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A Continuous Stirred Tank Heater PDF
A Continuous Stirred Tank Heater PDF
a
Centre for Process Systems Engineering, Department of Chemical Engineering, Imperial College London, London SW7 2AZ, UK
b
Department of Chemical Engineering, I.I.T. Bombay, Powai, Mumbai 400 076, India
c
Department of Chemical and Materials Engineering, University of Alberta, Edmonton, Canada T6G 2G6
Abstract
This article presents a rst principles simulation of a continuous stirred tank heater pilot plant at the University of Alberta. The model
has heat and volumetric balances, and a very realistic feature is that instrument, actuator and process non-linearities have been carefully
measured, for instance to take account of the volume occupied by heating coils in the tank. Experimental data from step testing and
recordings of real disturbances are presented. The model in Simulink and the experimental data are available electronically, and some
suggestions are given for their application in education, system identication, fault detection and diagnosis.
Keywords: Benchmark simulation; Disturbance; Experimental validation; First-principles model; Hybrid model; Performance analysis; System identi-
cation
The approach taken by [17] combined measurements It is a small model in comparison with many of those
from a real process with a simulated exothermic reaction. reviewed above, and there is no chemical reaction. It does,
The process is a tank that behaves as if an exothermic however have a complete characterization of all the sensors
reaction is taking place. There are no real reactants and and valves and the heat exchanger. Its simplicity makes it
instead the reaction is simulated. The reactant feed rate primarily of value in a classroom setting, while the incorpo-
in the model is set to the measured cold water feed rate, ration of constraints and non-linearities and the use of real
while directly injected steam provides the heat released noise sequences provide a practical benchmark for control-
by the simulated reaction. The partially simulated reac- ler design and data-driven identication and diagnosis.
tor provides a platform for testing of control strategies
under realistic conditions of process constrains, measure- 3. Process description and model
ment noise, quanitized measurements and sampled data
control. 3.1. The continuous stirred tank heater
2.5. Equipment models The pilot plant in the Department of Chemical and
Materials Engineering at the University of Alberta is a stir-
Published models are available for components and red tank experimental rig in which hot and cold water are
items of equipment. The DAMADICS simulation [2] pro- mixed, heated further using steam through a heating coil
vides a benchmark challenge in identication of control and drained from the tank through a long pipe. The cong-
valve faults. It comprises a Simulink model of a specic uration is shown in Fig. 1. The CSTH is well mixed and
valve in a sugar renery with properties such as friction therefore the temperature in the tank is assumed the same
together with data from the renery that capture normal as the outow temperature. The tank has a circular cross
running and several valve faults. [6] created an empirical section with a volume of 8 l and height of 50 cm.
model of a valve with parameters that specify deadband
and the amount of stick-slip without the need for determin- 3.2. Utilities and instrumentation
ing friction forces, the mass of the moving parts or the
spring constant. Its behaviour matched closely to that of The utilities of the CSTH are shared services and there-
a rst principles model. fore subject to disturbances from other users. The cold and
Models for items of equipment such as motor drives, hot water (CW and HW) in the building are pressurised
generators and turbines are well developed and commer- with a pump to 6080 psi, and the hot water boiler is
cially available in Simulink SimPower Systems from the heated by the university campus steam supply. The steam
Mathworks. The documentation gives an example of the to the plant comes from the same central campus source.
use of a steam turbine model within an IEEE benchmark Control valves in the CSTH plant have pneumatic actu-
simulation [1] for a synchronous generator. ators using 315 psi compressed air supply, the seat and
stem sets being chosen to suit the range of control.
2.6. Models for teaching and training Flow instruments are orice plates with dierential pres-
sure transmitters giving a nominal 420 mA output. The
Benchmark simulations have a role in teaching and sev- level instrument is also a dierential pressure measurement.
eral of those mentioned above feature in mainstream pro- Finally, the temperature instrument is a type J metal
cess control text books. sheathed thermocouple inserted into the outow pipe with
In the workplace, simulators are used to train process a Swagelock T-tting.
control operators especially in start-up and shut-down pro-
cedures and dealing with emergencies. Such simulators are
specic for the process for which they were designed and
generally include constraints and detailed representations FT
TC hot water
of instruments, valves and equipment such as pumps. The FC
Honeywell Shadow Plant simulator [13] is an example of
a commercial training simulator. FT
steam
cold water
2.7. Motivation for the CSTH simulation
flow sp
LC
The stirred tank heater model presented in this article is a
hybrid simulation which uses measured data captured from LT
a process to drive a rst principles model. The noise and dis-
turbances signals therefore have more complex and more
realistic characteristics than if they were created by a ran- TT
dom number generator. There are also experimentally mea-
sured data available for the purposes of identication. Fig. 1. The continuous stirred tank heater.
