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The Journal of Engineering

Research Article

Simulation and analysis of a gas insulated eISSN 2051-3305


Received on 21st December 2018
Accepted on 21st January 2019
switchgear explosion accident caused by a doi: 10.1049/joe.2018.5468
www.ietdl.org
failure of high-voltage circuit breaker in a
thermal power plant
Xun Zhang1, Kai Dai2 , Wei Niu1, Rongbin Xie3, Huarong Zeng1, Yi Wen1, Xiaohong Ma1
1ElectricPower Research Institute of Guizhou Power Grid Co. Ltd, Guiyang 550002, People's Republic of China
2StateKey Laboratory of Power Transmission Equipment & System Security and New Technology, Chongqing University, Chongqing 400044,
People's Republic of China
3Guiyang Power Supply Bureau, Guiyang550002, People's Republic of China

E-mail: 20161102121t@cqu.edu.cn

Abstract: This study analyses a gas insulated switchgear explosion accident caused by a failure of the circuit breaker (CB) in a
thermal power plant, which resulted in the explosion of the CB and the burning of the potential transformer (PT). Through X-ray
detection and disassemble examination of the damaged CB, it is found that the A-phase moveable contact was not opened
completely. After analysing the voltage waveform obtained from the phasor measurement unit recorder system, it is speculated
that this failure is caused by the process of repeated arc strike. For verification and further analysis, the fault process is
simulated in the EMTP; the arc is properly modelled by an extended KEMA's equation-based model which is proposed in this
study. The simulation results match well with the actual situation; the contact gap would be repeated breakdown because its
breakdown voltage is reduced, and the very fast transient overvoltage (VFTO) would be generated in these repeated strike
processes. Due to the steep front and high amplitude of VFTO, the insulation of the PT would be damaged and led to the
occurrence of PT short-circuit fault. The current would increase rapidly and causes the CB to explode subsequently.

1 Introduction The famous arc models include the early Mayr model and
Cassie model, which provide a qualitative description of the arc in
The gas insulated switchgear (GIS) has been widely used in the the high- and low-current regions, respectively. Then some models
power plant and substation because of its advantages such as being based on these classic models are proposed, such as Habedank
independent of the atmospheric environment, small footprint, high model, Schwarz model, KEMA model and so on [9–12], which are
reliability, low maintenance and so on [1]. However, the very fast widely used and keeps updated in arc analysis [13, 14].
transient overvoltage (VFTO) with steep front and high amplitude The KEMA model is a semi-empirical arc model based on the
would occur during the switching operation in GIS [2]. Mayr–Cassie equation and a large number of experiments. Since
The fundamental reason for VFTO is the breakdown of the the mathematical description of the KEMA model is derived from
contact gap, which leads to a steep rising voltage spread inside the the Cassie and Mayr equations, which has a complete physical
GIS. Due to the different structure and parameters of GIS circuit meaning. In theory, it can simulate the arc of the various circuit
components, the transient impulse voltage caused by constant breakers (CBs) more accurately [15].
refraction and reflection in GIS may cause damage to the insulation To make an accurate simulation of this fault, a simulation model
safety of the equipment [3–5]. of the repeated breakdown of the CB contact gap is established,
A 220 kV GIS CB fault happened in the transmission line and the repeated strike process is simulated in ATP-EMTP. The
between Maoming power plant and Xie Ping Ling (XPL) station in proposed model includes the block of the KEMA arc model and the
China in May 2016, this fault led to the explosion of the CB and CB breakdown control unit. Since most of the black box models
the burning of the potential transformer (PT). The CB was checked lack the capabilities to realise the analysis of the repeated
by X-ray immediately after the fault, where, the result showed that breakdown of CB and related research rarely exists, this system
A-phase movable contact was not in the normal opening position, will be of great significance to the study of arc modelling.
and it was not opened completely comparing with the position of To analyse the VFTO accurately, accurate models for the GIS
other phase parts. components are established. Based on the equivalent model, a
Through analysing the voltage waveform obtained from the simulation of the accident will be carried out. The simulation
phasor measurement unit (PMU) recorder system before this fault, results will be compared with the record data, and the process of
it is found that such waveforms are very rare in the current study. fault development will be analysed in detail. However, it is difficult
This failure may be due to the incompletely open of the CB, causes to simulate the reason of the PT damage, therefore, based on the
the system power repeated charged to the CB, and the VFTO simulation and the recorded data, an inference of the reason of the
would generate in the repeated strike process after the relevant PT damage will be present at the last.
analysis. To verify the cause of this fault, computer simulations and The rest of this paper is organised as follows. In Section 2, the
further analysis are necessary. background of the CB failure is described, and a simple analysis of
Arc generation and extinguishment are an integrated process this failure is carried out. In Section 3, the proposed CB model is
involving physical quantities such as heat, gas, and magnetism, and described in detail. In Section 4, based on the simulation results in
that is very complex. At present, the arc model can be roughly ATP-EMTP, the failure is analysed in detail. The discussion and
classified into two categories: physical model [6] and black box conclusion are drawn in Sections 5 and 6, respectively.
model [7]. The black box model has been paid more and more
attention by researchers because of its simpler mathematical
equation and the dynamic study of the arc conductance [8].

