accc installation guidelines.pdf

8/11/2019 ACCC Installation Guidelines.pdf

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ACCC-TW Conductor InstallationGuidelines

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WI-750-004

Revision:A Page 1of13

A Division of Composite Technology Corporation

1. PURPOSE

1.1.The purpose of this document is to provide experienced transmission engineers, fieldinspectors, utility personnel and linemen with guidelines, recommendations andrequirements necessary to safely install the ACCC-TW composite-core bare overheadconductor. This document is intended to provide an overview of the differences ininstallation techniques between the composite-core ACCC-TW conductor andconventional steel-core conductor, but is not intended to serve as a more intensive trainingmanual or act as a substitute for required personnel skill sets or industry experience.

2. SCOPE

2.1.These guidelines apply to equipment and techniques required to installACCCconductor.

3. TRAINING

3.1.CTC strongly recommends that all linemen, safety inspectors and construction crew attenda CTC sponsored training seminar prior to or in conjunction with the pre-constructionmeeting, at a time and place agreed to by all parties. Attendance by all InstallationSupervisors is mandatory prior to the start of construction. Should a change in crew occurduring the course of construction, CTC should be notified as soon as possible so that

additional field training and support can be provided in a timely manner. Improperinstallation techniques are not covered by the CTC Warrantee Program and could result inpremature line failure.

4. ASSOCIATED DOCUMENTS

4.1.IEEE Standard 524Guide to the Installation of Overhead Transmission Line Conductors.

5. DEFINITIONS

5.1.ACCC/TW is defined as Aluminum Conductor Composite Core Trapezoidal Wire.

6. RESPONSIBILITY

6.1.It is the responsibility of the Utilitys Project Engineer and the Prime ContractorsSupervisors and Field Inspectors to ensure a safe installation by following the instructionsprovided in this guideline, as well as customary safe installation practices.

7. TOOLS, GAGES, FIXTURES

7.1.All equipment shall be maintained in accordance with applicable safety standards.


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7.2.Only sheaves identified herein as correct for each conductor size shall be used.

8. SAFETY REQUIREMENTS

8.1.All safety requirements associated with the operation of approved equipment shall befollowed.

8.2.Electrical grounds shall be placed on all equipment and cable per OSHA Regulation1910.269 and 1926.950.

8.3.CONDUCTOR GROUNDS MUST BE PLACED DIRECTLY ON THE ALUMINUMSTRANDS AS THE COMPOSITE CORE IS ESSENTIALLY NON-CONDUCTIVE.

9. SHIPPING

9.1.Aluminum conductors are shipped in sturdy, carefully designed containers or reels thatsafe-guard the conductor from damage in transit, storage, and at the point of installation.The conductor is carefully inspected during all stages of fabrication; packaging isinspected prior to shipment, and only properly packaged material is delivered to thecarrier. All reels will be steel, with a 36 diameter drum (D) or larger and have a 5.25arbor hole for reels with flanges 90 and larger, and 3.25 arbor holes for reels with flanges78 or smaller.

9.2.Reels should be properly controlled during the loading, unloading, and staging process,and cannot be dropped or allowed to roll freely down ramps to the ground.

9.3.Cranes or other equipment of adequate capacity should be used to avoid damage or resultin a safety hazard.

9.4.It is important that reels ofACCCcable are not lifted by placing the forks of the forkliftdirectly under the drum area of the reel which would allow the forks to come in directcontact with the conductor or its wrapping material.

9.5.Lift reel by approaching from the side and placing forks under flanges. The trapezoidal

strands of the conductor are annealed, and are subject to damage.

9.6.Reels may also be lifted using fork truck approaching from side of reel so the weight islifted on reel flanges or through the center of the reel.

9.7.A spreader bar with slings or chains attached directly to the reel is the preferred method oflifting a reel.

9.8.At no time should the reel be laid on its side for transport or unloading or storage.


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9.9.Do not field rewind the conductor to another reel as damage to the aluminum strands mayoccur.