350
3.3. Volumetric and heat balance 3.4.5. Heat transfer from steam system
The heat transfer from the steam system depends on the
The dynamic volumetric and heat balances are shown in steam valve setting. The relationship was determined
the following equation: empirically from steady state running at dierent steam
dV x valve settings since the heat exchange area and heat trans-
fcw fhw fout x 1 fer coecient could not be measured. The heat balance
dt
dH when the CSTH is in a steady state running with a cold
W st hhw qhw fhw hcw qcw fcw hout qout fout x 2 water inow only is:
dt
where x is the level; V the volume of water; fhw the hot W st hout qout fout hcw qcw fcw
water ow into the tank; fcw the cold water ow into the
tank; fout the outow from tank; H the total enthalpy in and fcw = fout in steady state.
the tank; hhw the specic enthalpy of hot water feed; hcw The calculations for Wst are in Table 1. The steady
the specic enthalpy of cold water feed; hout the specic en- state ow in these experiments was 9.04 105 m3 s1 , the
thalpy of water leaving the tank; qcw the density of incom- incoming cold water temperature was 24 C with hcw =
ing cold water; qhw the density of incoming hot water; qout 100.6 kJ kg1 and qcw = 997.1 kg m3.
the density of water leaving the tank; and Wst the heat in- The results of the calculations are used in a piecewise-
ow from steam. linear look-up table that determines the amount of steam
The temperatures of the hot and cold water feeds were set heating for a given steam valve setting. The data in Table
to 50 C and 24 C respectively in the base case simulation. 1 may be used in simulation under non-steady conditions
given some assumptions:
3.4. Related equations
(i) That the tank is well mixed so the temperature of the
The following algebraic equations also apply. outow is the same as that in the tank. The assump-
tion is reasonable, because stirrer provides a high
3.4.1. Specic enthalpy liquid velocity across the heating coils and distributes
In the well mixed case: heat quickly throughout the tank.
H (ii) That the amount of heat transferred at a given steam
hout 3 valve setting is not dependent on the temperature of
V qout
the water in the tank. The assumption is reasonable
since most of the heat in the steam is its latent heat
3.4.2. Level, x of 2257 kJ kg1 compared to, say, the dierence of
The relationship between level and volume is not linear 62.7 kJ kg1 between water at 25 C and 40 C.
because of the volume occupied by heating coils in the lower (iii) That all the steam condenses and that circumstances
half of the tank. The relationship between level and volume do not arise where steam goes to waste. This assump-
was measured experimentally, as discussed in Section 3.5. tion is reasonable unless the level is very low so that
the heating coils are signicantly exposed. It was
3.4.3. Outow observed that the maximum achievable temperature
The manual outow valve was xed at 50% as a stan- at the standard operating conditions was 65 C when
dard operating condition. At this xed setting, the empiri- the steam valve was fully open. The steam should
cal expression below was derived experimentally by seeking condense fully under these conditions.
a square root relationship between the head of water in cm
above the manual outow valve and the measured ow in 3.5. Sensor and valve calibration
m3 s1.
p The inputs to the CSTH are electronic signals in the
fout 104 0:1013 55 x 0:0237
range 420 mA that go to the steam and cold water valves.
The outputs are measurements from the temperature, level
The expression has this particular form because the manual
outow valve is 55 cm below the bottom of the tank and
Table 1
the head of water therefore is 55 + x where x is the level Relationship between heat transfer rate and steam valve setting
in the tank in cm.