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2 Failure background illustrated in Fig. 2, and the fault sequence diagram is shown in
Fig. 3.
2.1 Failure description
On 10 May 2016, due to the regular maintenance schedule, the 2.2 On-site examination
second transmission line between Maoming power plant and XPL
station was planned to be changed from the working state to the The CB was checked by X-ray immediately after the fault. The
standby state. The #2970 SF6 CB (245 kV/50 kA) at the Maoming result showed that the movable contact of phase A was not in the
normal opening position, and it was not opened completely
power plant side was switched off at 9:00 a.m., with the relevant
comparing with the position of B-phase movable contact, as shown
equipment operating normally.
in Fig. 4.
The CB at the XPL station side was switched off at 9:40 a.m.,
This fault occurred after the CB at the XPL station side was
later the bus differential protection operated on the second bus of
opened, and the protection record at the power plant side did not
Maoming power plant and the voltage was also getting lost then. It
start. However, voltage and current waveforms of the faulty
was found that the GIS transformer room was smoking according
transmission line before the fault were obtained from the PMU
to the on-site inspection, while the #2970 SF6 CB broke down and
recorder system, as shown in Fig. 5. The ratio of the actual voltage
the PT burned down, as shown in Fig. 1. The simplified wiring
to the recorded voltage is 2200, and the ratio of the actual current
diagram between the Maoming power plant and XPL station is
to the recorded current is 1600.
To make a detailed analysis of the fault, the recorded data are
divided into two stages in chronological sequence.
In stage I, which is from 9:40:00 to 9:42:46, the voltage
presents the shape of the flat-topped waveform while the current is
an impulse-like waveform.
In stage II, which is from 9:42:46 to 9:43:00, a sharp increase in
the current happened.
Generally, the line current should always be zero as well as the
line voltage should decay to zero soon from the operating voltage
when the CB at the station side was opened after the power plant
jumping out to the hot standby state. However, in this case, the
three-phase voltage constantly exhibited a flat-topped voltage
waveform which periodically changes polarity, and the impulse
current was monitored in A-phase at that time in stage I, as shown
in Fig. 5a. The comparison of the station side voltage of the faulty
Fig. 1  Failure equipment: the breakdown of the SF6 CB arc-extinguish
CB and the power plant voltage is shown in Fig. 5c. The following
chamber
points can be seen from stage I.

Fig. 2  Simplified wiring diagram between the Maoming power plant and XPL station

Fig. 3  Diagram of the fault sequence

Fig. 4  Result of X-ray inspection


(a) Moving contact of phase A, (b) Joint shaft of phase A, (c) Moving contact of phase B, (d) Joint shaft of phase B

