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Variable Frequency Transformer—Concept and Electromagnetic Design


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Article  in  IEEE Transactions on Energy Conversion · January 2009


DOI: 10.1109/TEC.2008.2001460 · Source: IEEE Xplore

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IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 23, NO. 4, DECEMBER 2008 989

Variable Frequency Transformer—Concept


and Electromagnetic Design Evaluation
Arezki Merkhouf, Member, IEEE, Pierre Doyon, and Sanjoy Upadhyay, Member, IEEE

Abstract—Variable frequency transformer (VFT) is a control-


lable bidirectional transmission device that can transfer power be-
tween asynchronous networks. The construction of VFT is similar
to conventional asynchronous machines, where the two separate
electrical networks are connected to the stator and rotor respec-
tively. Electrical power is exchanged between the two networks by
magnetic coupling through the air gap of the VFT. This paper de-
scribes the basic concept of the VFT and presents an overview of
the mechanical and electromagnetic design of a unit having four
poles and rated at 100 MW, 17 kV/17 kV, 60 Hz.
Index Terms—Asynchronous rotating machines, flexible ac
transmission system, high-voltage dc (HVdc) substations, inter-
connected power systems, load flow control, phase angle reg-
ulator, phase-shifting transformer, power transmission, rotating
transformer.

I. INTRODUCTION Fig. 1. Core components of the VFT.


HE WORLD’s first variable frequency transformer (VFT)
T for bulk system power transfer between large asyn-
chronous power grids has been successfully installed, tested, they do reduce the drawbacks indicated before. However, they
and commissioned, and it started commercial operation in early suffer from various limitations of their own, including problems
2004 [1]. Although the VFT concept is new, VFT equipment of harmonics and resonance, risk of torsional interactions, risk
is composed of well-established hydro generator, dc motor, and of rapid bypass for grid disturbance, and short overload capa-
variable-speed drive technology. bility resulting from low thermal time constant [2]. The VFT,
The VFT is essentially a continuously variable phase-shifting when used as a phase-shifting transformer, overcomes all these
transformer that can operate at an adjustable phase angle. A di- difficulties.
rect application of a VFT is as a phase-shifting transformer, The versatility of the VFT, however, lies in connecting two
which connects two power systems operating at the same fre- systems that are asynchronous. The alternative method of con-
quency and controls the power flow. A conventional phase- necting two such asynchronous systems is to use back-to-back
shifting transformer is used to control real power flow along a high-voltage dc (HVdc) connection. There are essential differ-
transmission line. The “natural” power flow on the transmission ences between these two separate technologies, and each may
line is dependent on the voltage difference and the impedance be useful in certain circumstances. Such an application of the
of the line. Due to the dominant inductive component of the VFT has been reported in [3].
line impedance, a variation of the magnitude of the voltages
would mostly influence the reactive power flow. In a conven-
tional phase-shifting transformer, the introduction of a boost II. VARIABLE FREQUENCY TRANSFORMER CONCEPT
voltage that has a leading phase shift of 90◦ (without affecting The core technology of the VFT is the rotary transformer
the magnitude of line voltage) generates line currents in phase with three-phase windings on both the rotor and the stator [4].
with the line voltage, thus affecting primarily real power flow. A three-phase collector system conducts current between the
The drawbacks of this equipment are that the operation is step- three-phase rotor winding and its stationary busduct. The two
wise (rather than continuous) and slow (to deal with stability- separate electrical networks are connected to the stator and rotor,
related constraints on the grid), and components wear out due to respectively. Electrical power is exchanged between the two
repetitive action. When such conventional phase-shifting trans- networks by the magnetic coupling through the air gap. A drive
formers are used in conjunction with power electronic devices, motor and a variable-speed drive system are used to provide
frequency matching by continuous rotation in either direction
Manuscript received February 21, 2006; revised December 30, 2007. Current and to provide regulated torque, thereby controlling the direction
version published November 21, 2008. Paper no. TEC-00063-2006. and the magnitude of the power flow through the VFT.
The authors are with the GE Energy (Hydro), Peterborough, ON K9J 7B5, Fig. 1 shows the core components of the VFT. Fig. 2 illus-
Canada (e-mail: arezki.merkhouf@ge.com; pierre.doyon@ge.com; sanjoy.
upadhyay@ieee.org). trates a conceptual system diagram of the VFT. Conventional
Digital Object Identifier 10.1109/TEC.2008.2001460 transformers are used to match the transmission voltage to the
0885-8969/$25.00 © 2008 IEEE
990 IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 23, NO. 4, DECEMBER 2008