Valve/mA T/C hout/kJ kg1 qout/kg m3 Wst/kJ s1
4 24 100.6 997.1 0
3.4.4. Thermodynamic properties
7.5 30 125.7 995.2 2.24
The relationships between specic enthalpy, density and 9 31 129.9 994.8 2.61
temperature in liquid water were taken from steam tables 11 36.5 152.8 992.9 4.65
and used for the conversions of h to T, T to h, and T to 14 48 200.9 988.7 8.89
q in piecewise linear look-up tables. Specic enthalpies 17 61 255.3 982.3 13.60
20 65 272.0 980.2 15.04
are referenced to 0 C.
351
and cold water ow instruments, nominally in the range 4 the level in the tank to an instrument output on a 420 mA
20 mA. Calibration models were determined by measure- scale while the volume calibration gives a look-up table
ment at several points in the range, and are represented converting level in the tank to volume. The steam heating
in the model as piece-wise linear look-up tables. The level coils occupied a noticeable volume in the lower half of
of detail presented in this section was found necessary to the tank and became fully covered when the level was
provide a high delity match between experimental obser- 16.9 cm. Therefore the volume versus level characteristic
vations and the simulation. is not linear when the level is low.
3.5.1. Level and volume 3.5.2. Cold and hot water ow calibration
Data for the calibration of level and volume are plotted Calibration of the cold and hot water valves is shown
in Fig. 2a and b. The level instrument calibration converts in Fig. 2c and d in which the volumetric ow rate is
50 50
measured level/cm
measured level/cm
40 40
30 30
20 20
10 10
0 0
0 5 10 15 20 25 0 2 4 6 8
level output current/mA volume/litre
0.25 0.25
measured flow/litre.s1
measured flow/litre.s-1
0.2 0.2
0.15 0.15
0.1 0.1
0.05 0.05
0 0
0 5 10 15 20 25 0 2 4 6 8 10 12
CW valve demand/mA HW valve demand/mA
-5
x 10
0.25 11
measured flow/litre.s-1
0.2
10
outflow/(m3.s-1 )
0.15
9
0.1
0.05 8
0 7
0 5 10 15 20 25 7.5 8 8.5 9 9.5 10
flow output/mA (55+x)/cm
1/2
15 70
measured temperature/ oC
60
13
TI output/mA
50
11
40
9
30
7 20
5 10 15 20 6 8 10 12 14
Steam valve demand/mA TI output/mA
Fig. 2. Calibration graphs. (a) output of the level instrument and measured level, (b) measured volume and measured level, (c) cold water valve demand
and measured cold water ow, (d) hot water valve demand and measured hot water ow, (e) cold water ow instrument output and measured cold water
ow, (f) calibration of the outow, (g) steam valve demand and thermocouple output and (h) thermocouple output and temperature measured with a
thermometer.
352
requires specication of the control and integrator gain, as between simulation and experiment is generally acceptable
follows: giving condence that the simulation can act as a reliable
I proxy for the physical CSTH plant.
Cs P
s
6. Disturbances
where P = Kc and I = Kc/si. A consequence of the Simulink
form is that both P and I must change in proportion if the
Disturbances to the experimental pilot plant comprise a
controller gain Kc is adjusted.
deterministic oscillatory disturbance to the cold water ow
rate, a random disturbance to the level, and temperature
5. Model validation
measurement noise. The strategy used for preparation of
the benchmark simulation was to capture data from the
This section presents a comparison between simulation
experimental pilot plant and to feed those data into the
and experimental results in open and closed loop.
simulation from data les in order to provide realistic
disturbances.
5.1. Open loop testing
Open loop testing involved steps in the positions of the 6.1. Cold water ow disturbance
cold water ow and steam valves and observation of the
cold water ow rate and temperature. For the temperature The cold water ow in the experimental plant had a
tests, the level was held constant at a set point of 12 mA deterministic oscillatory disturbance with a period of about
(20.48 cm). The results are shown in Fig. 3 where it can 40 s that originated elsewhere in the building. This distur-
be seen that the steady state gains and the dynamics of bance was captured by measuring the cold water ow
the transients are generally simulated accurately especially through the valve with the cold water valve open at its
in the middle of the operating range. The lower left panel of mid-point on the 420 mA scale. The outlet valve of the
Fig. 3 suggests the steam valve sometimes behaves dier- tank was opened fully during the experiment, therefore
ently when closing, an eect that has not been captured the tank ran empty. A portion of the disturbance is shown
by the simulation. in the top panel of Fig. 6 where its oscillatory nature can be
seen.
