CONT ANNEX C SPEC DOCUMENT TITLE FIREPROOFING PROCEDURE □ APPROVED □ APPROVED AS NOTED NEED NOT RESUBMIT □ APPROVED AS NOTED RESUBMIT □ RESUBMIT AFTER REVISION This approval or review does not relieve the vendor subcontractor of his responsibilities to meet all requirements of the purchase order ORIGINAL CHECKED APPD(PRJ) SIGN DATE SAMSUNG ENGINEERING CO , LTD SMP VP NO SMP V596 MOD PRC 0010 SECL VP NO SC6452 MODULE 02 F0FAB009 000 017 REQUISITION NO MODULE 02 PURCHASE ORDER NO 5000068831 ITE.
SCOPE
This Project Specification outlines the essential requirements for fireproofing materials and application techniques for structural steel components and hazardous equipment within the fire scenario envelope, specifically for the Sarawak Methanol Project.
Fireproofing shall be applied according to document No SMP-SECL-ARC-JSP-0001: Specification for Fireproofing of Structural Steel
TERMS AND DEFINITION
OWNER : Sarawak Petchem Sdn Bhd., or its subsidiary company CONTRACTOR : Samsung Engineering Co., Ltd (SECL)
VENDOR : Amecc Mechanical Construction JSC (AMECC)
LICENSOR : LICENSOR is a process technology provider
QA/QC : Quality assurance/Quality control
PERFORMANCE CRITERIA AND MATERIAL REQUIREMENTS
Fire Potential Equipment (FPE)
Fire potential equipment includes vessels, pumps, compressors, heat exchangers, fired heaters, and other equipment that contain flammable or combustible liquids or vapors These items are recognized as potential fire sources and must be classified according to API 2218 standards.
Fire Scenario Envelope (FSE)
The area within a 9-meter radius from the edge of any specified Fire Potential Equipment, extending vertically from ground level to a height of 9 meters, is defined in the Fire Exposed Envelope drawings.
Fire Resistivity Rating
Fire resistivity rating for any steel structure and steel support shall be minimum 2 hours rating in accordance with UL-1709.
Fireproofing Material
The materials utilized in construction must possess adequate quality to ensure functionality and safety Unless stated otherwise in the project specifications, these materials should adhere to relevant codes, standards, or approved manufacturer guidelines The minimum requirements for each material are outlined below.
Chartek 2218, Epoxy Intumescent will be used with HK-1(M) material mesh as fireproofing materials
Thickness of the fireproofing material shall be average of 8.7 mm and shall be based on minimum 2-hour fire rating in accordance with UL 1709
Blasting Sa 2.5 and apply primer (Intergard 269), Second coat Chartek
2218, Top coat Interthane 990 50 micron, Grey (RAL 7035)
Steps of work for Fireproofing
Paint System Steps Paint Appl Color DFT
Step 4 Mesh HK1 White/Black -
PAINTING APPLICATION
Applicator
Prior to fireproofing application, the surface of the structural steels shall be Painting System No.7 defined in Surface Preparation and Painting Procedure (SMP-V596-MOD-PRC-0008)
Surface preparation, painting application and their inspection & test shall be in accordance with Surface Preparation and Painting Procedure (SMP-V596- MOD-PRC-0008
Personnel not qualified to tradesman level, shall document training and experience to the same level as a formalized tradesman education.
FIREPROOFING APPLICATION
Material Pre-Heating
Before using plural component equipment, it's essential to pre-heat the material to at least 35°C for 24 hours to ensure optimal spraying performance Cold materials can lead to poor spray quality, while overheating can shorten pot-life and working time Effective heating methods include utilizing heated storage units or hot rooms.
Insulated storage containers are typically used to create hot boxes, equipped with controllable heaters to maintain the desired temperature For smaller projects, custom hot boxes can effectively heat pails, ensuring daily production levels are met The engineering team is responsible for designing heated storage units or hot rooms specifically for heating painting materials To monitor material temperature, probe thermometers or infrared guns can be utilized.
Plural Component Equipment
Fireproofing Paint shall be applied by plural component equipment that is specifically designed for epoxy fireproofing application Plural component
Contract No: The equipment pumps parts A and B separately until they are mixed and sprayed through a short whip hose These fixed ratio displacement pumps feature transfer pumps, pressurized and heated holding tanks, inline fluid heaters, material line heaters, and a high-pressure mixing block with a static mixing tube, whip hose, and spray gun Note that air and power requirements may differ among various equipment manufacturers.
