LPG Filling Station Carousal System

Transcription

The CUC Filling System
1.
GENERAL DESCRIPTION
The standard system consists of:
•
Chain conveyor cylinder transport system
•
Central encoding station.
•
Carousel
•
Filling machines
•
Automatic introduction
•
Automatic ejection
•
Check scale
•
Leak detector
•
Power supply
•
Network (power and data), connecting all the machines and the PC together.
•
PC (only used for statistics)
Cylinders for filling will be conveyed to the central encoding (is already set-up for
running a specific cylinder type). Operator keys the cylinder tare in. All data (cylinder
type, cylinder net, tare value) is archived in the cylinder data buffer, ready for use on the
filling machines.
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Cylinders are conveyed to the carousel where the cylinder is introduced on to the
carousel-filling machine. On the carousel filling machines the cylinders will be filled with
LPG. The filling is controlled by the filling machine CUC controller, so the cylinder data
(earlier archived) is transferred from the encoding CUC controller to the actual filling
machine CUC controller. When data is received and the filling head is connected the
filling is started.
The CUC controller fills the cylinders according to the cylinder data. After a successful
filling, the cylinder is ejected to the chain conveyor by the outlet and the cylinder data is
transferred from the filling machine CUC controller to the cylinder data buffer of the
outlet CUC controller, ready for use on the check scale.
Immediately after filling, the cylinders are check weighed on a check scale unit. The
check scale unit ensures that the cylinders going to the customers are filled correctly.
The cylinders are check weighed according to the cylinder data. Incorrectly filled
cylinders are sorted out to a separate conveyor. Optionally if PC statistics, the check
scale sends the results and cylinder data to the PC, where they and the filling data are
logged in a database for later inspection and statistical use.
Following the check scale, the cylinders enter an electronic leak detector. The leak
detector checks that there is no leakage in the valves or the valve connections. Leaky
cylinders are sorted out to a separate conveyor.
2.
CENTRAL ENCODING STATION
Consists of:
Keyboard/HMI with controller, 2 cylindersstops (1 accumulationsstop and 1 encoding
stop), photocells.
2.1
FUNCTIONAL DESCRIPTION
Initial position, stops open. Cylinders are conveyed to stop 1 (waiting stop) and when
the cylinder has passed the stop, the stop closes behind the cylinder, so the cylinder is
isolated from the next cylinder on the conveyor. When the cylinder arrives stop 2
(encoding stop), the stop closes and the cylinder is waiting at the stop. Now the
operator has one cylinder between the stops. It can easily be rotated, so the operator
can find the tare or inspect the cylinder. When the operator has keyed in the tare and
pushed the “enter”-button, both stops open and a new cycle starts.
The cylinder data will be sent to the FIFO-databuffer between encoding and introduction
(register in the CUC), ready for use at the introduction. FIFO means First In First Out.
The data will follow the actual cylinder flow. Data for the cylinders will be accumulated in
a row similar/parallel to the cylinders physically are accumulated in a row. When
cylinder no.1 physically will be at the introduction point, the cylinder data for cylinder no.
1 also will be the next data in the row to be transferred to a filling machine.
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Buffer area
Buffer area
Filling
Filling
Leak detection
Encoding
Check weighing
Inlet/Outlet
9
FirstInFirstOut
Leak detection
Encoding
8
Check weighing
7
6
5
4 321
FirstInFirstOut
Buffer area
Buffer area
4
3
2
1
5
Filling
Filling
6
7
8
Encoding
9
Leak detection
Check weighing
Encoding
9
Inlet/Outlet
Leak detection
Check weighing
8
FirstInFirstOut
7
6
5
4321
FirstInFirstOut
Cylinders between encoding and introduction must not be manually removed from the
conveyor. This will interrupt the FIFO-data buffer.
2.2
KEYING-IN METHODS
Encoding methods
(example  tare weight = 15,3 kg)
1. 15,3  [1]+[5]+[,]+[3]+[Enter] = 5 digits
2. 15,3  [5]+[3]+[Enter] = 3 digits
3. 15,3  [5]+[3] = 2 digits
HMI-CUC
Keying in the tare on keyboard can be done in different ways.