5.2. Closed loop testing
6.2. Level disturbance caused by bubbles
Closed loop tests were made on the temperature and
level control loops at dierent controller settings. The P The experimental plant has the facility to blow com-
and I values were chosen to span the range from sluggish pressed air into the tank. The compressed air causes bubbles
to overly tight control. Figs. 4 and 5 show the match which disturb the level in the tank. The bubble disturbance
20
20
steam valve/mA
CW valve/mA
15
15
10
10
5
0 1000 2000 3000 4000 0 500 1000 1500
time/s time/s
20
14
temperature/mA
CW flow/mA
15
12
10
10
8
5
0 1000 2000 3000 4000 0 500 1000 1500
time/s time/s
Fig. 3. Open loop tests. Left hand panels: temperature steps, Right hand panels: steps in the cold water ow. Black lines are the simulation, grey lines are
experimental results.
354 N.F. Thornhill et al. / Journal of Process Control 18 (2008) 347360
12 12
temperature/mA
P = 1, I = 0.1 P = 1, I = 0.2
10 10
8 8
0 200 400 600 0 200 400 600 800 1000
12 12
temperature/mA
P = 3, I = 0.1 P = 3, I = 0.2
10 10
8 8
0 100 200 300 400 0 100 200 300 400 500
12 12
temperature/mA
P = 6, I = 0.1 P = 6, I = 0.2
10 10
8 8
0 100 200 300 400 0 200 400 600 800
time/s time/s
Fig. 4. Comparison of closed loop step tests in the temperature loop, simulation and experiment. Black lines are the simulation, grey lines are experimental
results.
P = 4, I = 0
16
level/mA
12
P = 1, I = 0.1 P = 1, I = 0.15
16 16
level/mA
12 12
8 8
P = 4, I = 0.1 P = 4, I = 0.15
16 16
level/mA
12 12
8 8
Fig. 5. Comparison of closed loop step tests in the level loop, simulation and experiment. Black lines are the simulation, grey lines are experimental results.
was monitored as the output from the level instrument with 6.4. Simulation with disturbances
the tank half full and with the inlet and outlet valves both
closed. The nature of the disturbance is random. The disturbances can be added to the simulation as follows:
6.3. Temperature measurement noise The cold water ow disturbance dcw in mA is added to
the cold water valve position to give mvd(t) = mv(t) +
The temperature measurement noise was monitored with dcw, where mv is the time domain output of the valve
the tank half full and under closed loop level and tempera- transfer function (4).
ture control. It has high frequency components and some The level disturbance in mA is converted to a
medium term lower frequency uctuations can also be seen. disturbance in volume dV by means of an algebraic
355
CW flow deviation/mA
temperature/mA
10.7
0.2
10.5
0
10.3
-0.2
5.52
HW Valve/mA
5.50
level deviation/mA
0.2
5.48
0
12.02
level/mA
-0.2
12.00
11.98
temp deviation/mA
0.2
CW Valve/mA
7.8
0
7.7
-0.2 7.6
0 200 400 600 800 1000 0 500 1000 1500 2000
time/s time/s
Fig. 6. Upper panel: CW ow disturbance, Middle: level disturbance due Fig. 7. Simulated demonstration of a controller interaction in which
to bubbles, Bottom: temperature measurement noise. temperature noise upsets level and cold water ow.
heater operating with only a cold water feed and the other 7.3. Operating point 2
with both hot and cold water feed.
The steady state valve positions and instrument condi- 7.3.1. Open loop state-space model
tions in each case are shown in Table 2. Variables in the lin- The state-space model is
earized models are deviations from the operating point.
dx
Time delays are present at the input and output. The CW Ax Bu0
valve has a time delay of 1 s while the temperature mea- dt
surement delay is 8 s. y0 Cx
0 0 1 0 1 0 1 0 0 1
u1 t u1 t 1 y 1 t y 1 t
7.2. Operating point 1 B 0 C B C B C B C
@ u2 t A @ u2 t A and @ y 2 t A @ y 02 t A
u03 t u3 t y 3 t y 02 t 8
7.2.1. Open loop state-space model
The state-space model is
dx where u1 is the cold water valve position in mA; u2 the
Ax Bu0 steam valve position in mA; u3 the hot water valve position
dt
y0 Cx in mA; y1 the level measurement in mA; y2 the cold water
0 1 0 0 1 ow measurement in mA; y3 temperature measurement in
0 y 1 t y 1 t
u1 t u1 t 1 mA; x1 the tank volume, output of the integrator in Eq.