Material shall be pre-heated to a minimum of 35 o C prior to introduction to the pump units Thoroughly mix part A and B separately prior to use
The pump and all lines shall be clean and free from any contamination
Make sure all the fluid lines, air lines, connections at air motor and lower units are tightened and check on daily basis
Set tank heaters: part A 60 o C / part B 60 o C or the coating manufacturer’s recommendation
Set inline fluid and line heaters to a temperature range of 60-71°C, or follow the coating manufacturer's guidelines Re-circulate fireproofing paint at low pressure until the material's exit temperature at the mixing block reaches 50-55°C, ensuring it is adequately heated for spraying.
Check ratio to ensure a 1:1 ratio mix by volume
Verify gun exit temperature of 50-55 o C (123 o F-132 o F)
Displacement pump pressure should be between 175 bar-310 bar (2500 psi – 4500 psi)
Verify that the spray tip is not worn in the range of 0.027”-0.035”
Preparation of trowel, knife, scissors, roller, wet film thickness, table, balance, etc
Table 1: PLURAL EQUIPMENT SETTINGS FOR APPLICATION
Material fluid heaters 60 - 71 o C Temperature at gun 50 - 55 o C Tank Pressure 175 - 310 bar (2500-4500 psi) Tank Pressure, Part A 2.5 Bar (36 psi)
Tank Pressure, Part B 4 Bar (58 psi)
Environmental Condition
Before application of fireproofing, confirm that proper environmental conditions are met Minimum ambient temperature: 5 o C (41 0 F) and rising, maximum relative humidity 85%, steel surface temperature must be at least
Confirm that the surface has been prepared to specification
Verify that primer coat and sealer coat approved has been correctly installed to correctly thickness and is properly cured
Confirm that all block out and areas that may receive overspray are properly masked off.
Fireproofing Application
The top surface of fireproofed beams, which support steel flooring or piping, shall not be fireproofed
The area that can’t be properly coated by spraying, it will be applied by trowel and roller
Measure WFT to ensure that the required coating thickness in accordance with specification
For optimal results, utilize malleable fabric wire mesh according to the manufacturer's guidelines A single roll of HK-1(M) mesh provides theoretical coverage of 167m² (152m x 1.1m) Apply the mesh by hand onto wet Chartek, ensuring it is wetted and integrated using rollers moistened with GTA123 solvent.
Apply the wire mesh into the wet fireproofing paint at the approximate mid- point
Application at the ambient temperature below 5 0 C should be avoided
In principle, materials during mixing and application shall not receive direct sunshine In an unavoidable case, the constructor may change this item after consulting with Purchaser or its representative
All joints between fireproofing and steel shall be chipped or tooled and filled with waterproofing mastic
All hollow sections require a complete (100%) wrap with wire mesh with a 50 mm (2”) overlap at all seams
All jet fire applications require a complete (100%) wrap with wire mesh with a
50 mm (2”) overlap at all seams
To achieve optimal results, ensure that the mesh is fully embedded in the wet fireproofing paint using trowels or solvent-resistant mohair rollers To facilitate back rolling, lightly mist the rollers with an approved solvent.
After installing the mesh, it is essential to apply a light coat of fireproofing paint, measuring 1mm (40 mils), to completely encapsulate the mesh Alternatively, you can proceed with the application of the next full coat of fireproofing paint, which should be 8.7mm thick.
Build material to final thickness in as many coats required using solvent moistened mohair rollers to smooth any imperfections in the coating Surface finish must meet project specifications
After the passive fire protective coating material has cured, the thickness of the coating shall be checked.
For effective fireproofing spray application, ensure the surface is properly troweled to eliminate any voids It is crucial to adhere to the product datasheet and manufacturer's guidelines regarding the optimal timing for roller application following the spray.
Approved caulking shall be applied to seal termination end of steel structures.
