?” asked Jim again with
his broadest, most persuasive smile.
“Yes, I will,” said Betty Wales, and that matter was definitely settled.
“I think ends are frightful,” Betty confided to Madeline, who was
helping her pack up on the day after commencement. “I’m glad I’ve
got to hurry, because it will soon be over—the end of Betty Wales.
Ends are frightful, because you have to finish everything up just so.
No more chances to try again, or smooth things over, or change to
something else. And a messy person like me has so many silly little
odds and ends to attend to.”
“Such as?” queried Madeline, absently packing a brass candlestick
on top of Betty’s best hat.
Betty rescued the hat skilfully. “Since I’m not going to have any bride
things to speak of I must save what I’ve got,” she explained. “Oh,
odds and ends like seeing that the shy, homely girls on the summer
employment list get positions right away, because the new secretary
mightn’t think they were good for much; and seeing that Emily Davis
isn’t putting herself out too much by staying on for a while to coach
Georgia; and trimming Nora’s little niece’s hat, as I’ve done every
summer, until she’s gotten to depend on it; and saying good-bye to
the Stocking Factory people that I know best; and—oh, dozens of
silly little things like those.”
“Incidentally you’ve got to decide on a wedding day, haven’t you?”
“Oh, yes,” said Betty easily. “That is, I wrote to Mother to choose any
day she preferred the week after Babbie’s. I’m too busy to think, and
the day really doesn’t matter. It’s going to be at our Lakeside cottage,
you know,—on the big back piazza, I guess, because that’s the
prettiest, biggest room in the house.”
A few minutes later a maid brought a telegram to Betty: “Lakeside
cottage burned down last night. How about that impromptu wedding?
Will Wales.”
“Gracious, what a mess!” exclaimed Betty, and looked very sober for
at least three minutes. Then she smiled again. “I’m glad that the
cottage burned down now, if it had to burn at all. Lakeside is so
dreadfully sandy, and now that we haven’t any house at all, I can just
as well be married in the very place that I’ve always wanted to go to
a wedding in. I can stay here quietly with Dorothy, except when I
rush off to Babbie’s, and Nan can come up from Boston a lot easier
than she can go to Cleveland, and Mother and Father and Will can
come here as well as not. They’ve never seen the Tally-ho, and they
ought to, before it stops being a little speck mine. And so I can be
married in that little glade in Paradise—the one that widens out from
the narrow path that looks like an aisle.”
“How lovely!” cried Madeline eagerly. “I should think that was nicer
than any cottage! And the bridal party and the guests can go in boats
—so much more romantic than carriages or motor-cars.”
“And the wedding feast can be a picnic,” laughed Betty. “Bob will be
extra-specially delighted with that idea.”
“And the music——” began Madeline, when the maid interrupted
again. This time it was callers.
“A lady and a gentleman,” Maggie explained. “They didn’t give no
names.”
“The tribe of O’Toole,” Madeline guessed gaily, “come to reproach
you for your prospective abandonment of their offspring, and for
having let Straight Dutton give her that dreadful dictionary of slang.
Her conversation is a mass of quotations from it.”
“Oh, dear, I hope they won’t be cross about anything,” sighed Betty,
starting for the door.
“If they are, call me. I’ll finish them in short order,” Madeline
promised savagely.
Betty was gone a long time, but she did not send for Madeline, who,
forgetting that the new wedding arrangement would defer packing,
continued to pile candlesticks upon hats and to stuff Betty’s fresh
shirt-waists into her chafing-dish and her copper teakettle, to save
room. Finally a lazy mood fell upon her, and she curled up on Betty’s
cushioned window-seat, to think about the picnic-wedding—how she
would trim the bride’s boat, and what would be the very nicest “eats”
for a wedding feast in a wood. It was to be a Wedding Feast, with
capitals, Madeline decided; calling it a picnic took away the novelty
and the dignity of the occasion.