Fig. 2. System diagram of the VFT.

machine voltage. Shunt capacitors are used to compensate for


the reactive currents.
As with any other ac power circuit, the real power flow
through the rotary transformer is proportional to the phase angle
difference between the stator and the rotor. The impedance of the
rotary transformer and the ac grid determines the magnitude of
Fig. 3. VFT power ramps at Langlois substation during asynchronous opera-
phase shift required for a given power transfer. Reactive power tion with the NY and QC power networks.
flow through the VFT is determined by the series impedance
of the rotary transformer and the difference in magnitude of
voltages on the two sides. for a large range of system conditions—normal, abnormal, and
Power transfer through the rotary transformer is a function extreme. Fig. 3 shows the variation of the power and frequency
of the torque applied to the rotor. When the systems are in syn- of the VFT during actual operation and the successful recovery
chronism, the VFT rotor remains in the position in which the from a local disturbance.
stator and rotor voltages are in phase with associated systems. The VFT control system has automated sequences for en-
In order to transfer power from one system to the other, the ergizing, starting, and stopping. When starting, the VFT auto-
rotor of the VFT is turned out of this initial position. If torque matically nulls the phase angle across the synchronizing switch,
is applied in one direction, then the power flows from the sta- closes the breaker, and engages the power regulator at zero MW.
tor winding to the rotor winding. If torque is applied in the The operator then enters a desired power order (in megawatts)
opposite direction, then the power flows from the rotor wind- and ramp rate (in megawatts per minute). Power regulation is the
ing to the stator winding. The power flow is proportional to normal mode of operation. The VFT uses a closed-loop power
the magnitude and direction of the torque applied. The motor regulator to maintain constant power transfer at a level equal to
and drive systems are designed to continuously produce torque the operator order. The power order may be modified by other
while at zero speed (standstill). If no torque is applied, then control functions, including governor, power-swing damping,
no power flows through the rotary transformer. When the two and power runback [5].
systems are no longer in synchronism, the rotor of the VFT
rotates continuously and the rotational speed is proportional to
III. ROTARY TRANSFORMER MECHANICAL DESIGN OVERVIEW
the difference in frequency between the two power grids. Load
flow is maintained during this operation. The VFT is designed VFT is composed of three main components: 1) rotary trans-
to continuously regulate power flow with drifting frequencies former; 2) drive motor; and 3) collector. The rotating assembly
on both grids. Regardless of the power flow, the rotor inherently is the core of the system. The various components are shown in
orients itself to follow the phase angle difference imposed by Figs. 1 and 4.
the two asynchronous systems. As stated earlier, the rotary transformer is a conventional dou-
Power systems are subject to various disturbances, resulting bly wound electrical machine with three-phase windings on both
in frequency and voltage deviations. The VFT control system the rotor and the stator. The three isolated phase collectors are at
must constantly take action and compensate for any frequency the top of the rotary system. The collector uses the conventional
variations across the two asynchronous networks in order to technology of carbon brush on copper slip rings. The collector
maintain the relative position of the rotor with respect to the rings are connected to the rotor windings via a three-phase bus
stator. This, in turn, ensures a constant power transfer. A closed- that runs through the hollow shaft. Fig. 5 shows the site assem-
loop power regulator maintains power transfer equal to an op- bly of the collector system. The drive motor is a conventional
erator set point. The regulator compares the measured power dc motor. The rotating components have very little self-cooling
with the set point and adjusts motor torque as a function of capability owing to their typically low rotational speed. Hence,
power error. The power regulator is fast enough to respond to they need to be forced-air cooled.
network disturbances and maintain stable power transfer. To en- The inertia of the total rotary system is rather large. In per-unit
sure proper behavior for normal system operation and sufficient (p.u.) base of 100 MV·A, four poles, 60 Hz (i.e., 1800 r/min base
robustness during system events, the VFT stations are designed speed), the rotating components have an equivalent H-factor of
MERKHOUF et al.: VARIABLE FREQUENCY TRANSFORMER—CONCEPT AND ELECTROMAGNETIC DESIGN EVALUATION 991

