Classifications

• • E—FIXED CONSTRUCTIONS
  • E21—EARTH OR ROCK DRILLING; MINING
  • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
  • E21B7/00—Special methods or apparatus for drilling
  • E21B7/04—Directional drilling
  • E21B7/046—Directional drilling horizontal drilling

Definitions

• the present invention relates to a drillpipe module for drilling a borehole in ground, to a system for drilling such borehole in ground including drillpipe modules, to a control unit and an operation unit for use in drilling such borehole in ground, to a method for drilling such borehole in ground to a corresponding computer program.
• trenchless provisions of underground pipes, conduits, cables or the like including horizontal directional drilling (HDD), microtunneling, pipe ramming or jacking or horizontal auger boring, while larger diameters may require tunneling and smaller diameters (with short distances) may be provided by moling or the like.
• HDD horizontal directional drilling
• microtunneling pipe ramming or jacking
• horizontal auger boring As the trenchless approach provides minimal disruption as to the surface, this approach is of major importance in particular in areas where stopping traffic or business on the surface may not be feasible or where a nature protection area may allow no or only a very limited footprint in terms of trenching or excavating.
• horizontal directional drilling or boring sees an extensive use, while there is a desire for extending the range (in terms of possible distance or reach) and capabilities (e.g. in terms of diameter of borehole). An extended reach allows for coverage of greater distances without the need for additional entry and exit points.
• a larger diameter may allow for providing just one borehole instead of multiple parallel
• an approach for extending the reach in creating a borehole in ground where there are provided an inner pipe and an outer pipe having an annular region therebetween, while the inner pipe is used for exerting (axial) force on just a drilling head and not on the outer pipe, safe for a tensional force on the outer pipe provided by a clamp and a bearing, while the outer pipe is advanced separately therefrom by means of an axial force exerted from the outside.
• the annular region between the inner and the outer pipe is filled with air or the like, the effective weight of the drilling arrangement in the borehole is significantly reduced, thus reducing a friction between the wall of the borehole and the outer pipe. The reduced friction allows for a longer range.
• An aim underlying the present invention is to allow for an extension in particular in term of reach of a drilling in ground in comparison to conventional trenchless approaches.
• a system for drilling a borehole in ground is proposed as defined in claim 9, in particular comprising a plurality of buoyancy enhanced drillpipe modules according to the invention and a drilling head arranged for being attached to a drillpipe formed by the plurality of drillpipe modules.
• a control unit for use in drilling a borehole in ground with a drillpipe including a plurality of buoyancy enhanced drillpipe modules is proposed as defined in claim 9, wherein drilling fluid is provided through the passage of the drillpipe to a drilling head and the drillpipe is immersed in debris laden drilling fluid returning from a work face of the drilling head, wherein the control unit is arranged for outputting control signals for controlling the density of the debris laden drilling fluid for adjusting the effective weight of the drillpipe by adjusting a density of the drilling fluid provided through the passage, adjusting a pump rate of the drilling fluid through the passage and/or adjusting a rate of advancement of the drillpipe.
• an operation unit for use in drilling a borehole in ground with a drillpipe including a plurality of buoyancy enhanced drillpipe modules is proposed as defined in claim 10, wherein drilling fluid is provided through the passage of the drillpipe to a drilling head and the drillpipe is immersed in debris laden drilling fluid returning from a work face of the drilling head, wherein the operation unit includes means for adjusting a density of the drilling fluid provided through the passage, adjusting a pump rate of the drilling fluid through the passage and/or adjusting a rate of advancement of the drillpipe, so to control the density of the debris laden drilling fluid for adjusting the effective weight of the drillpipe, wherein the operation unit is arranged to operate the means in response to control signals.
• a method for drilling a borehole in ground is proposed as defined in claim 12, in particular comprising the steps of providing a plurality of buoyancy enhanced drillpipe modules according to the invention forming a drillpipe and a drilling head attached to the drillpipe, advancing the drillpipe with the drilling head being pushed and/or turned, wherein drilling fluid is provided through the combined passages of the plurality of drillpipe modules to the drilling head, the drilling fluid returning as debris laden drilling fluid immersing the drillpipe.
