GB2580658A - A method and system for controlling gas flow rate in a boiler - Google Patents

A method and system for controlling gas flow rate in a boiler Download PDF

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Publication number
GB2580658A
GB2580658A GB1900808.5A GB201900808A GB2580658A GB 2580658 A GB2580658 A GB 2580658A GB 201900808 A GB201900808 A GB 201900808A GB 2580658 A GB2580658 A GB 2580658A
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GB
United Kingdom
Prior art keywords
gas
boiler
pressure
controller
air
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB1900808.5A
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GB201900808D0 (en
Inventor
Charles Farrell Christopher
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Canetis Metering Ltd
Original Assignee
Canetis Metering Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Canetis Metering Ltd filed Critical Canetis Metering Ltd
Priority to GB1900808.5A priority Critical patent/GB2580658A/en
Publication of GB201900808D0 publication Critical patent/GB201900808D0/en
Publication of GB2580658A publication Critical patent/GB2580658A/en
Withdrawn legal-status Critical Current

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23NREGULATING OR CONTROLLING COMBUSTION
    • F23N3/00Regulating air supply or draught
    • F23N3/002Regulating air supply or draught using electronic means
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23DBURNERS
    • F23D14/00Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
    • F23D14/02Premix gas burners, i.e. in which gaseous fuel is mixed with combustion air upstream of the combustion zone
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23NREGULATING OR CONTROLLING COMBUSTION
    • F23N1/00Regulating fuel supply
    • F23N1/02Regulating fuel supply conjointly with air supply
    • F23N1/022Regulating fuel supply conjointly with air supply using electronic means
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23NREGULATING OR CONTROLLING COMBUSTION
    • F23N5/00Systems for controlling combustion
    • F23N5/003Systems for controlling combustion using detectors sensitive to combustion gas properties
    • F23N5/006Systems for controlling combustion using detectors sensitive to combustion gas properties the detector being sensitive to oxygen
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24HFLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H9/00Details
    • F24H9/20Arrangement or mounting of control or safety devices
    • F24H9/2007Arrangement or mounting of control or safety devices for water heaters
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24HFLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H9/00Details
    • F24H9/20Arrangement or mounting of control or safety devices
    • F24H9/2007Arrangement or mounting of control or safety devices for water heaters
    • F24H9/2035Arrangement or mounting of control or safety devices for water heaters using fluid fuel
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23NREGULATING OR CONTROLLING COMBUSTION
    • F23N2225/00Measuring
    • F23N2225/04Measuring pressure
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23NREGULATING OR CONTROLLING COMBUSTION
    • F23N2225/00Measuring
    • F23N2225/08Measuring temperature
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23NREGULATING OR CONTROLLING COMBUSTION
    • F23N2225/00Measuring
    • F23N2225/08Measuring temperature
    • F23N2225/14Ambient temperature around burners
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23NREGULATING OR CONTROLLING COMBUSTION
    • F23N2225/00Measuring
    • F23N2225/08Measuring temperature
    • F23N2225/20Measuring temperature entrant temperature
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23NREGULATING OR CONTROLLING COMBUSTION
    • F23N2225/00Measuring
    • F23N2225/26Measuring humidity
    • F23N2225/30Measuring humidity measuring lambda
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23NREGULATING OR CONTROLLING COMBUSTION
    • F23N2233/00Ventilators
    • F23N2233/06Ventilators at the air intake
    • F23N2233/08Ventilators at the air intake with variable speed

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Regulation And Control Of Combustion (AREA)
  • Control Of Steam Boilers And Waste-Gas Boilers (AREA)

Abstract

A boiler control system for a gas boiler includes a pressure sensor 20 configured to measure the pressure of a gas supply at the gas inlet to the boiler and a controller 14 is configured to modify the volume of air demanded by the boiler based on the measured gas pressure by, for example, variable fan 16. If the pressure at the boiler gas inlet is reduced below the pressure expected to be delivered by a regulator 4, e.g. due to low mains pressure or demand in the pipe, then the fan speed and thus air demand is reduced to prevent over cooling of the burner 12 to maintain efficiency. The pressure sensor or a separate sensor may also measure an inlet gas temperature to further modify the air demand. An atmospheric air pressure sensor may also supply the controller for control of air demand to reflect the changes in calorific value of the gas based on elevation above sea level. A flue gas oxygen sensor 24 may be used to monitor completeness of combustion and validate the air fan and control valve settings.