9.10.At the end of the pull, if there is surplus conductor left on the reel, it is important that theend of the conductor is carefully secured back to the side of the reel to prevent theconductor end from whipping loose.

10. Storage

10.1.If the conductor is to be stored for an extended period of time before use, the reelcontaining the conductor should be kept off of the ground and otherwise protected frompossible damage.

10.2.Identification tags and other markings should be retained on all packages until such timeas the conductor is to be used.

10.3.For future identification purposes, it is good practice to retain and track the reel taginformation corresponding to the section of line in which the conductor is used. Key reeltag information includes, but not limited to the manufacturing date of the ACCC/TWconductor, the ACCC/TW manufacturing lot number, the length of conductor on the reel,and the CTC core component number.

10.4.The reels come from the factory with a pressboard type reel wrap, held down with bandsover the outermost layer of conductor. It is recommended that the cover be left on thereels if they are going to be stored for an extended period of time.

11. STRINGING CONDUCTOR

11.1. Conductor reels should be loaded into their pay-out cradles prior to the removal oflagging or protective wrapping. When the conductor is loaded onto the payout cradles, thereel shall be situated such that the conductor is pulled off the top side of the reel towardsthe bull-wheel tensioner. After the removal of the covering, all reels must be examined fornails or other sharp objects that may damage the conductor as it is unreeled.

11.2.A reel brake mechanism must be utilized at all times to avoid spring action oruncoiling. Adequate back-tension must be applied at all times during the pullingoperation to prevent the conductor from unraveling, binding, or jumping out ofalignment with tensioning or stringing equipment.

11.3.Tensioner bull wheels must be a minimum o f 40X the diameter of the conductorbeing strung measured at the bottom of the grooves of the bull wheel sheaves.

11.4. Conductor must be continuously inspected as it is fed into the stringing equipment for dirt,bits of foreign material, nicks, or abrasions in the conductor.


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11.5. Precautions should be taken to keep pulling lines and stringing sheaves free from dirt andforeign debris that would cling to the conductor as it passes through the sheaves.

11.6. The conductor must not be pulled across the ground or underlying structure (such as afence) as that could damage the soft aluminum strands causing electrical discharge orcorona when energized.

11.7. It is a good practice to retain the reel tags and document the section of line where thespecific reels of conductor are used.

11.8. It is recommended that the protective outer wrap that is removed from the reels be placedon the ground to protect the conductor during set up and splicing operations.

11.9. At splices and dead-ends, all die marks, flashes, and the body of the aluminum sleeveshould be cleaned up with files and sanding medium in order to avoid corona.

11.10.Should the conductor unintentionally come in contact with the ground, any dirt or debrisbuild up should be cleaned off.

11.11. Always use Neoprene or Urethane lined dollies, sheaves, rollers, blocks, etc. as sized inaccordance with Table 1 when stringing conductor. With exception for use for a rollingground sheave, unlined metal sheaves must never be used. This is to avoid scratchingthe surface of the aluminum strand wires.

11.12.MINIMUM STRINGING SHEAVE DIAMETER- The minimum stringing sheavediameter(s) shall be as per Table 1.

11.13. Never bend the conductor less than the recommended minimum bend diameter (seeTable 1). During handling and installation, the radius of curvature for any bendmade in the conductor must never be less than the value that is listed in Table 1.


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Table 1 - Sheave Sizes Required

ConductorDiameter

(O.D.)Conductor

Name

MinimumBendingRadius

ofCurvature(inches)

First and LastStructureMinimumSheave

Diameter(inches)*

IntermediateStructureMinimumSheave

Diameter(inches)*

Al l Angle orElevationChangesMinimumSheave

Diameter(inches)*

0.563 Penguin 4 10 10 10

0.720 Linnet 6.5 14 12 14

0.858 Hawk 9 20 16 20

0.927 Dove 10.5 22 20 22

0.990 Grosbeak 11.5 28 20 28

1.196 Cardinal 13.5 28 22 28

1.345 Bittern 13.5 28 28 28

1.108 Drake 16 35 28 35

1.504 Lapwing 17 35 28 35

1.602 Chukar 18 42 35 42

1.762 Bluebird 19.5 42 42 42

* The diameter indicated is the bottom of the groove diameter where the conductor rolls over.It is not to be confused with the dimension of the overall sheave roller wheel.