• the arrangement of the buoyancy enhanced drillpipe module of the present invention addresses the stability of the overall drillpipe and thus the applicable force by taking into consideration a ratio between the absolute value of the effective weight of the drillpipe (module) and its ability to withstand and conduct an axial force.
• the provision of the buoyancy unit allows for a reduction of the absolute value of the effective weight force of the drillpipe when immersed in (debris laden) drilling fluid.
• the modular design allows not only for a simple assembling when in use but also give further advantages.
• the provision of the connection units improve the overall strength of a drillpipe formed by the drillpipe modules against buckling, similar to the nodes in a bam- boo stem.
• the modular design limits a failure in the outer pipe in which debris laden drilling fluid enters though the outer pipe to just one module, allowing for the drilling to be continued.
• the drillpipe modules are designed such that a neutral lift occurs within such range, rather than at one of the extremes thereof.
• the reachable drilling range may be optimized, the (average of the) absolute value of the effective weight force being as small as possible throughout the different conditions resulting in differing density of the debris laden drilling fluid.
• the present invention may be realized by using drilling fluid having a conventional density in the range of 1 .0 to 1 .1 kg/I. Nevertheless, it is also possible to provide fresh drilling fluid already having a comparatively higher density.
• Drilling fluids with a density higher than that conventionally used for horizontal drilling are known, for example, in drilling for an artesian well or in case of drilling for oil or gas with an increased reservoir pressure.
• the density of the debris laden drilling fluid is higher than that of the fresh drilling fluid due to the inclusion of debris generated at the working face of the drilling head during operation (unless the debris would have a density lower than that of the drilling fluid).
• the elements of the drillpipe module that are due to transfer axial force have a compressive strength of 50 MPa or more, averaged over the total cross section.
• the ratio of between the absolute value of the effective weight force per meter of the drillpipe in operation (i.e. with fresh drilling fluid in the passage and immersed in debris laden drilling fluid) and the transferrable axial force is ⁇ 0.0002 1/m.
• the first and second connection unit are arranged such that, when the drillpipe module is connected with another drillpipe module, the axial force transferrable by the elements of the drillpipe that are due to transfer axial force at each point along the length of the drillpipe module, except a shoulder portion of the connection units having a higher strength, does not vary by more than 20 %, preferably by no more than 5%.
• connection units - due to their design in defining the front and back enclosure of the buoyancy unit - will typically have a geometrical moment of inertia higher than the average moment of other portions along the length of the module.
• the pipe is an inner pipe and encloses the passage
• the drillpipe module further includes an outer pipe fixed to the first and second connection unit, wherein the buoyancy unit is provided in the space between the outer pipe and the inner pipe, wherein the buoyancy unit is preferably formed by gaseous material
• the pipe encloses the passage and the buoyancy unit at least partially encloses the pipe, wherein the buoyancy unit is formed by solid material
• the pipe encloses the buoyancy unit formed by solid material
• the buoyancy unit encloses the buoyancy unit formed by solid material
• the buoyancy unit encloses the passage
• the buoyancy unit is formed by solid material and includes a first unit and a second unit, wherein the first unit encloses the passage and the second unit encloses the pipe, which encloses the first unit.
• Such combinations of pipe and buoyancy unit allow for a high pressure inside the passage and a high pressure outside the drillpipe, wherein the (in comparison to just the inner pipe) increased cross sectional area provides a large area for receiving forwardly directed (axial) push force and the geometrical moment of inertia provides resistance against folding or buckling.
• the arrangement where there is a further (outer) pipe, which, in turn, surrounds the buoyancy unit, is particularly beneficial insofar as it allows for the buoyancy unit being made of a material (e.g. polyurethane foam or another material like polyethylene with gas or air bubbles therein) which by itself may not be able to withstand the conditions inside the borehole, e.g. due to abrasion at the walls of the borehole or due to pressure of the debris laden drilling fluid return from the working face.
• the outer pipe may have a smaller wall thickness, so just to withstand the pressure from the outside.
• the arrangement of an inner pipe and an outer pipe also allows that the buoyancy unit is formed by gas enclosed between the pipes. It is also possible, provided suitable (a) material(s) for the buoyancy unit are used, that the drilling fluid is provided inside the buoyancy unit, which is enclosed by the pipe, wherein the pipe may also be sandwiched between two portions of the buoyancy unit.