1) Full encoding “15,3 kg” (1), (5), (,), (3) and (enter). 5 digits.
2) Decade encoding,(5),(3),(enter). 3 digits. The tare range must be inside a decade ex.
10,0 to 19,9.
3) quick decade, no enter (accept), 2 digits. You cannot edit the encoded figures.
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2.3
OPTIONS/ALTERNATIVES
3
1
2
1. Bar code scanner for fully automatic reading, if cylinders are marked with barcodes.
2. Pre-weighing scale if the filling machines are with massflowmeter.
3. Pusher for sorting of cylinders with negative tare or unreadable tare, in this case the
operator has also the possibility to manually sorting out cylinders for maintenance
ect. Can give a optimal cylinder flow, because sorting is done before filling.
2.4
THEME
Mechanical filling machines (pneumatic controlled) can not communicate with other
machines on cylinderdata level, so the central encoding station arrived with the PLC
control. With the PLC it begame possible to communicate between machine on
cylinderdata level, but through a PC. With the CUC controller, 2 machines with CUC
controller can send data to each other without a PC.
3.
INTRODUCTION
Consist of:
Keyboard/HMI with controller (the same unit that are controlling the central encoding),
cylindersstop, pushing device, photocells
3.1
The cylinders are conveyed to the waiting stop. The stop secure that there is only one
cylinder in the pushing position at the same time. When the pushing device is in initial
position and there is no cylinder in the pushing position the cylinder stop will open. Then
the cylinder is conveyed to the pushing position and it will be introduced on to the
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carousel when a free filling machine with filling head in initial position (filling machine
mirror up, interface for introduction) is arriving on the carousel. At the same time as the
cylinder is pushed onto the filling machine, the filling machine number is read on a code
plate underneath the carousel. Now the introduction CUC controller knows the actual
filling machine/CUC controller number and will send the cylinder data (cylinder type,
cylinder net, cylinder tare). The oldest data (the next data in the row) in the FIFO-data
buffer will be send.
3.2
•
4.
Radial introduction
FILLING MACHINE
Consist of:
HMI with CUC controller (one for each filling machine), weighing platform with load cell,
centering unit, filling head, gasstop valve, interface mirror for introdution/ejection.
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4.1
The cylinder is pushed onto the filling machine platform. On the carousel filling
machines the cylinders will be filled with LPG. The filling is controlled by the filling
machine CUC controller, so the cylinder data (earlier archived) is transferred from the
encoding CUC controller to the actual filling machine CUC controller. When data is
received and the load on the filling machine (load cell) is above 5 kg the filling process
is automatically started, the centering unit clamps around the cylinder diameter, filling
head connects cylinder valve and then the filling flow is started. When the filling
machines reaches the actual gross weight (net+tare) the filling is stopped. The gasstop
valve closes and the filling head decouple the cylinder valve. When the filling head is in
its initial position the cylinder is ready for ejection.
4.2
4.3
•
Pusher on each machine instead of central ejection unit.
•
Filling heads for centre valve, manual, semi automatic or full automatic.
•
Filling heads for screw valve, manual or semiautomatic.
•
Massflow meter.
•
Automatic valve open/closer for screw valve.
THEME
The filling accuracy is improved a lot with electronic load cells/control instead of knifes,
pans and pneumatic activators on the mechanical machines. The zero-adjustment is
also a lot easier; just push the button “zero-setting”.
A PLC was too big and complicated for a filling machine, so the CUC have simplified
the filling machine control and user interface.
On a electronic filling machine, the filling process can be stopped if there is no load
increase/ or only small increase on the load cell, maybe there is a bad connection
between filling head and cylinder valve (gas leak). The pneumatic control on a
mechanical filling machine was “stupid” compared to today’s CUC controller.
5.
CAROUSEL
Consist of:
Central column with bearing, swivel connection for LPG, pneumatic air, electrical
power/data, frame, running wheels, supporting rail, easy movable cover around the
carousel diameter.