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11.14. Excessive Bend Angles If, at any time during the installation process theACCCcableis bent at a sharp angle in excess of the bending radius that is shown in Table 1, AND ifthis portion of the conductor is going to be put up under tension or non-tension, thissection of conductor must be cut out and a full splice installed. The sharp bend may haveinadvertently damaged some of the fibers in the pultruded core material. Sharp anglescan be avoided by proper sheave placement, sheave size, and attention to control of theback tension and brake applied on the payout reel. The pultruded core fibers providethe backbone strength component for the conducto r. If they become damaged thestrength of the conductor may be compromised.

11.15.It is cr itical that a minimum of a 3 to 1 distance to height ratio be used betweenthe bull-wheel tensioner and the stringing sheave on the fir st st ructure and betweenthe puller and stringing sheave on the last struc ture. This is to avoid bending theconducto r at a severe angle during the installation of the conductor . The tensionermust be right hand lay, meaning the conductor coming off of the wire reel goes into the leftside of the tensioner, and the conductor going to the first structure will be coming out of theright side of the tensioner. The let off trailer, the tensioner, and the stringing sheaves mustall be in good alignment. It is unadvisable to have a change in angle direction immediatelyat the first structure.


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The formula to calculate the tension required to pull in the conductors is based on therolling efficiency of the conductor stringing blocks.

The formula for calculating the stringing tension for pulling in the conductor is

=

nED

LWT

1

8max

2

Where

Tmax = pulling tension (assume level pull)W = weight of the cable (lb/ft)L = span length (ft)D = sag length (ft) (while pulling in the conductor)E = % roller resistance efficiency (expressed as a decimal)

= 0.98 for the large stringing sheaves used for ACCC/TWn = number of rollers

11.16.Maximum Pulling Force: The maximum pulling force applied to the conductor stringshould not exceed 10% of the rated strength of the ACCC conductor. For example a

HAWK ACCC/TW conductor with a rated strength of 23200 lb the maximum pulling forceexcerpted on the conductor pair should not exceed 2320 lb force during the installation ofthe conductor.

11.17. Only multi-groove tensioners should be used.

11.18. V-groove tensioners cannot be used for the back-tensioning ofACCC cable.

11.19.Longest Length - While it is possible to string in multiple reels of the ACCC/TWconductor, attention must be paid to the maximum stringing tension limit requirement.Conductor ends may be joined together using a double pulling sock arrangement.

11.20.Support of Stringing Blocks at Angles - For angle changes greater than 15 degrees, thestringing block should be externally supported (example - tied off) to allow the ACCC/TWconductor to roll along the bottom of the groove. When the stringing block is notsupported, the conductor may not track evenly through the stringing block and may impartuneven contact point pressure. This uneven contact pressure may result in movement ofand subsequent deformation to the aluminum strand wires along the conductor.

11.21.Pulls with Angle Changes - Angle changes are defined as directional changes whereyou have a change in line elevation and/or line angle direction. It is recommended thatno installation be made in one continuous pull which contains more than 45 degrees intotal angle change. For pulls with more than 45 degrees in accumulated angle changes,


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the pull should be broken up into separate pulls.

The vertical angle change of the conductor running from the bull-wheel to the first structureand the vertical transition from the last structure to the pulling unit is not be included in the45 degree total angle calculation. Larger stringing blocks should always be used at anyangle change.

11.22. Pulling Grips Standard Kellem grips, also known as sock splices, basket grips, or wiremesh can be used to pull ACCC cable.