Description

A METHOD AND SYSTEM FOR CONTROLLING GAS FLOW RATE IN A
BOILER
Background
Domestic central heating and hot water systems typically include a boiler unit for heating the incoming (cold) water supply. In the UK, such domestic boilers typically use gas or oil as the fuel source. A gas boiler will include a gas valve that operates to vary the amount of gas provided to a burner in the boiler. If a large demand for hot water is made in the heating or hot water system, for example multiple hot water taps are turned on simultaneously, or the central heating is activated from cold, then the gas valve is operated to provide a maximum amount of gas to the burner, whereas if the hot water demand is lower then the gas valve operates to provide a lower amount of gas. In addition to the gas valve, the boiler will include a fan that operates to draw in air that is also supplied to the burner to provide the necessary oxygen for the combustion of the gas.
Typically, the speed of the air fan is also variable and is typically linked to the operation of the gas valve. Consequently, a large demand of hot water results in both the gas valve and air fan operating together to provide a high rate of gas and air.
The operation of the variable gas valve and air fan presumes that the pressure of the gas supplied to the boiler is substantially constant at approximately a known value. For example, in the UK the gas pressure at the boiler gas inlet (and other gas appliances) is normally expected to be approximately 20 millibar (2000Pa). Consequently, the proportion of air provided for a given amount of gas, via the gas valve, that is required to achieve complete combustion of the gas is pre-set based on this expected gas pressure (and therefore gas flow rate). However, there may be occasions when the gas pressure is below this expected value of 20 millibar, for example due to an unexpected drop in the mains gas supply pressure. In this circumstance the amount of gas provided by the gas valve within the boiler for any particular setting is reduced, but the air volume is not, since the operation of the fan is linked to the gas valve operation, thereby leading to excess air being supplied for the complete combustion of the (reduced) amount of gas. This leads to an unwanted cooling of the gas flame at the burner, and therefore reduced efficiency of operation of the boiler.
It would therefore be beneficial to provide a method and system for at least mitigating the effect of reduced gas pressure at the boiler.
SUMMARY OF THE INVENTION
According to an aspect of the present invention there is provided a boiler control system for a gas boiler including a pressure sensor configured to measure the pressure of a gas supply at the inlet to the boiler and a controller configured to modify the volume of air demanded by the boiler based on the measured gas pressure.
The controller may be configured to operate the speed of an air fan within the boiler.
The boiler control system may include a gas temperature sensor configured to measure the temperature of the gas at the boiler gas inlet, the controller being further configured to modify the demanded air volume based on the measured gas temperature.
The boiler control system may include an atmospheric pressure sensor configured to measure the atmospheric pressure in the proximity of the boiler, the controller being further configured to modify the demanded air volume based on the measured atmospheric pressure.
The boiler control system may further include an oxygen sensor located in the boiler exhaust gas flue configured to provide a signal to the controller indicative of the oxygen content of the exhaust gas, wherein the controller is configured to further modify the demanded air 20 volume based on the exhaust gas oxygen content.
The controller may be configured to control a gas delivery valve within the boiler to control the rate of gas burn by the boiler.
According to a further aspect of the present invention there is provided a method of controlling a gas boiler, the boiler including a gas valve and an air fan, the method comprising determining the gas pressure at a gas inlet to the boiler, determining a demanded as valve setting, and modifying an air fan setting corresponding to the gas valve setting based on the gas pressure.
The method may further comprise determining the gas temperature and modifying the air fan setting based on the gas temperature.
The method may further comprise determining the atmospheric pressure and modifying the air fan setting based on the atmospheric pressure.
The method may further comprise determining the oxygen content of the boiler exhaust gas and further modifying the air fan setting based on the oxygen content.
According to another aspect of the present invention there is provided a domestic hot water system comprising a boiler having a gas valve and an air fan and a boiler control system according to the first aspect of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of illustrative example only, with reference to the accompanying figures, of which: Figure 1 schematically illustrates a boiler control system; Figure 2 schematically illustrates a boiler control system in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