• one or more stiffeners are provided between the inner pipe and the outer pipe, wherein the one or more stiffeners preferably extend along the whole length of the buoyancy unit and in radial direction from the inner pipe to the outer pipe.
• the stiffeners With the stiffeners extending along the whole length of the buoyancy unit, the stiffeners by themselves may contribute to the transfer of axial force. However, independently from receiving and transferring any axial force, the stiffeners contribute to the buckling or folding resistance of the drillpipe module in linking the inner and the outer pipe against a radial deforming of either pipe. In addition, the stiffeners provide further strengthening of the outer pipe in terms of hoop stress or collapse resistance, i.e. assist in preventing that the outer pipe collapses under the pressure of the debris laden drilling fluid.
• the stiffeners and the inner and outer pipe are not necessarily made of the same material (or material class).
• the inner and outer pipe may be made of steel, as with conventional drillpipes, while the stiffeners may be made of, for example, fiber-reinforced plastic. It is, however, also possible to provide other mixes of materials, including, for example, an inner pipe made of steel, stiffeners made of steel or aluminum and an outer pipe made of fiber reinforced plastic, possibly provided with a further coating.
• At least one of the one or more stiffeners is arranged to fix the inner pipe and the outer pipe together and/or the outer pipe is releasably fixed to the connection units.
• a fixing of the inner and outer pipe by means of the stiffeners allows for a further improvement in terms of stability, as such fixing not only prevents, for example, a radial deforming of the outer pipe in the direction to the inner pipe but also a deforming in the opposite direction.
• the outer pipe only abuts the stiffeners and is furthermore connected to the connection units is a releasable manner, so that the outer pipe may be removed and replaced easily in order to address wear and tear.
• connection units are arranged for allowing a releasable connection with the other drillpipe module, wherein the releasable connection is preferably a screwed connection, wherein the connection units most preferably include a pin connection unit and a box connection unit.
• connection between drillpipe modules of the present invention is comparable or even compatible with connections conventionally used for, for example, HDD arrangements.
• a particularly preferred example of such embodiment includes that there are provided an API box connection and/or an API pin connection, while also other connections may be provided, preferably including trapezoidal threading and a sealing shoulder.
• the pin connection unit includes a projection portion provided with a sleeve arranged for being attached over the projec- tion portion.
• modules it is known from conventional drilling, that such module may be damaged, e.g. during handling in the course of assembling the drillpipe modules or of disassembling, wherein, in particular, a damage to the ends of the module are of concern where adjacent modules are linked.
• a damage to the ends of the module are of concern where adjacent modules are linked.
• variations of the respective length of a drillpipe module of a series of drillpipe modules are of no concern, rather than discarding a damaged module, the damaged end may be cut off, while a new connection is provided, e.g. by cutting a fresh thread in case of threaded connections. This may be done rather easily if at least one of the connection units projects from the buoyancy unit.
• the sleeve may be provided so to provide a rather smooth and flush outer surface of the connection area.
• the sleeve if needed, may also be cut accordingly for fitting.
• a preferred variation of such sleeve includes two halves, which are fit on the connection area and fixed together along secants of the cross section, e.g. by bolts.
• the pump provided for pumping the drilling fluid through the drillpipe may be a centrifugal pump and/or is preferably arranged to pump drilling fluid with a sold content of 5% or more.
• the drilling fluid provided to the drilling head does not necessarily has to be freshly composed drilling fluid, as it is indeed possible to recycle the debris laden drilling fluid by at least partially removing debris therefrom.
• fresh drilling fluid this is to be understood as being in contrast to the debris laden drilling fluid returning from the working face.
• the drilling head or some other suitable element of the arrangement inside the borehole may be provided with steering elements, wherein furthermore the drilling head is prefera- bly provided with a position, orientation and/or attitude detecting element.
• a preferable implementation of the invention includes the provision of a motor for driving the drilling head, arranged between the drillpipe and the drilling head, wherein most preferably the motor is a mud motor driven, in turn, by the drilling fluid.
• a transmission may be provided between the mud motor and the drilling head.
• the drilling method includes adjusting a density of the drilling fluid provided through the passage, adjusting a pump rate of the drilling fluid through the passage, and/or adjusting a rate of advancement of the drillpipe, so to control the density of the debris laden drilling fluid for adjusting the effective weight of the drillpipe.