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Fig. 5  Data obtained by the PMU recorder system
(a) Three-phase voltage and Three-phase current in stage I, (b) Three-phase voltage and three-phase current in Stage II, (c) Comparison of station side voltage of the faulty CB and
the power plant voltage in Stage I, (d) Comparison of A-phase voltage and B-phase voltage in stage I

i. The variation of the faulty transmission line voltage polarity was oscillating in the system inductance and capacitance
was consistent with the change of system voltage polarity. element, so the voltage had changed.
When the voltage between the CB contact gaps reaches a limit ii. The current rose sharply to 4.7 kA at 9:42:48, indicating a
value, the transmission line voltage jumps to the system short circuit happened in the system. Since the current
voltage at that moment. The high-frequency component of measured by the current transformer (CT) was mainly the
shock and rapid attenuation appeared at the moment that the current flowing through the GIS busbar and the current in the
flat changed the oscillation transients may occur at the voltages PT, and the melting hole on the GIS is the position where the
higher than the system operating voltage. As the sampling rate PT is mounted, it can be seen that a short circuit had occurred
of the PMU recorder system is 4.8 kHz, the details of the high- at the PT.
frequency shock cannot be clearly recorded. However, the
record shows that the high-frequency shock was there and It is possible to speculate about the cause of the fault from the
maybe VFTO. PMU record. The #2970 CB at the Maoming power plant side was
ii. The current appeared as a discontinuous impulse current first opened and malfunction in this process, leading to that the
pattern, and the maximum value is 475 A. The pulse breakdown voltage of A-phase was significantly reduced to a value
occurrence time corresponds to the time of voltage polarity below the operating voltage of the system. However, the
conversion that means the high-frequency shock explained in transmission line at the XPL station side was still connected to the
(i) causes these impulse current. system, and the voltage across the 2970 CB is synchronised so the
iii. The voltages also existed in the B-phase and C-phase, but the fault did not appear from 9:00 to 9:40.
amplitude is significantly lower than that of A-phase. The The line voltage no longer changes with the system voltage
comparison of the A-phase and B-phase voltage is shown in when the CB at the XPL side opened at 9:40, so the voltage across
Fig. 5d, which demonstrated a good phase congruency, it the 2970 CB shows periodic changes. As the breakdown voltage of
means that the observed B-phase and C-phase voltage are the 2970 CB dropped below the operating voltage, the CB contact
induced from the A-phase. gap would be broken down when the voltage across it reaches a
critical value, and then the transmission line charged by the power
However, the voltage and current in stage II presented a different source at the plant side through the arc generated in the CB. Then,
pattern from stage I. The voltage rose to the system voltage after the voltage of the transmission line would rise rapidly to the supply
the breakdown but then decreases and reverses, and the current is voltage, and the impulse current appeared. The voltage of the
very small at this time. Then the current increased rapidly to 4.7  transmission line would remain unchanged until the next
kA, and the voltage fluctuated within small amplitude, as shown in breakdown after the arc extinguished.
Fig. 5b. The following points can be seen from stage II. The fault can be summarised as the repeated process that the
transmission line charged by the power source at the plant side
i. Instead of maintaining the magnitude of the system voltage at through the arc generated in the CB. Every time the CB contact gap
the time of breakdown, the line voltage decayed and became was broken down, a steep rising voltage would spread inside the
negative after the breakdown. This indicated that the energy GIS. It can be inferred that the constant refraction and reflection of

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Fig. 6  Schematic diagram of the proposed model of CB
Fig. 7  Breakdown voltage at each moment
the steep rising voltage in GIS would initiate VFTO, and the
insulation of the PT would be destroyed by the VFTO at last. The 3
current becomes large because of the short circuit of the PT, and U= ∑ ui, (5)
then the CB exploded. This process will be validated by i=1