11.23.Swivels When pulling in the conductor, a swivel shall be used between the pullingcable and the pulling sock that is attached to the conductor.

11.24.Sagging Grips There are two basic types of grips used to attach onto the ACCC/TWconductor for the conductor sagging operation. One type is a clam-shell type that boltsclosed over the top of the conductor. These are known as pocket book or come alongtype grips. The other type of grip is a pliers type of grip that pinches down onto thesurface of the conductor. These are known as a Chicago Grips or Klein Grips. Eithertype of grip may be used to grip the conductor when tensioning the conductor. When theChicago type of grip is used, it is important that it is the long body version. These gripsmust also be sized properly to match the conductor diameter in order to minimize stranddistortion and maximize gripping power.

11.25.Consult with the grip manufacturer for the correct sizing and the recommendedinstallation procedure.

11.26.All of the conductor grips must be clean, properly sized, and load tested prior to use toensure that they will exceed the intended maximum installation tension(s).

11.27.It may be necessary to use tandem grips for certain high tension applications.

11.28.Tandem grips do not provide double the gripping power.

11.29.Consult with the equipment manufacturer as to the rating system they apply for tandemgrips.

11.30.Dead-ends and Splices Specially designed compression fittings are used for all dead-ends and splices. See Sections 12 and 13 below. Because the aluminum strands areannealed TW, installation of compression dead-ends and splices may cause conductordistortion and minor birdcaging. These can usually be corrected by reshaping with a smallwood block or piece or rubber pipe. Installation techniques should be modified to minimizethe potential for birdcaging to form. It is suggested that any grounding clamps be safelyattached as far downstream from the dead-end as possible in order to allow for maximumtravel of the extruded trapezoidal strands. A distance of 20 feet has shown success.


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11.31.Jumper Connections Jumper connections are made up using a compression typejumper fitting. To minimize the formation of birdcaging in the aluminum strand wiresbetween the jumper ends, a modified compression technique may be used. See Sections12 and 13 for more information.

12. DEAD-END INSTRUCTIONS12.1.The ACCC FCI Burndy cable dead-end assembly kit includes the following: Threaded

internal collet housing, collet assembly, threaded eyebolt, aluminum filler sleeve, outeraluminum housing compression sleeve, Penetrox A13, and sanding medium.

12.2.Remove prescribed amount of aluminum stranding from core. This is best done with acircumciser due to the fact that the core cannot be nicked or damaged in any way. Theexposed end of the core needs to be cut very cleanly. This is best done with a hacksaw.

12.3.Lightly sand the exposed core with sanding medium provided in the kit.12.4.Clean and remove any dirt or particulate matter off of the exposed core with clean cloth

lightly dampened with a suitable solvent.12.5.Slide the inner sleeve over the conductor with the tapered end facing the end of the

conductor. Slide it down about three feet.12.6.Slide the outer sleeve over the conductor with the pad two feet from the cut end of the

conductor.12.7.Slide the collet housing, wrench flats toward the aluminum strands onto the core, and butt

it against the aluminum strands.

12.8.Install the collet, narrow end towards the housing, onto the core leaving inch of the coreexposed from the wide end of the collet.12.9.Install the eye and hand tighten before fully tightening with a wrench to 85 ft lbs of torque.12.10.Thoroughly wire brush the top layer of the aluminum s trands and apply the

Penetrox A13 along the brushed length of the aluminum strands. Rebrush thesurface allowing the Penetrox inhibitor to penetrate the spaces between the strands.

12.11.Slide the aluminum outer sleeve towards the eye.12.12.Liberally apply the Penetrox A13 to the outer diameter of the aluminum inner sleeve and

slide the inner sleeve into the outer sleeve all the way to the stop point.12.13.Crimp using a 60 ton press with the prescribed die size (see Table 2). The crimps need

to overlap in the area marked on the aluminum outer sleeve. The direction of the crimpingmust always start at the steel eyebolt of the fitting and crimp out towards the span lengthof the conductor. You must never back press dead-end fittings.