Figure 1 schematically illustrates a typical arrangement for a domestic hot water gas boiler and its supply of gas. The mains gas supply 2 is provided to a pressure regulator 4. The function of the pressure regulator is to reduce the pressure of the mains gas supply 2 to a lower and more constant value more appropriate for use in a domestic dwelling. For example, in the UK the pressure of the gas supply 2 coming into a domestic dwelling is typically about 75 millibar and the gas regulator 4 is set to output gas at a reduced pressure of approximately 21 millibar. The gas outlet of the regulator 4 is connected to the input of a gas meter 6, the purpose of which is to record the flow of gas into the dwelling for the purposes of billing the occupants for the gas used. Generally the gas meter 6 and regulator 4 are located external to the dwelling. From the meter 6 the gas, still at approximately 21 millibar pressure, is provided to the various gas appliances within the dwelling, including in the example shown a gas powered domestic hot water boiler 8. The boiler includes a controllable gas valve 10 that receives the gas supply and outputs it, when demanded, to the burner 12 of the boiler. The gas valve 10 of the boiler 8 is controlled by means of a control signal to the gas valve provided by a boiler controller 14. The controller 14 will typically include one or more microprocessors arranged to determine the gas valve 10 setting desired. Also within the boiler is a controllable variable speed air fan 16 that is controlled by the same control signal provided by the controller 14 that is used to control the gas valve 10.
Consequently, when more gas is demanded the gas valve I 0 operated accordingly under controller 14, the air fan 16 is also automatically controlled to provide increased airflow. As previously discussed, the ratio of gas flow to air provided by the fan is predetermined based upon a presumption that the gas supply to the boiler 8 is maintained at the "normal" supplied pressure of 21 millibar.
However, there may be some circumstances in which the gas pressure at the inlets to the boiler falls below 21 millibar. There are a number of possible causes for the gas pressure to drop within the property, for example the elevation of an appliance from the meter point, or undersized gas pipes that reduce the working gas rate, ie pressure. Other cause can arise when multiple appliances, e.g. cookers and fires, share the same gas pipe within the home. Therefore the pipework needs to be able to accommodate the combined volume of gas for the appliances but also maintin the flow rate at the required pressure. A key problem with low working gas pressures is the potential to introduce air into the gas pipe, as an appliance that is trying to draw gas from the pipe can induce air to enter the pipe from another appliance that is being used. For example, if the boiler doesn't get enough gas this may cause low gas pressure such that if the gas hob is also turned on air may be drawn into the gas pipe. This is very dangerous as there exists the potential for a combustible mix of gas and air to be present within the gas pipe. Ifs also possible for the main gas supply 2 Lo the regulator to have lower working pressures, for example during the peak gas times of the day in large residential areas. Other aspects that effect the gas pressure include atmospheric pressure and temperature of the gas.
If the pressure of gas supplied to the boiler 8 falls below the expected 21 millibar, then for any given controlled setting of the gas valve 10, the gas flow through the valve 10 to the burner 12 will be lower than normal and lower than expected. However, in the arrangement shown in Figure 1, because the speed of the air fan 16 is directly linked to the gas valve control signal, the air fan setting, and operation, will remain at the level that was presumed to be required for a normal, higher, gas pressure. This therefore causes an excess amount of air to be provided by the air fan 16 relative to the reduced gas supply to the burner 12. This has the undesired effect of cooling the burner 12 output more than expected thereby reducing the expected temperature of the hot water provided by the boiler, either for central heating purposes or domestic hot water supply, which in turn is likely to give rise to an increased demand for gas flow in the boiler, thus reducing the overall efficiency of operation.