For small areas and repairs, fireproofing can be applied by trowel, plasterers float, or other similar tools, and then smooth-off using appropriate means
This method of application is not recommended for large areas, but can be carried out if larger areas can be managed within period of the material’s pot life
To prevent air entrapment in the material, it's essential to mix only the amount that can be applied within its pot life, as specified in the datasheet and supplier recommendations This method of application is relatively slow, and factors such as weather conditions and steel surface temperature must also be considered.
A layer of Interthane 990 grey, thickness 50 micron, shall be applied after
Chartek application is completed, fully cured
Defects occur during and after application should be removed Cutting and slicing using angle grinders followed by mechanically chopping and scraping using hand held pneumatic chisels should be employed
In case cracks occur after construction, if the crack’s thickness exceeds 2mm, follow the procedure below to repair it:
To repair damaged mesh, first, cut away any sharp edges and remove the damaged sections Strip away the fireproofing paint from the exposed areas of the mesh If the mesh is significantly damaged, completely remove it from the affected area and install new mesh that overlaps the existing mesh by at least 50 mm Secure the ends of both the existing and new mesh using twisted wire or similar fasteners, ensuring proper alignment throughout the repair process.
If the existing Fireproofing paint is too dry, wipe it around with clean water
Mix the Fireproofing paint according to the mixing procedure
When repairing, finish with the existing material level If more than one coating is needed, it is left with the surface first applied so that the adhesion is good.
Fireproofing Thickness
Fireproofing thickness shall be 8.7 mm and its tolerance will strictly follow Paint Manufacturer’s recommendation and calculation
For column and beams of contour design, naturally rounded off corners of proper thickness are acceptable
Thickness of the special material shall be followed by the Manufacturer's certification compatible to the 2 hours of UL 1709
INSPECTION AND QUALITY CONTROL
Inspection and testing shall be carried out in accordance with item 7.3 to 7.4 for Inspection and Test Procedure (MP-V596-MOD-SPN-0001)
Surfaces will be accessible until final inspection and reporting.
SAFETY
Material Safety Data Sheets (MSDS) must be readily accessible during transportation and before product application Adhering to the manufacturer's guidelines for safe product handling is essential to reduce the risk of injuries and health hazards for personnel.
Storage, mixing and application of the paint and coating materials shall be performed strictly in accordance with the manufacturer's recommendations
The correct use of personal protection equipment (PPE) shall be employed during the coating preparation and application
Abrasive blasting and spray coating shall be performed with approved equipment by experienced operators
The Vendor/Subcontractor is required to supply all operators with OSHA-approved hoods for protection against abrasives and paint masks suitable for extended use It is mandatory for these hoods and masks to be worn at all times during work activities.
Pressure vessels, such as sand hoppers and compressed-air volume tanks, shall be protected from over-pressurization with automatic pressure relieving devices
Pressure nozzle controls must be designed as fail-safe, dead-man types to ensure safety during operation All pressure hoses should undergo rigorous pressure testing and certification, while hose connections need to feature a reliable positive locking mechanism to avert accidental disconnections, such as incorporating safety wire in quick-connect fittings.
Adequate ventilation shall be provided in confined areas with blowers capable of a minimum of 12 air changes per hour
Spray and blasting equipment in confined areas shall be securely grounded to dissipate static electrical charges
Hand tool shall be made of spark-proof materials
During blasting and coating operations, it is essential to use appropriate air-fed masks, while nearby personnel should wear suitable protective masks or respirators as needed Ensuring adequate ventilation in confined spaces is crucial, particularly when using air-fed masks, to mitigate the risk of explosive vapor accumulation At a minimum, measures should be taken to direct dust, rust, and vapors away from the operator using wind or extraction fans.
All equipment, particularly nozzles, tanks, piping and cable trays and cable ladders shall be earthed to prevent sparking and electric shocks from static electricity.
EXTENT OF FIREPROOFING WITHIN A FIRE SCENARIO ENVELOPE
Pipe Rack
In fire scenarios, pipe rack columns that support pipes or cable trays with a diameter of 6 inches or less must be fireproofed from the base of the column to the first cross beams, including the cross beams themselves.
Fig.1 Max piping dia ≤6” or Cable Tray Pipe rack
Fireproofing is essential for vertical and horizontal supports extending from the ground up to 9 meters when the pipe rack supports piping with diameters exceeding 6 inches above the first horizontal beam or when large hydrocarbon pumps are positioned beneath the rack.