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5.1
LPG is connected on top of the central column, and pneumatic air, power and data from
the bottom. A hydraulic driving unit rotates the carousel frame, a drive belt is going
around the carousel diameter. This gives the minimum forces on the central bearing.
The hydraulic method gives a continuous and stable rotating speed.
5.2
5.3
•
Automatic change of carousel speed according to cylinder type.
•
LPG connection from the bottom of central column.
THEME
With code plates underneath each filling machine on the carousel, we can measure the
carousel rotating speed. Observing that the speed is inside the correct limit will prevent
some failures when taking cylinders in and out of the carousel. This was not possible
with a pneumatic controlled introduction.
6.
EJECTION
Consist of:
Keyboard/HMI with controller (the same unit that are controlling the check scale), pulling
device, photocells.
6.1
After having been filled with LPG, the cylinders are drawn back to the chain conveyor by
means of a pneumatically operated arm (pulling device). The arm goes in between 2
filling machines, and when the cylinder/filling machine has moved/rotated into the arm,
the arm with cylinder inside is drawn back to the chain conveyor.
If the filling head has not been disconnected from a cylinder, when it arrives at the place
of ejection, the filling machine interface mirror for ejection is not up, so that the cylinder
cannot be removed from the carousel. Also if there are accumulated cylinders on the
chain conveyor after the ejection (no room for more cylinders), the cylinder cannot be
removed from the carousel (the arm will not go in). Therefore the cylinder remains on
the carousel until the filling head has been disconnected or the cylinder accumulation is
over. At the same time as the cylinder is pulled out of the carousel and onto the chain
conveyor, the actual filling machine CUC controller send the cylinder data to the FIFO
data buffer between ejection and the check scale, which register is placed in the
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ejection CUC controller. Cylinders between ejection and check scale must not be
manually removed from the conveyor. This will interrupt the FIFO-databuffer.
6.2
7.
•
Radial ejection
•
Comandoplate under the carousel. Controlling pushing when pusher on each filling
machine.
CHECK SCALE
Consist of:
Keyboard/HMI with controller (the same that are controlling the ejection), weighing
platform, lifting table, cylinderstop, out-pusher, photocells.
7.1
The cylinders are conveyed from the ejection to the waiting stop in front of the check
scale and when the cylinder has passed the stop, the stop closes behind the cylinder,
so the cylinder is isolated from the next cylinders on the conveyor. Then only one
cylinder is going to the weighing platform at a time. When the cylinder is above the
lifting table it will be lifted free of the conveyor and the weighing process is started
automatically, when the weighing is over the lifting table goes down and the waiting stop
opens for a new cylinder. If PC data collection the weighing result and cylinder data is
send to the PC. The weighed cylinder is conveyed to the pushing position, and if the
cylinder is over or under the allowed filling limits, it will automatically be pushed out. At
the same time as the cylinder is let through the waiting stop , the actual cylinder data
(incl. Tare value) is taken from the FIFO-data buffer and used in CUC controller for the
next weighing process.
7.2
•
Dynamic check scale
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7.3
THEME
With the CUC network system the operator at the check scale is no longer necessary.
The previous encoded tare value is reused and transferred automatically to the check
scale.
8.
LEAK DETECTORS
Consist of:
Keyboard/HMI with controller, centering unit , cylinder stop, out-pusher, photocells, gas
sensor on the Gas Detections GD-model or pressure transmitter on the Pressure rise
PT-model.
8.1
The electronic leak detector, type ET-GD/IR-CUC, is an independent unit designed to
be incorporated in-line in a chain conveyor plant, and is used for 100% leak test of
valves (centre or screw valves) and valve threads on filled LPG cylinders. The machine
operates fully automatically and performs a leak test on a cylinder valve based on a
preset maximum allowed leak rate, after which it decides whether the cylinder can be
approved or must be sorted out. This fully automatic function eliminates the possibilities
for human errors, which are known from traditional manual leak testing principles.