Figure 2 schematically illustrates an alternative arrangement of gas supply and hot water boiler for a domestic dwelling in accordance with an embodiment of the present invention. Those integers that are the same as those illustrated in Figure 1 are provided with identical reference numerals. Consequently, a gas supply 2 is still provided to a gas regulator 4 and pass through a gas meter 6 before entering the dwelling. Equally, the gas boiler 8 also includes a controllable gas valve 10, a controllable variable speed air fan 16, gas burner 12 and a control module 14 to control operation of the gas valve 10 and air fan 16. However, in accordance with the embodiment of the present invention as illustrated in Figure 2, an additional gas pressure sensor 20 is provided at the gas inlet to the boiler 8, so as to directly measure the actual gas pressure provided to the gas valve 10 of the boiler 8. The pressure sensor 20 provides a signal indicative of the measured pressure to the boiler controller 14. The boiler controller 14 is configured to provide separate control signals to the gas valve 10 and air fan 16. In the event of the pressure sensor 20 measuring a reduced gas pressure (i.e. less than the expected 20 millibar) then the boiler controller 14 is arranged to provide a modified control signal to the air fan 16 that causes the fan to operate at a lower speed than would otherwise be the case for the corresponding gas valve 10 setting. This avoids, or substantially reduces, the excess air that would otherwise be provided to the burner 12 in the event of low gas pressurellow rate as described above with reference to Figure 1. Consequently, the burner 12 is not excessively cooled and the demanded hot water temperature provided by the boiler 8 is substantially unaffected. Whilst the controller 14 is shown as an integrated unit in the embodiment illustrated in Figure 2, in other embodiments the signal from the pressure sensor 20 may be provided to a separate control module, that is separate from the normal control module 14 for the boiler, with the separate control module being arranged to receive and modify the single control signal provided by the controller 14 (as in the arrangement shown in Figure I) so as to provide a modified signal to the air fan 16.
The temperature of the burner 12 in the boiler 8 can also be affected by the temperature of the gas itself. Generally, the hotter the gas temperature then the cooler the burner 12 will actually operate at for any given gas valve 10 setting (due to the reduced entity of supplied gas). Therefore, in some embodiments of the present invention the sensor 20 may also measure the temperature of the gas at the boiler gas inlet, or alternatively a separate temperature sensor may be provided, with the sensor providing a further signal to the controller 14 indicative of the gas temperature and the controller being arranged to modify the demanded airflow via the air fan 16 based on both the gas pressure and temperature. The determination of the required air fan setting (airflow) can be determined by calculation by the processor of the controller of an equation or algorithm having one or both of gas pressure and temperature as variables, or alternatively may be determined by accessing a look-up table of stored pressure and temperature values having associated predetermined fan settings, the look-up table being stored for example, within a memory included within the boiler controller 14.
A further variable that effects the amount of air required for any given volume of gas is the calorific value of the gas, or in other words the energy density of the gas. Gas having a lower calorific value requires less air for complete combustion than gas having a higher calorific value. One factor that effects the calorific value of the gas is the altitude, and therefore atmospheric pressure, of the system. Gas supplied to a property located at sea level will have a higher calorific value than gas supplied at the same pressure to a property located at, say, 300m above sea level. In some embodiments of the present invention an atmospheric pressure sensor 22 is provided which additionally provides a signal indicative of the atmospheric pressure to the controller 14 which is further configured to modify the air fan setting in response to the atmospheric pressure signal.
In other embodiments of the present invention an oxygen sensor 24 may be provided within the exhaust flue 26 of the boiler, the oxygen sensor 24 being arranged to measure the oxygen content of the exhaust gases from the boiler and provide this information to the boiler controller 14. The controller is arranged to utilise the oxygen measurement of the exhaust gases from the boiler, in combination with the known gas pressure and/or temperature and gas valve and fan settings to determine the "completeness" of combustion of gas by the boiler. Preferably this information is used to validate the air fan and/or gas valve settings already determined by the controller using the signals from the other sensors. For example, the controller may be configured to modify the algorithms used to determine the desired air fan and gas valve settings or predetermined values based on information from the oxygen sensor. Whilst the gas valve and/or air fan operating settings may be modified by the boiler controller 14 directly in response to the signals from the oxygen flue sensor to correct for gas supply issues, this is in response to a drop in efficiency, whereas predicting the gas characteristics upstream of the boiler can help to prevent or reduce the reactive efficiency loss.
Embodiments of the present invention therefore provide a mechanism by which the boiler efficiency can be increased under circumstances where the pressure of the gas provided to the boiler is lower than expected.