• a particular density (i.e. composition) of the drilling fluid provided to the drill head it may be sufficient in certain cases to just set a particular density (i.e. composition) of the drilling fluid provided to the drill head, to provide for a certain advancing of the drilling and to provide for a certain pump rare of the drilling fluid. Controlling of these parameters, which influence the density of the debris laden drilling fluid, however, allows for adjusting in view of different drilling conditions. If, for example, due to the situation at the working face, the rate of advancement needs to be reduced, so that there is less debris in the returning drilling fluid, the density of the provided drilling fluid may be increased for compensation. Depending on the ground, the composition (and thus the density) of the debris at the working face may also change, which might similarly be addressed by appropriately controlling the density of the drilling fluid, the pump rate and/or the rate of advancement.
• the method may also comprises detecting the density of the debris laden drilling fluid at the drill head and/or above ground, wherein the detected density is used in controlling the density. Measuring, sensing or detecting the density of the debris laden drilling fluid and modifying the control of the density of the (fresh) drilling fluid, the pump rate and/or the rate of advancement allows for a feedback control or regulation loop, while, however, the density of the debris laden drilling fluid and the ratio thereof in comparison to the density of the drillpipe may also be inferred otherwise. For example, the amount of friction between the drillpipe and the borehole may also be used, derived from the force needed for advancing and possibly from knowledge about the ground, as a basis for controlling the parameters influencing the uplift or downlift of the drillpipe in the borehole.
• the method for drilling preferably further includes a steering of the drill head (indirectly via the drillpipe and/or directly) during the drilling. It is particularly preferred that the steering is based on positional information obtained in situ, e.g. by means of a sensor or probe attached to the drill head providing position information of the drill head or allowing a detection of the drill head's position from above surface.
• the positional information may preferably be supplemented with information on the attitude and/or orientation of the drill head.
• Conventional approaches on steering and determination of the position and the like may be used in the context of the invention, as appreciated by the skilled person.
• the present invention allows for, depending on the particular embodiment, advancing the drillpipe by pushing the drillpipe (with the drill head being driven independently from the drillpipe) or by rotating or turning the drillpipe itself so to turn the drill head. This might be combined with the steering.
• the drillpipe may be pressed at its end above the surface in a known way.
• a drill motor or mud motor included in the overall drilling arrangement (specifically between the drillpipe and the drill head)
• the drillpipe may be pressed at its end above the surface in a known way.
• the pre-assembly is, of course, only possible if there is sufficient space, while the benefit lies in the reduced amount of time needed for inserting the numerous drillpipe modules directly at the entrance of the borehole.
• Fig. 1 shows a schematic representation for illustrating a first exemplary embodiment of the present invention
• Fig. 2 shows a schematic representation of a buoyancy enhanced drillpipe module according to an embodiment of the invention
• Fig. 3 shows a schematic representation of a buoyancy enhanced drillpipe module according to another embodiment of the invention
• Fig. 4 shows a schematic representation of buoyancy enhanced drillpipe modules according to another embodiment of the invention
• Fig. 5 shows a schematic representation of buoyancy enhanced drillpipe modules according to another embodiment of the invention
• Fig. 6 shows a schematic representation of buoyancy enhanced drillpipe modules according to another embodiment of the invention
• Fig. 7 shows a schematic representation of buoyancy enhanced drillpipe modules according to another embodiment of the invention
• Fig. 8 shows a schematic representation of a system for drilling a borehole in ground according to an embodiment of the invention.
• Fig. 9 shows a schematic flow diagram of an exemplary embodiment of a method for drilling a borehole in ground according to the invention.
• Fig. 1 shows a schematic representation for illustrating a first exemplary embodiment of the present invention.
• a pump 10 and a drill rig 12 which are coupled to a drillpipe 16, which extends inside a borehole in ground 14.
• a mod motor 18 is provided, which is coupled to a transmission 20, which in turn is coupled to a drilling head 22.
• the drilling head 22 includes a drive 24, which drives the drilling bit 26 at the working face of the borehole.
• fresh drilling fluid 28 is provided through the drillpipe 16 to the mud motor 18 and further to the drilling bit 26, where the drilling fluid takes up debris from the drilling operation and returns in the space between the drillpipe 16 and the walls of the borehole as debris laden drilling fluid 30.