Fig. 6. Rotary transformer phasor relationship. (Not to scale)

where
PVFT power through VFT from stator to rotor;
Vs voltage magnitude on stator terminal;
Vr voltage magnitude on rotor terminal;
Xsr total reactance between stator and rotor terminals;
θs phase-angle of ac voltage on stator, with respect to a
reference phasor;
θr phase-angle of ac voltage on rotor, with respect to a
Fig. 4. VFT rotating components. reference phasor;
θrm phase-angle of rotary transformer rotor with respect
to stator;
θnet θs − (θr + θrm ), where the phasor relationships are
indicated in Fig. 6.
As with all ac power transmission systems, there is a max-
imum theoretical power transfer possible through the VFT in
either direction (PXM AX ). The absolute magnitude of this is
Vs Vr
PXM AX = (2)
Xsr
which occurs when the net angle θnet is near 90◦ in either
direction, i.e.,

θnet = θs − (θr + θrm ) = ±90◦ . (3)

For stable operation, the angle θnet must have an absolute


value significantly less than 90◦ . This implies that the power
transfer will be limited to some fraction of the maximum theo-
Fig. 5. Assembly of VFT three phase collector.
retical level given by (2). Within this range, the power transfer
follows a monotonic and nearly linear relationship to the net
approximately 26 p.u.·s. This large inertia may help to maintain angle, which can be approximated by
stability during grid disturbances.
PVFT ∼
= PXM AX θnet (4)
IV. THEORY OF OPERATION where θnet is in radians.
Key relationships are described here to aid understanding of The angles of the ac voltage phasors are given by the time
the basic operation of the VFT. integrals of their respective frequencies, while the angle of the
rotary transformer rotor is given by the integral of its speed over
A. Theory of Power Control time, i.e.,
  
The power regulator adjusts the torque order, regulating the PVFT ∼ = PXM AX (ωs (t) − ωr (t)) dt − (ωrm (t)) dt
power transfer through the VFT. The power transfer through the
VFT can be approximated as (5)
where
Vs Vr ωs (t) frequency of ac voltage at stator terminals as a func-
PVFT = sin(θs − (θr + θrm )), or
Xsr tion of time;
Vs Vr ωr (t) frequency of ac voltage at rotor terminals as a func-
PVFT = sin θnet (1) tion of time;
Xsr
992 IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 23, NO. 4, DECEMBER 2008

also differ by the same ratio. This can be expressed as


Vs = Ns fs Ψa (8)
and
Vr = Nr fr Ψa (9)
or
Vr Vs fr
= (10)
Fig. 7. VFT real and reactive power flow diagram.
Nr Ns fs
where
Vr voltage on rotor winding;
ωrm (t) speed of rotary transformer rotor as a function of
Vs voltage on stator winding;
time.
fs electrical frequency on stator winding (Hz);
Thus, power through the machine is directly affected by the
fr electrical frequency on rotor winding (Hz);
time integral of shaft speed over time.
ψa air-gap flux.
The effective gain from speed to power is inversely related
The nature of the machine is such that in steady state, the rotor
to the total path reactance, including the effective Thevenin
speed is proportional to the difference between the electrical
reactance of the two ac systems. The relationship to the Thevenin
frequency of the stator and rotor windings, i.e.,
equivalent system is similar to the relationship given before for
measurements of local stator and rotor voltages and angles. frm = fs − fr (11)
and
B. Power Flow and Frequency-Shifting Relationships
120
The later equations are based on an ideal rotary transformer ωrm = frm (12)
NP
with negligible leakage reactance and magnetizing current. Fur-
ther, for clarity, only real power flow is addressed. where
Fig. 7 illustrates a VFT system connected between two power frm rotor mechanical speed in electrical-frequency units
systems with a third power system providing a power sink or a (Hz);
source for the torque-control drive system. NP number of poles in rotary transformer;
The directions of power flow shown in Fig. 7 are based on ωrm rotor mechanical speed in revolutions per minute.
generator convention and are positive. The actual power flow The power exchanged with the drive system can be expressed,
direction may be either positive or negative depending on the using (6)–(10), as
operating condition.
P D = Ps + P r
Power balance requires that the electrical power flowing out
of the stator must flow into the combined electrical path on the = Vs Is + Vr Ir
rotor and the mechanical path to the drive system:   
Vs fr Is
= Vs Is − Nr Ns
Ps = PD − P r (6) Ns fs Nr
 