“What do you think?” began Betty Wales, breaking excitedly into
Madeline’s meditations. “What do you think has happened now,
Madeline Ayres?”
“Paradise hasn’t burned up too, has it?” asked Madeline lazily.
“Because I’m planning the loveliest features for a Paradise wedding.”
“Don’t be silly, Madeline.” Betty ungratefully ignored the promised
features.
“Well, have the O’Tooles persuaded you that it’s a fatal mistake for
you to abandon Montana Marie?”
“Please don’t be silly,” Betty reiterated. “It’s nothing about the
wedding or about me. It’s about Harding. Mr. O’Toole is just splendid,
Madeline. He’s quick-tempered and short-spoken like Mr. Morton,
but he’s awfully nice. And he’s going to give Harding—well, it’s not
decided what, but something perfectly splendid.”
“Oh, was that why President Wallace was so interested in your
freshman?”
“Certainly not,” said Betty, with much dignity. “But I know now why
President Wallace was so anxious to have her get through
successfully. You know there was a lot of trouble about her entering
Harding, and Mrs. O’Toole kept on insisting, because she hates to
have Marie disappointed in anything. She had always bought things
for her before, so she tried to buy her a chance to enter Harding
without entrance conditions or any worries of that kind. Of course
President Wallace refused, but he was sorry for Marie and he let her
in, as he sometimes has other exceptional girls, on condition that
she should keep her work strictly up to the standard. Then he was
naturally anxious for her to succeed, both for her own sake and to
show her mother that honest work and not money are the
requirements of this college. Mr. O’Toole understood all that. He was
dreadfully annoyed when he heard what his wife had done. He says
if he had been President Wallace he’d have just ‘sent those fool
women-folk flying.’ He thinks President Wallace has done a lot for
Marie, and now he wants to ‘square up,’ as he calls it. He wants me
to suggest what Harding needs, and to explain to President Wallace
that this gift is entirely different from Mrs. O’Toole’s offer. That won’t
be hard, since Marie is going to leave.”
“Is she?” cried Madeline, making a wry face. “Just as I’d definitely
decided to use her for the heroine of my next novel!”
“Mrs. O’Toole has decided that she cares less about a title in the
family than about Marie’s being happy, and as Marie never had any
trouble in deciding what she couldn’t live without, she’s going to
marry a nice man from Montana just as soon as she can get ready.
Next fall, I suppose that will be.”
“She’s been rather amusing,” reflected Madeline, “if she has
bothered a lot at times.”
Betty stared, wide-eyed, at this wrong-headed view of things. “She
never meant to bother. And she was the one who made me decide
about Jim.”
Madeline laughed gleefully. “I wondered how long you’d keep on
talking as if splendid gifts to Harding College were your chief interest
in life, Betty Wales. By the way, speaking of tea-shops, has Mr.
Morton answered your letter?”
“He telegraphed,” Betty explained. “He just said, ‘He’s a nice boy,
Miss B. A., and you can manage him, so I wish you much joy.’ Not a
word about the Coach and Six. I hope he isn’t hurt at my backing
out. Do you think he can be, Madeline?”
For answer Madeline picked her small friend up and tucked her in
among the cushions of the window-seat. “You are not to worry about
people’s feeling hurt,” she ordered. “People will feel sorry, of course
—foolish people like me. I have an idea that I’m going to miss you
fearfully, Betty Wales. A career is an awfully lonely thing, the week
your very best little pal is getting married. But you’ve always been
true to your title. You’ve been Miss B. A. to Mr. Morton and to every
single other soul you’ve ever had anything to do with. That’s why
we’re bound not to lose you now, for all of Jim.”
“You dear old Madeline! As if Jim or I wanted to lose our dearest
friends! Now tell me about the wedding-with-features, so I can write it
all to Mother, and then she won’t mind so much about the cottage.