• the illustrated path of the drilling fluid 28 is to be understood as schematically.
• the drillpipe 16 is formed by buoyancy enhanced drillpipe modules, which includes a pipe 32 and a buoyancy unit 34, wherein the buoyancy body has a lower density than the debris laden drilling fluid 30 and the dimensions of the buoyancy body 34 and the passage inside the pipe 32 in which the fresh drilling fluid 28 flows are set such that a density ratio between a combined density of the drillpipe 16 including the fresh drilling fluid 28 and a density of the debris laden drilling fluid 30 is such that, the effective weight of the drillpipe is thus reduced significantly.
• the details of the drillpipe modules including the arrangement of the connection units thereof and not shown and reference is made insofar to Fig. 2 to 7.
• Fig. 2 shows a schematic representation of a buoyancy enhanced drillpipe module 40 according to an embodiment of the invention. Specifically, Fig. 2a) shows a partial view of the drillpipe module, Fig. 2b) shows a view of the left face of the drillpipe module shown in Fig 2a) and Fig. 2c) and 2d) show cross sectional views at corresponding positions.
• the drillpipe module 40 is immersed in debris laden drilling fluid 30 and includes a passage 46 in which fresh drilling fluid 28 is provided.
• the drillpipe module 40 comprises an inner pipe 41 made of steel, which is surrounded by an outer pipe 41 ' also made of steel. At their ends (only one which is shown in Fig. 2) the pipes 41 , 41 ' are connected to a respective connection unit.
• the connection unit is formed by a steel shoulder 45 together with a connection portion of the inner pipe 41 .
• the inner pipe 41 in its form, corresponds to a conventional drillpipe module having API box and pin connections.
• the inner pipe 41 , the steel shoulder 45 and the outer pipe 41 ' enclose and define a hollow portion filled with air, which forms the buoyancy unit 42 of the drillpipe module 40.
• the area between the inner pipe 41 and the outer pipe 41 ' is provided with stiffeners or stabilizers 48, which extend radially from the inner pipe 41 to the outer pipe 41 ', adding to the stability and strength of the combination of inner and outer pipe 41 , 41 '.
• the inner pipe has a diameter of 1 10 mm and a wall thickness of 12.5 mm, while the outer pipe is provided with a diameter of 324 mm and a wall thickness of 5 mm.
• stiffen- ers having a length (in radial direction) of 101 .5 mm and a thickness of 5 mm.
• Fig. 3 shows a schematic representation of a buoyancy enhanced drillpipe module 50 according to another embodiment of the invention.
• the module 50 includes a steel pipe 51 and a buoyancy unit 52 made of high density polyethylene (having a density of 0.985 kg/I), wherein the HPDE surrounds the steel pipe
• the effective weight of the module 50 is basically compensated by the buoyancy of the module 50 in the drilling fluid.
• the module 50 is furthermore provided, at each end thereof, with a steel shoulder 55, which serves as protection and break-out area for an API pin connection 53 and an API box connection 54 provided with the steel pipe 51 , which allow combination of the module 50 with other such modules.
• a typical length of such module 50 is about 10 m.
• connection units 53, 54 of the steel pipe 51 form the connection units, wherein these connection units have the buoyancy unit 52 provided therebetween.
• Fig. 4 shows a schematic representation of buoyancy enhanced drillpipe modules 60 according to another embodiment of the invention. Similar to the drillpipe modules 40, 50 shown in Fig. 2 and Fig. 3, the buoyancy enhanced drillpipe modules 60 include a steel pipe 61 and a buoyancy unit 62, wherein the steel pipe 61 is provided with API pin and box connections 63, 64 and defines a passage 66 for drilling fluid. In the illustration of Fig. 4, the details of the drillpipe modules 60 in terms of the connection units are not shown, while, however, the connection 63, 64 extend beyond a shoulder form by or in the respective connection unit, while the modules 60 are provided with a sleeve 67.
• the steel pipe 61 projects from the shoulders of the drillpipe module on both sides in lengthwise direction.
• the sleeve 67 is provided, such that also in the area of projection of the steel pipe 61 in comparison to the remaining portion of the drillpipe module 60 there is a rather smooth surface, substantially without a recess or a projection beyond the periphery of the module 60 otherwise.