Claims (11)

  1. CLAIMSA boiler control system for a gas boiler including a pressure sensor configured to measure the pressure of a gas supply at the gas inlet to the boiler, and a controller configured to modify the volume of air demanded by the boiler based on the measured gas pressure.
  2. The boiler control system of claim 1, wherein the controller s configured to operate the speed of an air fan within the boiler.
  3. The boiler control system of claim I or 2 further including a gas temperature sensor configured to measure the temperature of the gas at the boiler gas inlet, the controller being further configured to modify the demanded air volume based on the measured gas temperature.
  4. The boiler control system of any preceding claim, further including an oxygen sensor located in the boiler exhaust gas flue configured to provide a signal to the controller indicative of the oxygen content of the exhaust gas, wherein the controller is configured to further modify the demanded air volume based on the exhaust gas oxygen content.
  5. The boiler control system of any preceding claim further including an atmospheric pressure sensor configured to measure the atmospheric pressure in the proximity of the boiler, the controller being further configured to modify the demanded air volume based on the measured atmospheric pressure.
  6. The boiler control system of any preceding claim, wherein the controller is configured to control a gas delivery valve within the boiler to control the rate of gas burn by the boiler.
  7. A method of controlling a gas boiler, the boiler including a gas valve and an air fan, the method comprising: determining the gas pressure at a gas inlet to the boiler; determining a demanded gas valve setting; and modifying an air fan setting corresponding to the gas valve setting based on the gas pressure.
  8. The method of claim 7 further comprising, determining the gas temperature and modifying the air fan setting based on the gas temperature.
  9. The method of claim 7 or 8 further comprising, determining the atmospheric pressure and modifying the air fan setting based on the atmospheric pressure.
  10. 10. The method of claim 7, 8 or 9, further comprising determining the oxygen content of the boiler exhaust gas and further modifying the air fan setting based on the oxygen content.
  11. 11. A domestic hot water system comprising a boiler having a gas valve and an air fan and a boiler control system according to any one of claims 1 to 6.
GB1900808.5A 2019-01-21 2019-01-21 A method and system for controlling gas flow rate in a boiler Withdrawn GB2580658A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1900808.5A GB2580658A (en) 2019-01-21 2019-01-21 A method and system for controlling gas flow rate in a boiler

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1900808.5A GB2580658A (en) 2019-01-21 2019-01-21 A method and system for controlling gas flow rate in a boiler

Publications (2)

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GB201900808D0 GB201900808D0 (en) 2019-03-13
GB2580658A true GB2580658A (en) 2020-07-29

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GB1900808.5A Withdrawn GB2580658A (en) 2019-01-21 2019-01-21 A method and system for controlling gas flow rate in a boiler

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112797620A (en) * 2020-12-18 2021-05-14 重庆海尔热水器有限公司 Gas heating water heater and control method thereof

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1235891A (en) * 1968-03-30 1971-06-16 Wilkins & Mitchell Ltd Improvements in or relating to gas heaters
JPS63210522A (en) * 1987-02-25 1988-09-01 Paloma Ind Ltd Safety device for gas water heater
CN105890178A (en) * 2016-06-12 2016-08-24 中山市恒乐电器有限公司 Control device for gas water heater and forced exhaust type gas water heater

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1235891A (en) * 1968-03-30 1971-06-16 Wilkins & Mitchell Ltd Improvements in or relating to gas heaters
JPS63210522A (en) * 1987-02-25 1988-09-01 Paloma Ind Ltd Safety device for gas water heater
CN105890178A (en) * 2016-06-12 2016-08-24 中山市恒乐电器有限公司 Control device for gas water heater and forced exhaust type gas water heater

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112797620A (en) * 2020-12-18 2021-05-14 重庆海尔热水器有限公司 Gas heating water heater and control method thereof

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Publication number Publication date
GB201900808D0 (en) 2019-03-13

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