and @ y 2 t A @ y 02 t A
u02 t u2 t (1); x2 the output of the integrator in the valve transfer
y 3 t y 02 t 8
function in Eq. (4) and x3 the total enthalpy in the tank,
where u1 is the cold water valve position in mA; u2 the output of the enthalpy integrator in Eq. (2).
steam valve position in mA; y1 the level measurement in 0 1
mA; y2 the cold water ow measurement in mA; y3 the tem- 3:7313 103 1:5789 106 0
B C
perature measurement in mA; x1 the tank volume, output A@ 0 2:6316 101 0 A
of the integrator in Eq. (1); x2 the output of the integrator 4:1580 103 1:5842 101 2:7316 102
in the valve transfer function in Eq. (4); x3 the total enthal- 0 5
1
0 0 4:2900 10
py in the tank, output of the enthalpy integrator in Eq. (2). B C
0 1 B @1 0 0 A
3:7313 103 3:6842 106 0
B C 0 6:4000 101 8:8712
A@ 0 2:6316 101 0 A 0 1
3 1 2 2690:0 0 0
4:1580 10 3:6964 10 2:7316 10 B C
0 1 C@ 0 1:5132 101 0 A
0 0
B C 1979:2 0 1:1226 102
B @1 0 A
0 1:4133
0 1
2690:0 0 0
B C 7.3.2. Open loop transfer function model
C@ 0 2:8421 101 0 A 0 1
1979:2 0 1:1226 10 2 G11 s 0 G13 s
B C
Ys GsUs @ G21 s 0 0 AUs
7.2.2. Open loop transfer function model G31 s G32 s G33 s
The transfer function model has the following form
where
where U(s) and Y(s) are the Laplace transforms of the vec-
tors of input and output variables. 1 4:2474 103 es
0 G11 s
G11 s 0 s 3:731 103 s 2:632 101
B C
Ys GsUs @ G21 s 0 AUs 1:5132 101 es
G21 s
G31 s G32 s s 2:632 101
where 3:1466 103 e9s
G31 s
9:9105 103 es s 2:732 102 s 2:632 101
G11 s
s 3:731 103 s 2:632 101 7:1849 103 e8s
2:8421 101 es G32 s
G21 s s 2:732 102
s 2:632 101
3:1422 103 e9s 1:1540 101
G31 s G13 s
s 2:732 102 s 2:632 101 s 3:731 103
1:5867 102 e8s 1:4683 102 e8s
G32 s G33 s
s 2:732 102 s 2:732 102
357
There are several possible educational and academic 8.2. System identication task
applications for a benchmark simulation that has accurate
measurement of non-linearities and constraints, real noise This section gives an illustration of the use of the CSTH
sequences captured from the plant, and full experimental simulation in a system identication experiment. The data
validation. Suggested uses include: are presented and a challenge laid down to identify the lin-
earized dynamics.
a teaching resource for a control systems course;
generation of realistic data for testing of data-driven 8.2.1. Closed loop system identication
methods; Simulation and experimental runs from a system iden-
testing of fault detection and diagnosis algorithms; tication experiment were carried out. The aim is to iden-
in conjunction with a valve model [6], generation of real- tify the two-by-two system with level and temperature as
istic data for valve fault diagnosis; measured outputs and level loop setpoint and temperature
13
Level set point/mA
12.5
12
11.5
11
13
12.5
Level/mA
12
11.5
11
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time/s
Temperature set point/mA
12
11.5
11
10.5
10
12
Temperature/mA
11.5
11
10.5
10
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time/s
Fig. 8. System identication. Upper panels: Level set point and measurement, Lower panels: Temperature set point and measurement. Black lines are the
simulation, grey lines are experimental results.