• Fig. 3 c) shows a simplified cross section of the arrangement shown in Fig. 3 b).
• the sleeve 67 is provided in the form of two halves, which are bolted in place in the recess formed between the shoulders of the neighboring modules 60.
• a connection unit may be formed by combining (e.g. welding together) a conventional (and standardized) drillpipe of comparative small diameter with a flange of larger diameter.
• Figs. 5 to 7 show schematic representations of buoyancy enhanced drillpipe modules 70, 80, 90 according to further embodiments of the invention.
• the buoyancy enhanced drillpipe modules 70, 80, 90 each include a steel pipe 71 , 81 , 91 and a buoyancy unit 72, 82, 92, wherein there is also provided a passage 76, 86, 96 for drilling fluid.
• the steel pipe 71 also projects beyond the buoyancy unit 72, while here the pipe 71 is provided, at each end respectively, with a pin connection 73 and a box connection 74 (including, as illustrated, trapezoid threads and sealing shoulders), which form the connection units between which the buoyancy unit 72 is provided.
• the buoyancy unit 72 surrounds the pipe 71 .
• a further pipe 81 ' which surrounds the buoyancy unit 82 and partially the connection units 83, 84. If the contacts between the connection units 83, 84 and the pipes 81 , 81 ' are sufficiently tight, instead of a buoyancy body 82 is the form of a plastic or foam material, there might also be provided just gas, e.g. air, in the compartment thus formed. While evacuating the compartment (e.g. providing a reduced pressure therein) might be possible, the resulting gain in weight reduction is insignificant. The provision of gas instead of a solid material allows for a reduced overall weight.
• gas instead of a solid material allows for a reduced overall weight.
• Fig. 7 shows an embodiment where the buoyancy unit 92 is provided inside the pipe 91 , i.e. the relative positions are exchanged in comparison to the embodiment shown in Fig. 6.
• Fig. 8 shows a schematic representation of a system 1 for drilling a borehole in ground according to an embodiment of the invention.
• the pump 10, the drill rig 12, the drillpipe 16 (made of drillpipe modules as discussed above), the mud motor 18, the transmission 20 and the drilling head 22 discussed above with reference to Fig. 1 are part of the system 1 , wherein the pump 10 and the drill rig 12 are part of an operation unit 37, which further includes a drilling fluid conditioning and recycling unit 38.
• the drilling head 22 is additionally provided with a density sensor 35 for detecting the density of the debris laden drilling fluid returning to the surface from the working face.
• the system furthermore includes a control unit 36.
• the control unit 36 receives data from the density sensor 35 and uses this data for determining whether the rate of advancement of the drillpipe 16 or the composition (and thus density) of the drilling fluid provided to the drillpipe 16 are to be changed in order to provide for a desired ratio between the density of the debris laden drilling fluid and the drillpipe (including fresh drilling fluid).
• the drill rig 12 and/or the drilling fluid conditioning and recycling unit 38 are controlled by the control unit 36.
• Fig. 9 shows a schematic flow diagram of an exemplary embodiment of a method for drilling a borehole in ground according to the invention.
• a system as illustrated in Fig. 8 is provided, including in particular a buoyancy enhanced drillpipe made of a plurality of drillpipe module as discussed above and a drilling head.
• drilling fluid is used, which - when laden with debris and returning from the working face - in operation immerses the drillpipe.
• the buoyancy unit has a lower density than the drilling fluid and the dimensions of the buoyancy unit and the passage are set such that the overall drillpipe module is dimensioned such a ratio between an absolute value of an effective weight force per meter of the drillpipe module in debris laden drilling fluid, with drilling fluid in the passage, and a total cross section of those elements of the drillpipe module that are due to transfer axial force is ⁇ 10,000 N/m 3 .
• the drillpipe is advanced upon pushing and/or turning the drilling head.
• the rate of advancement or drilling is controlled in a control step 103 and, in an adjustment step 104, the density of the fresh drilling fluid is adjusted.
• a further detecting step 105 the density of the debris laden drilling fluid is detected, wherein this data is then used in the control step 103 and/or the adjustment step 104.
• drilling fluid conditioning and recycling unit 40 50, 60, 70, 80, 90 buoyancy enhanced drillpipe module

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