Fireproofing shall be considered for knee and diagonal bracing that contributes to the support of vertical loads (See Fig 2)
Fig 2 Max piping dia >6” or Hydrocarbon Pump
Longitudinal beams and horizontal bracing shall not be fireproofed But longitudinal beams which are supported pipe line shall be fireproofed (see Fig 3)
Horizontal beams transmitting the piping load to the columns shall be fireproofed (see Fig 3)
If part of the member is included in a fire scenario envelope, full length of the member shall be fireproofed (see Fig 3)
Fig 3 Horizontal beam of Pipe rack
In scenarios where piping carrying flammable, combustible, or toxic materials is suspended from a pipe rack support using rod or spring connections, a fireproof "catch beam" must be installed if these connections are within a fire scenario envelope Both the catch beam and its supporting members should be adequately fireproofed to ensure safety.
Fireproofing shall be considered if dummy supports or suspended piping supports are installed within a fire scenario envelope (see Fig 4)
Fireproofing is essential for supports that carry piping with a diameter exceeding 6 inches, as well as for critical piping systems, including fire water lines, relief lines, blow-down lines, and pump suction lines from accumulators or towers.
Supports which carries piping with a diameter less than or equal to 6” pipe, or less than or equal to 300mm width perforated tray shall not be fireproofed
Vertical bracing members which contribute to the support of piping loads shall be fireproofed (See Fig.6)
Equipment Support Structure
When the elevation of fire potential equipment exceeds the fire scenario envelope, it is essential to fireproof the vertical and horizontal steel support members from the ground up to the level of the equipment's installation.
Fig 6 Multi-Level Structure Fire-Potential Equipment
Horizontal beams transmitting the equipment load to the columns shall be fireproofed (see Fig 7)
Horizontal beams supporting over 6” pipe or fire water line shall be fireproofed (see Fig 7)
Stairway, walkway and platforms which is designed for live loads shall not be fireproofed (see Fig 7)
When the elevation of fire potential equipment is below the fire scenario envelope, passive fire protection measures will be implemented for heights up to 9 meters above ground level Additionally, if elevated floors or platforms may accumulate flammable liquids or liquefied flammable gases, a supplementary fire scenario envelope must be taken into account.
Vertical bracing members which contribute to the support of equipment loads shall be fireproofed Bracing used only for wind and earthquake loading shall not be fireproofed (See Fig 8)
When Non-fire potential equipment is located in a fire scenario envelope, passive fire protection will be considered up to a height of 9 m above grade (See Fig 9)
Air Fin Cooler Support On Top of Structure or Pipe Rack
In the event of a fire scenario, it is essential to consider fireproofing for both vertical and horizontal support members of pipe racks, including those supporting air fin fan coolers, regardless of their height above ground level.
Wind or earthquake bracing and non-load-bearing stringer beams that run parallel to piping need not be fireproof (see Fig 10)
Fig 10 Air-Fin Cooler on top of pipe rack
Fig 11 Air-Fin Cooler on top of pipe rack section “A”
Tower and Vessel Skirts
Fireproofing shall be considered for the exterior surfaces of skirts that support tower and vertical vessels
When assessing fire safety measures, it is essential to fireproof the interior surfaces of skirts that contain flanges or valves, or have unsealed openings larger than 600 mm in diameter Additionally, fireproofing should be implemented for brackets or lugs used to secure vertical re-boilers or heat exchangers to columns or column skirts, particularly if they are situated within fire hazardous areas.
Leg Supports for Towers and Vessels
If towers or vessels are elevated on exposed steel legs, fireproofing the leg supports to their full load bearing height shall be considered.
Supports For Horizontal Exchangers, Coolers, Condensers, Drums,
Fireproofing is required for steel saddles supporting horizontal heat exchangers, condensers, drums, receivers, and accumulators with diameters over 750mm, particularly when the vertical gap between the concrete pier and the vessel's shell exceeds 300mm.
APPENDIX
APPENDIX 1: Fireproofing Details Using Special Materials
4 Nelson stud or equals (bent over)
Note: See structural steel design for members
10.2 APPENDIX 2: Fireproofing Details for Vessel Skirts
APPENDIX 4: Fireproofing Data sheet C2218 and Mesh HK1
(㎛) Method Checked date No of Coat Location Spec.