simulations in Section 4.
I = U ⋅ g. (6)
3 Arc model for the repeated breakdowns This model contains nine parameters with six of them being
3.1 Black-box arc model empirically derived constants, and satisfies the following numerical
quantities (5) or relation (6)
The significant characteristic of the black-box arc model is the
dynamic study of the arc conductance. The widely-used arc models λ1 = 1.4, λ2 = 1.9, λ3 = 2, (7)
include the early Mayr model and Cassie model, which provide a
qualitative description of the arc in the high- and low-current τ1 τ Π
regions, respectively. The expression of the Mayr is illustrated in τ2 = , τ = 2 , Π2 = 3 . (8)
K1 3 K2 K3
(1) and Cassie model is illustrated in (2)
K1, K2, and K3 are constants decided by the design of the breaker,
1 dg dln g 1 ui
= = −1 , (1) Π1, Π2 and τ1 are considered as free parameters, describing the
g dt dt τ P
state of the CB.
1 dg dln g 1 u2
= = −1 , (2) 3.2 Proposed model
g dt dt τ Uc2
To verify the aforementioned inference and make an accurate
where g is the conductance of the arc, u is the voltage across the analysis of the cause of this accident, an extended KEMA's
arc, i is the current through the arc, τ is the arc time constant, P is equation-based model is proposed in this study. The schematic
the cooling power, and Uc is the constant arc voltage. diagram of the extended KEMA's equation-based model for
Cassie model and Mayr model are under a different assumption, simulations is depicted in Fig. 6. This proposed model is composed
and only one kind of heat dissipation is considered in these two of two parts. One is the control unit of CB breakdown, which
models. The main application of Cassie model is the large current controls the breakdown of the CB contact gap; the other part is the
period before the current zero crossing, but the Mayr model is block of KEMA arc model, which describes the dynamic change of
suitable for a small current period with the current zero crossing. In the arc resistance during the extinguished process.
fact, the arc extinguishing process is carried out by the combination The control unit of CB breakdown includes the EMTP TACS
of these two assumptions. control, where the voltage across the CB and the breakdown
The KEMA model, which combined Cassie model and Mayr voltage as input parameters, the trip will be assigned then as an
model, can calculate the arc voltage itself, it is not entirely output parameter to decide the TACSSWIT state. The function of
dependent on the input parameters. This advantage implies that the the CB breakdown control unit is implemented by the MODEL
determination of arc voltage is more realistic, and the results will module in ATP-EMTP, using Fortran programming language. By
be in good agreement with the laboratory measurements. The comparing the breakdown voltage and the voltage across the CB,
differential equations of the KEMA model are described by three this unit will send out a control signal at each time step.
series of modified Mary equation, which is used to represent the The absolute value of breakdown voltage at each moment get
three regions of the arc. The expression of the KEMA model is from the PMU recorder system is shown in Fig. 7, the breakdown
shown in (1) voltage at each moment is different due to the instability of the arc.
To make the simulation results more realistic, the breakdown
dgi 1 λi 2 1 voltage in the simulation takes the actual value obtained from the
= g u − g, i = 1, 2, 3, (3) PMU recorder system.
dt Πiτi i i τi i
The switch is expressed by TACSSWIT (Type 13) in the
where gi is the conductance of the ith arc; ui is the voltage across simulation, which will get the signal from trip. The switch will
close when the voltage across the CB is higher than the breakdown
the ith arc; τi is the time constant of the ith arc; Πi is the power
voltage as the output value of trip is 1, which represents the
loss; λi is the Cassie–Mayr control of the ith arc. λ is 1 for Cassie breakdown of CB. The current starts flowing through it as the arc
model, and λ is 2 for Mayr model. occurs and the resistance is a very small value, which is set at 2 Ω.
The arc voltage U, arc current I and arc conductance g are After the arc continues to develop for 1 × 10−5 s [16], the output
described as follows: value changes to 0 and the switch is opened.
3
Then the arc starts to extinguish, and the block of MODEL
1
g
= ∑ g1i , (4)
works. Whenever there is the voltage across the CB, the resistance
value is calculated by the KEMA arc equation at each time step,
i=1