And help me think of some splendid gifts to suggest to President
Wallace, so I can see him to-day, and then write to Mr. O’Toole that
it’s all arranged. And help me to try on my bridesmaid’s dress for
Babbie’s wedding, to be sure if it fits. See how I can’t get along
without you, you dear silly Madeline!”
“That’s one way to say it,” Madeline told her, “but the truth is—— Oh,
stop me, somebody! If I get to sentimentalizing over the happy past I
shall weep, and with a rapid succession of festal occasions looming
before me I can’t spare a handkerchief so early in the game.”
The day of the Paradise wedding-with-features was a made-to-order
feature in itself. The sun sparkled on the water. A tricksy little wind
rippled the waves, and ruffled the leaves of Paradise wood. In the
deep, still glades the thrushes sang like mad. The bride’s boat, from
edge to water-line, was a mass of fine white “bridal wreath”
blossoms. The groom’s boat was decked with laurel. The guests sat
among daisy-wreaths. Somewhere in the wood human musicians
were hidden, and their notes came faint and far and fairylike in the
pauses of the thrushes’ concert. Betty’s soft white dress didn’t, as K.
said, look a bit “wedding-i-fied.” She looked like a sweet spring
flower, against the shadowy green of the wedding aisle, down which
she came with her father, the Smallest Sister leading the way, proud
and anxious and much excited, in her capacity of solitary attendant.
There were no bridesmaids, because Betty hadn’t been able to
choose among the Merry Hearts.
“And if I have them all,” she said, “why, there’ll be more bridesmaids
than wedding guests.”
Madeline had superintended the roping-off of the chosen glade with
daisy-chains, and bunches of daises tied to the branches of the trees
at one end made a blossomy background for the bridal party to stand
against.
“Oh, it takes such a little minute to be married!” cried Betty Wales in
an awestruck voice, when it was over.
“It’s going to take time to eat the Wedding Feast,” Madeline
announced, and led the way down a little side-path to the water’s
edge. There the Wedding Feast was spread on a long table, lovely
with ferns and more daisies. Bridget and Nora were in charge, but
under them worked a small army of water-nymphs, dryads, elves,
and woodland fairies, who seated the guests and then served them,
giving odd, fairy names to prosaic dishes, and pausing in their labors
to dance, sing, and chant the Lay of the Woodland Wedding, which
Madeline and Helen Adams had sat up the whole night before
Babbie’s wedding to compose, as an engagement present for Betty
Wales. The nymphs, elves, and fairies were professors’ small sons
and daughters, not yet off on their vacations, and Stocking Factory
children from the other hill—all as merry and companionable
together as possible. Mary Brooks Hinsdale and Emily Davis had
dressed them, according to Madeline’s orders. Georgia Ames had
taught them the songs and the Woodland Wedding Lay, and Bob,
who had learned a lot of folk-dances at a New York settlement, came
up two days early to contribute her share to the Loveliest Wedding.
That was what Mary christened it, as the wedding party took ship
again; and Mary’s names always stuck.
“Oh, it is, of course,” agreed Babbie, a little wistfully. She and Mr.
Thayer had planned their journeyings to include Betty’s wedding.
“And the most impromptu. It makes even yours seem quite cold and
formal, Mary.”
“For once,” put in Bob placidly, “I’ve eaten as much wedding cake as
I wanted. Picnics are the only time you can eat all you want, you
know, and still be a perfect lady. That’s why I particularly adore
them.”
Up at Morton Hall Jasper J. Morton, who had come to the wedding
with Babe and John, was berating them both roundly because he
had forgotten most of his present for Betty—the part he had
remembered was merely a wonderful old silver tea-service fit for a
princess.
“Oh, well, it’s no matter,” he acknowledged at last. “Nothing to boil
over at, Miss B. A. It’s very easy to describe the missing articles—a
deed to the Coach and Six and to my share in the Tally-ho.
Conditioned on your dining with me once every time you come to
New York to look after your properties.”