Dew Point Meter : Positester DPM; S/N:364050
Coating thickness gauge : Elcometer 456B; S/N:TE22874
No Drawing No ID Mark Painting
METHOD Remark:1st Coat date is touch-up date
Batch No Final Color DFT (㎛)
Fireproofing Procedure SMP-V596-MOD-PRC-0010
Project Name/ No SARAWAK METHANOL PROJECT
Painting System No No of Coat Painting Type Painting Name
ITP No SMP-V596-MOD-SPN-0001 Epoxy PFP systems Chartek 2218 +Hk-1
SURFACE PREPARATION & PFP PAINTING INSPECTION REPORT SECL Report No: ITR-FPF-AME-0001
Report No SC6452-PFP-STS-0001
OWNER: SARAWAT PETCHEM Sdn.Bhd CONTRACTOR: SAMSUNG ENGINEERING CO., LTD
Page 2 Of 2 SECL Report No:
Grade Profile Method Checked date No of Coat Location Spec.
AMECC INTERNATIONAL PAINT (KOREA) CONTRACTOR
Result Prepared by Review & Approved by
SURFACE PREPARATION & PAINTING INSPECTION REPORT
ITR-FPF-AME-0001 SC6452-PFP-STS-0001
No Drawing No Spool No Painting
APPENDIX 4 :Fireproofing Data sheet C2218 and Mesh HK1
Chartek® 2218 epoxy PFP systems can be used for installations requiring certification to the ANSI/UL1709 standard Using patented technology, Chartek
2218 offers our lowest certified thickness for longer duration fires with the capability of jet fire protection
Simplified installation and unique rapid cure, even at low temperatures, enable faster application, improve production rates and reduce overall costs. chartek.com
20% reduction in applied costs against most epoxy PFP
Up to 50% more steelwork coated per day compared to other epoxy PFP materials
Cold climate capability with cure down to -10°C (14°F)
Up to 4 hours pool and
Mesh free block outs and repairs in accordance with UL1709
Single coat 2-hour UL1709 rated epoxy passive fire protection system for reliable maintenance in the oil & gas industry
Chartek offers the most comprehensive selection of epoxy intumescent passive fire protection (PFP) coatings globally, making it the preferred choice for the oil and gas industry With a proven in-service track record exceeding [insert specific duration or achievement], Chartek ensures reliable fire safety solutions for critical applications.
45 years, Chartek provides safety, durability and efficiency through proven, economical and easy-to-apply solutions, meeting all project and customer requirements.
Chartek ® 7 boasts an impressive 25-year history of delivering outstanding protection against pool, jet fire, and high heat flux jet fire, while also offering proven long-term corrosion resistance As the most widely certified epoxy intumescent globally, it has safeguarded over 6 million square meters of steel around the world.
Chartek 7 is ideally suited to assets requiring long duration fire resistance, providing up to 3 hours jet fire protection.
Chartek 7E leverages the established Chartek 7 technology platform, offering the oil and gas sector enhanced options and improved efficiency Fully certified to essential industry standards, Chartek 7E features self-reinforcement for all fire types, eliminating the need for mesh reinforcement, which streamlines application This innovative solution delivers outstanding fire and corrosion protection, ensuring long-lasting asset integrity.
Chartek 7E offers outstanding pool and jet fire resistance for up to 2 hours and an up to 60% reduction in installed weight against other products in the market.
Chartek 8E provides exceptional pool fire performance with up to 30% lower installed weight compared to alternative PFP products, allowing for greater flexibility in structural design
Chartek 8E enhances coating efficiency by minimizing the number of required coats and eliminating the need for mesh for pool fire durations of up to 60 minutes This completely Boron-free solution can be applied in environments with continuous operating temperatures reaching 120ºC (248ºF), making it the perfect option for process equipment and areas subjected to heat radiation from flares.
Chartek 1620CSP is an innovative intumescent passive fire protection (PFP) coating that offers dual benefits of cryogenic spill protection (CSP) and fire safety Specifically engineered to safeguard against liquefied natural gas (LNG) leaks at extremely low temperatures of -162ºC (-260ºF), this coating enhances operational efficiency with its quick application and minimal thickness requirements Additionally, Chartek 1620CSP delivers outstanding resistance to corrosion and blasts, making it a reliable choice for demanding environments.