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Table 1 Component models and their parameters
Component Equivalent model Equivalent parameter
transformer inductance and L = 24 mH, C = 2500 pF
capacitance
GIS busbar distributed Z = 83 Ω, V = 2.9 × 108 m/s
transmission line
overhead line distributed Z = 300 Ω, V = 3 × 108 m/s
transmission line
SF6/oil bushing capacitance to C = 300 pF
ground
disconnecting capacitance to C = 80 pF
switch (closed) ground
PT capacitance to C = 300 pF
ground
CT capacitance to C = 20 pF
Fig. 8  Excitation characteristic curve of the voltage transformer
ground
surge arrester capacitance to C = 19 pF of the line-side voltage are the same as the voltage obtained from
ground the PMU recorder system. Every time the CB contact gap was
broken down, a steep rising voltage would generate in the line. Due
to the different structure and parameters of GIS circuit components,
and the value of the output resistance is presented on the the VFTO with high amplitude and steep front would appear. The
TACSRES (Type 91). The arc will extinguish when the resistance waveform diagram and spectrum diagram of the VFTO are shown
goes to infinite, then the thermodynamic control is complete. With in Figs. 9b and d, respectively.
the change of the power phase, the voltage across the CB may The current obtained from the simulation is shown in Fig. 9c,
exceed the breakdown voltage again, and the thermodynamic the impulse current flows through the GIS busbar at the moments
control will start due to a new arc occurring. of the sudden changing of voltage. The variation characteristics of
the current get from the simulation are the same as the current
4 Failure analysis obtained from the PMU record. However, due to the low sampling
frequency (about 4.8 kHz) of the PMU recorder system, some
4.1 Simulation on stage I pulse may not be noticeable in the recorded waveform.
To analyse the fault accurately, the components in GIS must be The simulation results are in good agreement with the actual
modelled properly. Since the VFTO would occur in the repeated situation in stage I, confirming the inference above towards the
strike process and mainly contains high-frequency components, failure. The stage I can be summarised as the power supply
most of the components have their capacitances that dominate the repeatedly charges the capacitance of ground from the line. The
other parameters. line-side voltage remains constant between the two breakdowns,
Then the busbar and overhead line are modelled as a distributed forming a stepped voltage waveform similar to a square wave. The
transmission line with a surge impedance of 63 and 300 Ω, impulse current occurs at the time of gap breakdown, and the
respectively. The power transformer is considered as the VFTO with steep front and high amplitude would appear in the
combination of lumped capacitance and inductance. The SF6 repeated strike process.
bushing, disconnecting switch, PT, CT, and surge arrester are
modelled as a lump capacitance to ground. The equivalent model 4.2 Analysis of stage II
and the specific parameter of the GIS component is shown in
The recorded data showed that the current rose to 4.7 kA before the
Table 1 [17].
fault occurred, indicating that the fault could be caused by the
As the maximum operating voltage of the system is 252 kV, so
overcurrent. As the current measured by the CT was mainly the
the amplitude of the voltage is set as follows:
current flowing through the GIS busbar and the current in the PT,
and the melting hole on the GIS was the position where the PT is
2 mounted, showing that a short circuit had occurred at the PT. Based
U = 252 kV × = 205.757 kV . (9)
3 on the simulation of stage I and the record data of stage II, the
damage of the PT may be caused by the VFTO.
The PT model considers saturation effects; the excitation branch is Due to the steep front and high amplitude of VFTO, the voltage
composed of the parallel resistance and the non-linear inductor. distribution in the PT windings would be very uneven, especially at
The resistance represents the voltage transformer loss, which is the head end of the winding. Therefore, a high voltage would drop
taken as 10 MΩ. The magnetising curve of voltage transformer is at the head end of the winding, which would cause the insulation of
shown in Fig. 8. the winding inter-turn to be damaged.
Based on the model established above, the failure process is If an inter-turn short circuit fault occurred, an additional closed
analysed using ATP-EMTP. The open time of the CB at the XPL loop would be added in the winding, as shown in Fig. 10a. The
station is set to 0.1 s and the time step is set to 1 × 10−9 s. The equivalent circuit for the shorted turns occurred in the winding is
voltage waveforms of the faulty CB on the station side and the shown in Fig. 10b, the induced electromotive force in shorted turns
power plant voltage from the simulation are shown in Fig. 9a for is the source of current in shorted turns. As the impedance of the
comparison. shorted turns was very low, the current would be as high as several
The results show that the line voltage is normal before the CB times of the rated current [18, 19].
at the XPL station side switching to open, and it is consistent with As the inter-turn short circuit caused the increase of the current,
the voltage on the power plant side. As the CB of the XPL station the temperature of the shorted turns would increase rapidly. The
side is open the line voltage changes. With the change of the insulation of the surrounding turns would be damaged under high
voltage at the power supply side, the gap of the CB contact will temperature, resulting in more and more shorted turns. As the
continue to break down. During the repeated strike process of the current would also increase with the increase of the number of
CB contact gap, the breakdown occurred near the peak of the shorted turns, the fault would expand rapidly and eventually lead to
voltage. The line-side voltage remains constant between the two the short-circuit fault of the PT.
breakdowns, forming a stepped voltage waveform similar to a In addition, when the voltage at the terminal of the PT goes
square wave, and the waveform frequency is the same as the beyond line-to-ground voltage, the core of PT would carry out deep
frequency on the power supply side. The variation characteristics
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Fig. 9  Voltage and current obtained through the simulation
(a) Comparison of station side voltage of the faulty CB and the power plant voltage, (b) Voltage at the moment of breakdown, (c) Current through the CB from the simulation, (d)
Spectrum diagram of the voltage at the moment of breakdown