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The ET-PT model is only for centre valves (self-closing valves), so the test head is
different. The machine operates in same way. Just instead of looking for a leak rate the
PT-model is looking for a pressure rise. A leak, if any, will cause a pressure rise. This
will actuate a pressure transmitter which will send a signal to the CUC for automatic
sorting out of the leaky cylinder. At the same time a red control lamp is lit.
However, if no leak is detected, the cylinder will continue on the chain conveyor.
8.2
TESTING AREAS
Leaks may originate from 3 points on a cylinder: in the cylinder body, in the cylinder
valve or in the threaded joint between the cylinder and the valve. Also the customer seal
can be defect and leaking when the regulator is put on.
The electronic leak detector type ET-GD can automatically check an LPG cylinder for
the following types of leaks (Depending on the valve type):
B
Tightness of
valve seat gasket
A
Tightness between
valve thread and
flange thread
C
Tightness between
valve spindle
and gasket
B
Tightness of
valve seat gasket
A
Tightness between
valve thread and
flange thread
Testing areas for
leak detector ET-GD
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Screw valves (POL valves):
•
Leaks in the threaded joint between the cylinder and the valve
•
Leaks at the valve seat (with closed valve)
•
Leaks at the safety valve (if any)
•
Leaks at the valve spindle (with open valve with nut/plug)
Centre valves (self-closing valves):
•
Leaks in the threaded joint between the cylinder and the valve
•
Leaks at the valve seat
•
Leaks at the safety valve (if any)
The machine cannot distinguish between the different types of leaks, which mean that it
cannot identify where the cylinder is leaking; it will just automatically sort out the
cylinder as being leaky. Moreover, the machine cannot detect leaks in the cylinder
body, which may originate from e.g. defective welding or corrosion. However, these
types of leaks in the cylinder body can be checked by using other kinds of equipment
(tightness testing equipment where the cylinders are immersed in a water basin and
checked visually).
The electronic leak detector type ET-PT can automatically check an LPG cylinder for
the following types of leaks (depending on the valve type):
D
B
Tightness of
the gasket of
the regulator
Tightness of
valve seat gasket
Testing areas for
leak detector ET-PT
•
Leaks at the valve seat (only on centre valve with inside costumer seal)
•
Defects on customer seal, check the tightness.
•
Damage on the cylinder valve top diameter (ovality).
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9.
POWER SUPPLY (CPI-EX)
Supply P
X1:
1
Supply N
2
PE
3
X3:
8
~
Junction point
7
~
6
External
voltage
13.5
VDC
GND
Power supply
5+
13.5 VDC
4
GND
3
+13.5 VDC
2
RS485A
1
RS485B
Power supply
RS485A
Host
RS485B
X2:
1
2
CUC Network
•
The CPI-Ex is approved for the designation EEx e m (ib) IIB T4, so that it may be
located in the filling hall (hazardous area).
•
The CPI-Ex makes electrical insulation between power in safe area and power in
hazardous area. The separation internally in the CPI-Ex is galvanic (no physical
connection between input side and output side, thus nothing on the input side can
damage components on the output side).
•
The CPI-Ex makes electrical insulation between data in safe area and data in
hazardous area. The separation internally in the CPI-Ex takes place optically (no
physical connection between input side and output side, thus nothing on the input
side can damage components on the output side).
•
The input signal is variable between 85-264 VAC, 47-63 Hz without the output
signal of 12 VDC being disturbed.
•
The CPI-Ex has a built-in transient protection, which protects the CPI-Ex against
excess voltage. Excess voltage is eliminated from the input side of the CPI-Ex, and
it continues without hindrance with the 12 VDC signal on the output side.
•
The CPI-Ex has a lamp indicator showing that it works as it should, as it is a central
component in the system, which should be capable of being controlled.
•
The CPI-Ex can deliver 600mA, which means that one unit is able to deliver current
sufficient for all the CUCs of a 24-scale carrousel with relating introduction/ejection
units, check scale and leak detector.