where fr
= Vs Is 1 −
Ps electrical power out of stator windings; fs
Pr electrical power out of rotor windings;  
fr
PD mechanical power to the torque-control drive system, or, PD = Ps 1 − . (13)
fs
eventually appearing as electrical power exchanged
with the power system to which the drive system is The torque produced by the drive system (TD ) can be ex-
connected. pressed, using (8)–(13), as
Since the machine behaves like a transformer, ampere-turns PD
must balance between the rotor and the stator: TD =
frm
Ns Is = −Nr Ir (7) [(fs − fr ) /fs ]
= Vs Is
where (fs − fr )
Ns number of turns on stator winding; Is
Nr number of turns on rotor winding; = Vs
fs
Is current out of the stator winding;
Is
Ir current out of the rotor winding. = Ns fs Ψa
Both the stator and rotor windings link the same magnetic fs
flux. However, the frequency differs; therefore, the voltage will or, TD = Ns Is Ψa . (14)
MERKHOUF et al.: VARIABLE FREQUENCY TRANSFORMER—CONCEPT AND ELECTROMAGNETIC DESIGN EVALUATION 993

Fig. 8. Rotary transformer active and reactive power at rated voltage, rated Fig. 9. Open circuit characteristic of the rotary transformer.
frequency, and at zero speed as a function of the rotor angle.

It should be noted that the drive system torque TD is indepen-


dent of rotational speed, being only proportional to the stator
current and air gap flux. Since the machine operates near con-
stant flux, the torque is proportional only to the stator current.
Hence, if the stator frequency is constant, the power through the
machine is proportional to the applied torque. At zero load, TD
is zero, and at one per unit load, it is one per unit. Hence, under
synchronous condition, the power transfer in both directions as
a function of the applied torque is linear. For an ideal machine, Fig. 10. Magnetizing reactance of the rotary transformer as a function of the
PD is zero under synchronous condition. For a real machine, applied voltage.
under the same condition, PD equals the no load losses of the
drive system. Using (13), for a 100-MW VFT with 3 Hz fre-
ideal transformer, the effect of leakage reactance and satura-
quency difference between the two power systems, PD equals
tion is substantial. The reactive power consumed by the stator
5 MW under asynchronous condition.
and rotor leakage reactance Ql is about 0.2 p.u. at rated load,
which accounts for two-thirds of the reactive power consumed
C. Reactive Power Relationship at rated load. Due to the large reactive power requirement, shunt
As shown in Fig. 7, the reactive power can come from both capacitor banks are used for compensation.
the grids, depending on the phase angles of the voltages on both
sides of the power system. Defining Qs as the reactive power V. ROTARY TRANSFORMER ELECTROMAGNETIC DESIGN
out of stator winding and Qr as the reactive power out of rotor EVALUATION
winding, the effective reactive power requirement of the rotary Extensive electromagnetic simulations were carried out dur-
transformer is ing the design phase of the rotary transformer. Finite-element
Qs + Qr = Qtot . (15) field simulations were employed to accurately analyze flux pat-
terns and the effect of air gap permeance variations for the
Now, Qtot can also be defined as purpose of evaluating electromagnetic performance of the ro-
Qtot = Qm + Ql (16) tary transformer [6]. The analysis in this paper is obtained from
one such field simulation carried out for a four-pole machine
where rated at 100 MW, 17 kV/17 kV, 60 Hz. The as-built product is
Qm the effective reactive power consumed by the magne- very similar to this machine, being characterized by the same
tizing reactance; rating but different design parameters. Equivalent circuit quanti-
Ql the combined reactive power consumed by the stator ties such as magnetizing reactance, leakage reactance, currents,
and rotor leakage reactance. power transfer, torque, and the phase angle of the rotor relative
Fig. 8 shows the flow of real and reactive power as a function to the stator were extracted from the field distributions.
of rotor position at zero speed (i.e., zero slip frequency, with Fig. 9 shows the predicted open-circuit characteristic of the
stator and rotor line frequencies at 1 p.u.), and both stator and rotary transformer. It is valid when the rotary transformer is
rotor line voltages at 1 p.u. without any phase shift between magnetized either from the stator or from the rotor side at rated
them. In this operation mode, there is no net transfer of reactive frequency. Fig. 10 gives the predicted magnetizing reactance
power across the rotary transformer, and both the rotor and the under rated frequency. It may be observed that at 1 p.u. line
stator share the magnetization of the machine equally. The total voltage, the magnetizing reactance has dropped to 82% of its
reactive power consumed is negative because of the convention unsaturated value.
chosen. As with any induction machine, the air gap size of the rotary
The magnetizing reactance of the rotary transformer is about transformer is limited by the magnitude of the magnetizing
10 p.u. So, Qm is of the order of 0.1 p.u. Since this is not an current, which, in turn, is restricted by system considerations
994 IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 23, NO. 4, DECEMBER 2008