358
loop setpoint as manipulated inputs. The level and the The Simulink model and experimental data are available
temperature setpoints were simultaneously perturbed with electronically, and a some suggestions are given for appli-
random binary inputs of amplitude 0.5 mA and 1 mA cations including a system identication task.
respectively generated using the idinput function in System
Identication Toolbox of MATLAB. The level and temper- Acknowledgements
ature variations are presented in Fig. 8 which shows the
simulation generally matches the experimental results The authors thank Mr Walter Boddez, Instrument Shop
well. The match suggests the simulation can provide a Supervisor in the Department of Chemical and Materials
resource for the investigation of new system identication Engineering, University of Alberta, for technical inputs
methods. and insights about the CSTH equipment. The rst author
The data and a simulation for system identication are gratefully acknowledges the support of the Royal Academy
provided at the simulation web site. As well as providing of Engineering (Foresight Award). The authors are grateful
the random binary inputs, it allows the additional distur- for the support of the Natural Science and Engineering Re-
bances from Fig. 6 to be activated to test the robustness search Council (Canada), Matrikon (Edmonton, Alberta)
of the system identication methods. and the Alberta Science and Research Authority through
Linearization of the closed loop model gives the trans- the NSERC-Matrikon-ASRA Industrial Research Chair
fer function presented below. The CW valve and temper- in Process Control. The authors thank the editors for the
ature instrument time delays cannot be referred to the opportunity to prepare a paper for this Special Issue of
input and output in this example because the level and the Journal of Process Control, and we oer Dale the most
temperature are under closed loop control. They are sincere congratulations and best wishes on the occasion of
handled as rst order Pade approximations giving rise his 65th birthday.
to right half plane zeros in the linearized transfer
functions. Appendix A1. The CSTH web site
The task is to use the simulated data of Fig. 8 (available at
the CSTH web site) to identify transfer functions which closely A web page has been prepared to house the CSTH sim-
match those derived from direct linearization of the model. ulation models and data. Its location is: http://www.ps.
ic.ac.uk/~nina/CSTHSimulation/index.htm. The contents
8.2.2. Transfer function model from direct linearization include
G11 s G12 s A general purpose Simulink model with level and tem-
Gs
0 G22 s perature control loops;
where A general purpose Simulink model with level and tem-
perature control loops and disturbances;
0:029732s 2s 0:0375 Open loop Simulink models for the operating points in
G11 s Table 2, together with MATLAB code to organize the
s 2:033s 0:05799s2 0:1881s 0:01139
linearization;
0:013915ss 2s 4s 0:2667
G12 s A Simulink model with level and temperature control
s 3:931s 2:033s 0:05799s 0:04015 loops for the system identication task of Section 8.2;
s 0:0375s 0:003731 Data les for the disturbance sequences in Fig. 6;
2
s 0:1881s 0:01139s2 0:1761s 0:01892 Data les for the input sequences in Fig. 8.
0:050561s 4s 0:2667s 0:03333
G22 s Additional materials are also available. These are (i) a
s 3:931s 0:04015s2 0:1881s 0:01139
set of data for fault identication, (ii) a simulation of a
5
modied continuous stirred tank heater from the labora-
tory of Professor Patwardhan at IIT Bombay, as described
9. Summary and concluding remarks briey in Appendix A2. This CSTH system has a recycle
and shows non-minimum phase behaviour at some operat-
A simulation of a continuous stirred tank heater at the ing points.
University of Alberta has been presented, and a Simulink
implementation used to generate results in open and closed Appendix A2. A modied CSTH model
loop. Instrument, actuator and process non-linearities have
been characterized and the simulation has a hybrid nature A modied CSTH has been developed in the Automa-
because real process and measurement noise sequences are tion Laboratory at Department of Chemical Engineering,
used as disturbances. Linearized state-space and transfer IIT Bombay. The reason for presenting the modied CSTH
function models are also provided for the purposes of lin- here is that a simulation is provided at the CSTH web site.
ear multivariable controller design and other activities This system consists of an additional stirred tank
where linear approximations are utilized. upstream of the CSTH (Fig. 9). The cold water entering
359
Tank1
TT-1
STH
4-20 mA Thyrister (Tank 2) LT
Power
Input Signal (u4) Heating
Controller
Coi l
TT-2 E-1
Thyrister
Power
Controller
Hot Water
Out-Flow 4-20 mA
TT-3 Input Signal (u3)
4-20 mA
Input Signal (u5)
F R u3 2u3 1=3600 103 [1] Anon, Second benchmark model for computer simulation of SSR,
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360
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