Chartek 1709 enhances our ANSI/UL 1709 listed product line, providing unmatched options for various applications With 15 years of experience covering millions of square meters, Chartek 1709 is a reliable choice for diverse fire scenarios, including pool fires.
4 hours, jet fires and vessel protection Its low installed weight and excellent application properties make Chartek 1709 the ideal choice for modular construction or site application.
Chartek 2218 is an advanced epoxy passive fire protection (PFP) system designed for installations that need to meet the ANSI/UL 1709 certification Utilizing patented technology, it provides the lowest certified thicknesses available, ensuring effective protection during prolonged fire exposure Chartek 2218 is certified for extended fire durations, making it an ideal choice for safety-focused applications.
The fire protection system offers 4 hours of pool fire resistance and has been tested for jet fire conditions for up to 2 hours Its simplified installation process and unique rapid curing capability, even in low temperatures, facilitate quicker application, enhance production efficiency, and lower overall costs.
• Up to 300% more steelwork coated per day compared to cementitious PFP
• Up to 50% more steelwork coated per day compared to any other epoxy PFP
• 20% reduction in applied costs compared to the market leading epoxy PFP chartek.com ® Registered trademark of AkzoNobel in one or more countries © 2019 Akzo Nobel N.V.
BYBU.XR645 - FIRE-RESISTANCE RATINGS - ANSI/UL 1709
Design/System/Construction/Assembly Usage Disclaimer
• Authorities Having Jurisdiction should be consulted in all cases as to the particular requirements covering the installation and use of UL Certified products, equipment, system, devices, and materials.
• Authorities Having Jurisdiction should be consulted before construction.
Fire resistance assemblies and products are designed by the submitter and evaluated by UL to ensure they meet relevant standards However, the published guidelines may not cover all specific construction scenarios encountered in practice.
When facing field issues, it is advisable to first reach out to the technical service team from the product manufacturer known for its design Users of fire resistance assemblies should refer to the General Guide Information for each product category and assembly group, which provides details on alternative materials and construction methods.
• Only products which bear UL's Mark are considered Certified.
BYBU - Fire-resistance Ratings - ANSI/UL 1709
See General Information for Fire-resistance Ratings - ANSI/UL 1709
Page 1 of 3 FIRE-RESISTANCE RATINGS - ANSI/UL 1709 | UL Product iQ
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1.Steel Column —Min size W10x49 The column surfaces must be free of dirt, loose scale and oil, and then primed with 0.050 mm of an epoxy based primer material.
Mastic and intumescent coatings should be applied in accordance with the recommended thicknesses outlined in the accompanying table, following the primer coat These two-component spray materials can be applied in one or more layers, as specified in the manufacturer's technical data.
Min Thkns mm (Mesh 3b or Mesh 3c)
INTERNATIONAL PAINT LTD — Type Chartek 2218 INVESTIGATED FOR UL2431 CLASSIFICATION CATEGORY I- A and EXTERIOR
The application of Charlok galvanized steel wire mesh is essential for reinforcing structural integrity before the intumescent coating is applied This mesh is strategically wrapped around both the inner and outer faces of the flange toes, extending halfway to the web, ensuring optimal protection and support.
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3b.Reinforcing Mesh —Carbon fiberglass mesh Type HK-1 applied over the flange tips at approximately mid-depth of the total thickness of mastic and intumescent coating.
The HK-2 reinforcing mesh, made from carbon and glass fibers, is strategically applied along the length of the column, positioned at the midpoint of the intumescent This mesh wraps around both the inner and outer faces of the flange toes, extending 80mm from the toe to the web, enhancing structural integrity and fire resistance.
4.Patch Up and Repair —(Not Shown) - The following systems and materials have been evaluated for the use of patch up and repair of pre-existing Chartek 2218 protected structures:
Type Chartek 2218 serves as a repair solution for previously applied Chartek 2218 material, ensuring compliance with hourly ratings specified in Design XR645 for up to 3 hours at a thickness of 12.33 mm, without the need for flange edge reinforcement The thickness of the repair material should match the existing Chartek 2218 coating thickness, and the total surface area of the repair should not exceed 0.74 m² For proper installation, refer to the manufacturer's guidelines.
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