like reactive power compensation. However, a smaller air gap,


which is required for lesser value of magnetizing current, leads
to higher torque harmonics for this type of slotted induction
machines.
Several designs were evaluated to verify that the harmonic
effects on the connected electrical system due to torque, volt-
age, and current are negligible, and that the torque pulsations
are small enough to meet normal design practice. Since the
VFT operates at variable slip frequencies and speeds, the anal-
ysis of harmonics is similar to that of other variable-speed ma-
chines (generators, synchronous motors, and induction motors).
This allows the use of analytical permeance models and finite-
element time-stepping techniques for the prediction of harmon-
ics [6], [7].
The major source for harmonics in rotating electric machines
are: 1) space harmonics in the air gap permeance due to stator
slotting; 2) space harmonics in the stator MMF due to winding
in discrete slots; 3) space and time harmonics in the air gap Fig. 11. Open circuit field lines at time t0 operating at a slip frequency of
permeance due to rotor slotting; and 4) space and time harmonics 1.2 Hz.
in the rotor MMF due to winding in discrete slots.
Simulations obtained using the permeance model show that
the operation of the rotary transformer over the range of slip fre-
quencies from 0 to 1.2 Hz results in torque harmonics with fre-
quencies ranging from 0 to 300 Hz. However, in order to reduce
the magnitude of torque harmonics at particular frequencies,
many different electromagnetic designs were evaluated.
To quantify the magnitudes of the harmonics, mathematical
formulation using time-stepping finite-element analysis (FEA)
of synchronous and asynchronous machines was utilized. The
FEA included rotor motion at mechanical slip frequency and
external circuits [8]–[15]. The rotor motion was simulated by
connecting separate FE models for the stator and the rotor along
a sliding surface in the air gap, nodes being spaced at equidistant
increments in the surface. These two models, having periodic
and antiperiodic boundary conditions, were connected electro-
magnetically at the coinciding nodes of their magnetic vector
potentials.
At each time step, the new rotor position is determined by Fig. 12. Open circuit field lines at time t0 + T 1 / 4 operating at a slip frequency
the mechanical speed (ω) obtained from the solution of the of 1.2 Hz.
kinematics equation of the shaft system
Figs. 11 and 12 show the field distributions under open-circuit
d condition at 17 kV / 17 KV. Fig. 12 displays the field lines at one
J ω = TD − TEM − TFRICT (17) quarter of a period (t = t0 + T1/4 ) later in time than in Fig. 11
dt
(t = t0 ), and illustrates the small amount of rotor movement
where while the stator field rotates by half a pole pitch (the equivalence
J moment of inertia of the whole shaft system; of a quarter of a period).
TD torque supplied by the drive motor; The results obtained under open-circuit operating condition
TEM electromagnetic torque computed from the magnetic (stator energized and rotor open), over the range of slip fre-
field solution at every time step using the Maxwell quencies varying from 0 to 1.2 Hz, indicate that small torque
stress tensor; pulsations exist. The magnitudes of the torque harmonics be-
Tfrict friction torque. come more apparent at load.
The rotor mechanical speed, and hence, the rotor position The origin of the harmonics can be attributed to interaction at
at the next time step are obtained from (17) using the one- slip frequency of stator fundamental MMF, rotor fundamental
step explicit Euler scheme. The kinematic system is therefore MMF, stator slotting, rotor slotting, and air gap permeance and
solved decoupled from the electrical circuit system. This does their various combinations.
not pose any risk of instability or loss of accuracy due to the Table I indicates the torque pulsations under rated power at
large mechanical time constant of the VFT. 1.2 Hz slip frequency. The torque pulsation at 72 Hz is
MERKHOUF et al.: VARIABLE FREQUENCY TRANSFORMER—CONCEPT AND ELECTROMAGNETIC DESIGN EVALUATION 995