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9.1
OPTIONS/ALTERNATIVE
•
10.
UPS (Unbreakable Power Supply) on the power supply to the PC and the CPI-Ex,
in order to ensure correct closedown of PC and to secure data of ongoing fillings.
NETWORK IN HAZARDOUS AREA BETWEEN CUC-CONTROLLED
MACHINES
CUC network
•
The system is intrinsically safe, therefore all connections may be broken or cables
be cut safely.
•
When the system is intrinsically safe, simple components can be used in many
places (cables, switches, T-connections, junction boxes), which reduces the price
and makes the installation and the maintenance easier.
•
The number of different electric components forming part of the network system is
minimal (the same components are used in many places), which makes
maintenance easier and minimizes the spare parts stock.
•
The bus system is carried in a cable containing both power and data
communication. The electrical conductors are twisted by twos so that power does
not disturb the data communication.
•
Data communication takes place via a standard RS485, which today is used in
many industrial bus systems (a.o. Profibus, Lonbus), where it has proved its
sturdiness as well.
•
Socket-outlets and plugs between the individual CUC/HMI controllers and Tconnections are according to standard RJ 45 (quick connection).
•
The network can function without being connected to PC, which makes the filling
process independent of a PC. Data communication can take place direct between
the individual CUC-Ex units.
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11.
CUC-CONTROLLERS
CUC
HMI
12.
• Designed for use in harsh
industrial environments
• Same user interface on all
machinery
• Easy setup (via local keyboard
or PC)
• Intrinsically safe (EEx ib IIB T4)
• ATEX approved (EN50014 &
EN50020)
• Weighing approved (OIML
R76/EN45501)
• Easy to use: clear display and
sturdy keyboard
• All software in one unit
• Interface to network
• Power from battery or power
supply
• Thoroughly tested - more than
5,000 units in use worldwide!
•
CUC-Ex is approved for the designation EEx ib IIB T4
•
All CUC units are identical, and thus they are all interchangeable and can be used
on all machines.
•
The number of input/output cables on the CUC-Ex depends on the type of machine
it is controlling (whether it is for instance a filling machine or an introduction unit).
•
All the CUC units can directly be set up to control all types of machines without reinstalling software, etc.
•
Upgrading of software without replacing hardware.
•
Testing tools for testing of input/output signals.
PC / DATA COLLECTION
•
Collects data from machines controlled by the CUC controller.
•
PC monitoring of realtime production status
•
PC report statistics for filling hall production overview and creating graphs.
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12.1
•
A PC can collect data from more carrousel systems at a time (max. 10).
•
The PC may be located as much as 1000 meters from the filling hall.
•
Disaster Recovery software has been installed, securing a quick re-installation and
functioning of PC in case of breakdown of PC.
•
Data are saved in a SQL database, ensuring a quicker search for reporting.
•
Software can be updated via modem.
PC MONITORING OF REALTIME PRODUCTION STATUS
•
Overall capacity overview and overall filling accuracy, quick total status (right now)
on filling tolerances, percentage of sorting outs, total amount of used LPG or
residual incoming LPG.
•
Alarmlog for CUC controllers, on-line supervision of failures on CUC controllers.
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•
CUC controller setup status and softwareversion, overview on all CUC controllers
•
Overview on every single filling machine, showing last 5 net values. Supervision on
the filling accuracy on every filling machine right now.