Betty gasped. “Oh, Mr. Morton, you shouldn’t give me anything more.
It isn’t right to give two—three wedding presents. Such splendid
ones, too!”
Mr. Morton smiled at her fondly. “You’ve given me lots of presents,
Miss B. A.,—a kind friend, a keen critic, a cure-all for bad temper and
impatience, and a teacher of all the fun there is in life, the real fun
that doesn’t depend on ‘doing’ the other fellow in business. Besides,
Miss B. A., about that tea-shop now. I’m a selfish old man. I don’t
want a tea-shop, and I do want to hang on to you. I’m interested in
your business theories.” He chuckled. “I want you to keep on
discovering ’em. I’m glad you’re Mrs. Jim Watson”—Betty jumped at
the strange new name—“but I’ll wager young Watson here doesn’t
want you to settle down into just Mrs. Jim. It’ll do you good to have a
tea-shop to think about sometimes. Not to worry about, mind you;
the Coach and Six is on a sound business basis. And remember,
Miss B. A., there’s one thing I haven’t changed about. I always did
perfectly hate to be thanked.”
“Then I shan’t try,” laughed Betty. “And I shan’t let you off one of
those dinners. I shall love having the tea-shops. It makes me feel
less as if this was the end of Betty Wales—less as if I’d been blown
out to make room for Mrs. Jim.” Betty made a funny little face at Jim,
who retorted with, “Haven’t forgotten that train, have you, Mrs. Jim?”
When the carriage came for them, the elves and wood fairies
surrounded it and pelted the bridal couple with armfuls of daisies
instead of rice and old shoes. So it was through a rain of daisies that
Betty caught her last glimpse of the Merry Hearts, who stood in a
little group by themselves waving her off.
“Good-bye, Betty Wales.”
“Good-bye, Mrs. Jim.”
“Here’s to Betty ’n Jim, drink ’em down,
Here’s to Betty ’n Jim, drink ’em down,
Here’s to Betty ’n Jim,
She is very fond of him,
Drink ’em down, drink ’em down, drink ’em down, down,
down!”
The carriage had rounded the curve in the road, but the Merry
Hearts still stared after it in rather somber silence.
“Just the same——” Madeline broke the pause disconsolately. “Just
the same, it is the end of Betty Wales.”
“Yes,” agreed Eleanor chokingly.
“Certainly it is,” put in Mary Brooks decisively “And high time, in my
opinion. Do you want her to wear herself out doing things for other
people, with nobody whose special business it is to do things for
her? Do you want her to miss any of the good things life has for her?
I say, hurrah for Montana Marie O’Toole, who helped Betty decide on
Jim.”
“That’s right, Mrs. Hinsdale,” broke in Mr. Morton excitedly. “I’ve been
doing my best for some time, but I guess I’m a poor hand at
matchmaking. Anyhow it took the young lady from Montana to pull
this affair off.”
“Things were so nice as they were,” mourned Madeline.
“They’re terribly nice as they are, I think,” said little Helen Adams
eagerly.
“Hurrah for the end of Betty Wales!” cried Bob.
“Hurrah for Betty Wales herself!” put in Madeline.
“Hurrah for Mrs. Jim!” shouted all the Merry Hearts together, so
loudly that Betty and Jim, who had stopped the carriage just around
the curve to shake off the daisies, heard it and smiled appreciatively
at each other.
“And for Mr. Jim!” went on the chorus impartially. “And for their
married life!” it ended, to round out the subject.
Betty snuggled closer to Jim. “It’s all been lovely, and I shall like
having the tea-shops to remind me of old times, but I like most extra-
specially much being just Mrs. Jim.”
“And I like more extra-specially than I can say having you for Mrs.
Jim,” her husband told her.
“Then everything is extra-specially all right, isn’t it?” said Betty Wales
Watson, with a happy little smile.
Other Stories in this Series are:
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