Table 2 Primary winding dc resistances of the PT


Phase Measure value Normal value, kΩ Difference, %
A 50.80 MΩ 34 ± 0.5 49,410
B 33.58 kΩ 34 ± 0.5 1.24
C 33.58 kΩ 34 ± 0.5 1.24

The damaged PT was disintegrated then, it is found that the


winding was burnt black and some coils were broken, as shown in
Fig. 11. This proves the inferences mentioned above, indicating
that the accident was caused by VFTO.
Fig. 10  Inter-turn short-circuit fault of winding
(a) An inter-turn short-circuit fault occurred in the winding, (b) Equivalent circuit for a 5 Discussion
shorted turns occurred in the winding
As GIS plays an important role in the power system, it is necessary
saturation, resulting in a sharp increase of the PT magnetising to study the fault cause of GIS. The results shown in this study
current. confirm that the cause of this certain fault is the incompletely open
As the heat was increased with the square of the current, the of CB through theoretical analysis and related simulation analysis.
increased current led to a continuous increase in the heat of the PT. As this accident is very strange and the waveforms recorded in
Due to the high amplitude of the current, the heat of the PT would the PMU recorder system are relatively rare, it is very meaningful
increase rapidly. to study the mechanism of the generated waveform. Since the
However, the magnetisation of the core would be reduced with recorded data presented a different pattern in two stages, it is
the increase of the heat of the PT [20]. Then the magnetising necessary to analyse the two stages separately.
inductance would decrease with the reduction of the magnetisation To verify the cause of this fault, computer simulations and
of the core, which would lead to an increase of the current. further analysis are necessary. However, most of the black box
Then the heat of the PT continued to accumulate, excitation models are used to simulate the interruption process of CB and lack
current continued to rise and this was a positive feedback the capabilities to realise the analysis of the repeated breakdown of
acceleration process. With the continuous increase of heat, the CB. The breakdown control unit is added in this study to extend the
thermal stability of PT was damaged, eventually led to the KEMA arc model, and then the arc model is established to simulate
occurrence of PT short-circuit fault. the repeated strike process of the CB contact gap. The simulation
The DC resistance of three-phase primary winding of damaged results are in good agreement with the values in the actual case,
PT was measured after this fault, and the results are shown in which verifies the soundness and applicability of the arc model.
Table 2. The results show that the DC resistance of A-phase is far The simulation reproduces the process in stage I. Since the
greater than the normal value, and the B-phase and C-phase are breakdown voltage between the two contacts of the CB is less than
normal, this indicates there is a breakdown in the primary winding the peak value of the system voltage, the contact gap will break
of A-phase. down twice in one cycle. The line-side voltage will remain constant

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between the two breakdowns, forming a stepped voltage waveform
which is similar to a square wave, and the high-frequency shock
happens in time of the voltage polarity conversion cause the
impulse current. The simulation results show that the repeated
strike process happen in stage I and the high-frequency shock was
VFTO,
Owing to the difficulty of simulation on stage II, the analysis of
stage II is carried out in the simulation on stage I and the recorded
data. Due to the steep front and high amplitude of VFTO, the
current will increase rapidly in the PT. The insulation of the PT
would be damaged and led to the occurrence of PT short-circuit
fault.
The reason for the fault is very clear now; the results indicate
the cause of this accident is the continuous discharge (VFTO) of
Fig. 11  Damage of the PT winding insulation
the contact gap in A-phase. Due to the rareness of this fault, this
study will have a great reference value to the engineering practice
and application. 8 References
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J. Eng. 7
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