TABLE I as replacement for phase-shifting transformers for synchronous


TORQUE PULSATIONS UNDER RATED POWER TRANSFER AT 1.2 HZ SLIP
FREQUENCY FOR A 100 MW, 17 KV/17 KV, 60 HZ, FOUR POLE DESIGN
connections.
The real power transfer through the rotary transformer is a
function of the magnitude and direction of the applied torque
on the rotor by the drive motor. The reactive power requirement
of the VFT is reasonably large and shunt capacitor banks are
needed for compensation.
Extensive electromagnetic simulations were carried out dur-
ing the design phase of the rotary transformer. The obtained
results show that the level of the torque harmonics at rated
power is less than 2% of the rated torque. It was identified that
the most important component occurs at second slot passing
frequencies for both the stator and the rotor.
The results also demonstrate that the level of the current
harmonics in the stator and the rotor is less than 1 % of the rated
current at 1.2 Hz slip frequency.
Future work will focus on documenting test data in terms
of reactance, harmonics, and efficiency. Comparison of tested
and predicted parameters of the rotary transformer will also be
included.

ACKNOWLEDGMENT
The authors gratefully acknowledge the contributions of
D. McLaren, E. Larsen, J. Gibney, L. Fujita, and K. Weeber
Fig. 13. Frequency spectrum of rotor current as percentage of rated current at of GE Energy.
1.2 Hz slip frequency.

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996 IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 23, NO. 4, DECEMBER 2008

[12] A. Merkhouf, “Prediction of electrical parameter of the hydro-generator Pierre Doyon received the B.Eng. degree from L’Université Laval, QC, Canada,
using finite element method,” presented at the 7th Int. Conf. Model. Simul. in 1987, and the Master’s degree from the University of Toronto, ON, Canada,
Electr. Mach., Converters Syst., Montreal, QC, Canada, Jun. 2002. both in electrical engineering.
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Arezki Merkhouf (M’00) received the B.Sc.Eng. degree from the University Sanjoy Upadhyay (M’01) received the B.E.E degree from Jadavpur Univer-
of Algeria, Alger, Algeria, in 1990, the M.Sc. degree from the University of sity, Kolkata, India, in 1993, and the M.Sc. degree from the University of
Pierre and Marie Curie, Paris, France, in 1992, and the Ph.D. degree from the Saskatchewan, Saskatoon, SK, Canada, in 2001, both in electrical engineering.
University of Sherbrooke, QC, Canada, in 1999, all in electrical engineering. He was with the Development Consultants Limited (DCL), a technical con-
In June 2000, he joined GE Energy (Hydro), Peterborough, ON, Canada, sultancy firm. He joined GE Energy as a member of the hydro generator design
where he is currently a member of the R&D team. His current research in- team, where he is currently involved in system design of hydro power plants. His
terests include analytical and numerical simulation of large rotating electrical current research interests include electrical machines, eletromagnetics, power
machines, numerical and analytical computation of electromagnetic fields, vari- electronics, power system dynamics, and hydro system dynamics.
able frequency transformers, and power electronic and drives. Mr. Upadhyay is a Registered Professional Engineer in the province of ON.

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