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12.2
PC REPORT STATISTICS FOR FILLING HALL PRODUCTION OVERVIEW,
CHOOSE TIME FOR START AND STOP
Plant report for 10.0 KG cylinders
-------------------------------------------------------------------From
: 1999-09-29-07.00
To
: 1999-09-29-17.00
Printed : 1999-09-29-17.16
Overall performance
-------------------------------------------------------------------Inlet
10000
100.0 %
Outlet
9537
95.4 %
Leak testing
-------------------------------------------------------------------GD 1 accepted
9537
95.4 %
GD 1 sorting out
180
1.8 %
Inspection statistics
-------------------------------------------------------------------Cylinders handled
10000
100.0 %
Cylinders filled
10000
100.0 %
Sortout due to:
Inspection date
0
0.0 %
Barcode not readable
0
0.0 %
Manual sorting out
0
0.0 %
Other errors
0
0.0 %
Sorting out totally
0
0.0 %
Carousel filling statistics
-------------------------------------------------------------------Cylinders handled
10000
100.0 %
Cylinders filled
9717
97.2 %
Sortout due to:
Underfilled
43
0.4 %
Overfilled
24
0.2 %
Negative tare
138
1.4 %
No read
0
0.0 %
Timeout
38
0.4 %
Other errors
40
0.4 %
Sortout total
283
2.8 %
LPG statistics (in kg)
-------------------------------------------------------------------Filled LPG
138010
Residual LPG
3040
Total delivered LPG
141050
•
Plant report, overall statistics. Total status on the plant in a chosen period. Number
of handled cylinders, percentage of sorting outs on check scale and leak detector,
total amount of used LPG or residual incoming LPG.
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Interruption report
-------------------------------------------------------------------------From
: 2003-04-07-00.00
To
: 2003-04-07-23.59
Printed
: 2003-10-09-15.13
Interruptions more than 5 minutes
From
To
Minutes
-------------------------------------------------------------------------2003-04-07-12.56.31 2003-04-07-13.27.58
31
2003-04-07-21.44.43 2003-04-07-22.41.52
57
Interruption intervals
-------------------------------------------------------------------------Minutes
5-10
10-15
15-20
20-25
25-30
30Total
Interruptions
•
0
0
0
0
0
2
2
Production interrupts. Showing stops in cylinder filling production over 5 minutes.
Kosan Crisplant RCC DEMO
Filling machine statistics for 14.2 KG
-------------------------------------------------------------------From
: 2003-10-10-00.00
To
: 2003-10-10-12.03
Printed
: 2003-10-10-12.03
Variations in Grammes
Filling <=-400
-300
-200
-100
0
100
200
300
>=400
Sum
machine
------------------------------------------------------------------ ----------Others
0
0
0
0
0
0
0
0
0
0
1
2
1
2
106
1044
75
0
0
0
1230
2
0
1
2
52
957
28
0
0
1
1041
3
2
0
3
54
632
523
4
0
0
1218
4
2
0
1
58
1145
42
1
0
0
1249
5
2
0
2
101
1206
73
2
0
0
1386
6
2
1
0
50
937
198
0
2
0
1190
7
1
0
2
54
525
623
2
0
0
1207
8
3
1
1
58
1145
42
0
0
0
1250
9
2
1
2
106
1044
75
0
0
0
1230
10
0
1
2
52
957
28
0
0
1
1041
11
2
0
3
54
632
523
4
0
0
1218
12
2
0
1
58
1145
42
1
0
0
1249
13
2
0
2
101
1206
73
2
0
0
1386
14
2
1
0
50
937
198
0
2
0
1190
15
1
0
2
54
525
623
2
0
0
1207
16
3
1
1
58
1145
42
0
0
0
1250
17
2
1
2
106
1044
75
0
0
0
1230
18
0
1
2
52
957
28
0
0
1
1041
19
2
0
3
54
632
523
4
0
0
1218
20
2
0
1
58
1145
42
1
0
0
1249
21
2
0
2
101
1206
73
2
0
0
1386
22
2
1
0
50
937
198
0
2
0
1190
23
1
0
2
54
525
623
2
0
0
1207
24
3
1
1
58
1145
42
0
0
0
1250
----------------------------------------------------------------------------Total
42
12
39
1599
22773
4812
27
6
3 29313
Total %
0.1
0.0
0.1
5.3
73.8
16.3
0.1
0.0
0.0
100.0
Average deviation per cylinder filled within -200 g to +200 g: 0.011 kg
•
Statistics for single filling machine overview, total overview of all cylinder filled in a
chosen period focusing filling accuracy on every single filling machine, good for
maintenance purpose.
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LPG Filling Station Carousal System

Transcription

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