12.14.Use a file to remove any burrs or flashing that result from the crimping.

Table 2 Compression Dead-End


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Installation Tooling(not included)

Y60BHU or Y60BHU-D

Hydraulic HYPRESSACCCkcmil

Exposed Corelength mm (ln)

Dead-EndDie Set

Terminal DieIndex

Linnet 431 190 mm (7.5 in) L727 717

Hawk 611 190 mm (7.5 in) L727 720

Dove 713 190 mm (7.5 in) L727 722

Grosbeak 816 190 mm (7.5 in) L727 724

Drake 1020 280 mm (11 in) L735 725

Cardinal 1222 280 mm (11 in) L735 727

Bit tern 1572 280 mm (11 in) L735 728

13. SPLICE INSTALLATION INSTRUCTIONS:

13.1.The ACCC cable splice assembly kit includes the following: Two threaded internal collethousings, two collets, splice coupling, collet retainer, two aluminum inner sleeves, outeraluminum sleeve, Penetrox A13 and sanding medium.

13.2.Remove prescribed amount of aluminum stranding from core. (See table) This is bestdone with a circumciser do to the fact that the core can not be nicked or damaged in anyway. The exposed end of the core needs to be cut very cleanly. This is best done with ahacksaw. Failure to fol low these instructions cou ld result in a failed connection.

13.3.Lightly sand the exposed core with the sanding medium provided in the kit.

13.4.Clean and remove any dirt or particulate matter off of the exposed core with clean clothand suitable solvent.

13.5.With the tapered end of the inner sleeves facing the end of the conductor, slide them overeach conductor about three feet.

13.6.Slide the outer sleeve over one side of the aluminum conductor with the end of the tubeabout two feet from the cut end of the conductor.

13.7.Slide the collet housing with the wrench flats toward the aluminum strands onto the coreand butt it against the aluminum strands.

13.8.Install the collet with the narrow end towards the housing onto the core, leaving inch ofthe core exposed from the wide end of the collet.

13.9.Install the coupling on one side and the collet retainer on the other side and hand tighten.Complete the tightening with wrenches to 85 ft lbs of torque. Ensure that approximatelyone inch of the core at the narrow end of the collets is visible.

13.10.Turn the pre-assembled coupling to release. Bring the two sides together and handtighten. Complete tightening with the wrenches.


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13.11.Thoroughly w ire brush the aluminum strands and apply the Penetrox A13 alongthe brushed length of the aluminum strands. Rebrush the surface allowing thePenetrox inhibitor to penetrate the spaces between the strands. Slide the aluminumouter sleeve towards the eye.

13.12.Liberally apply Penetrox A13 to the outer diameter of the aluminum inner sleeves, andslide the inner sleeves into the outer sleeve all the way to the stop point.

13.13.Crimp using a 60 ton press with the prescribed die size (see Table 3). The crimps needto overlap in the area marked on the aluminum outer sleeve. The direction of crimpingmust always start at the center of the splice assembly and crimp out towards the span

length of the conductor. You must never back press splice fitt ings.


Table 3 Compression Splice

ACCCkcmilExposed Core length

mm (in)

Installation Tooling(not included)

Y60BHU or Y60BHU-D

Hydraulic HYPRESSSplice Die Set

Linnet 431 190 mm (7.5 in) L727

Hawk 611 190 mm (7.5 in) L727Dove 713 190 mm (7.5 in) L727

Grossbeak 816 190 mm (7.5 in) L727

Drake 1020 280 mm (11 in) L735

Cardinal 1222 280 mm (11 in) L735

Bit tern 1572 280 mm (11 in) L735

14. JUMPER INSTALLATION INSTRUCTIONS:14.1.To reduce the potential of forming birdcaging in the aluminum strand wires between the

two bolted jumper fitting ends, one end is crimped in the normal fashion while the otherend is back pressed. Jumper connections are designed only for non-tension applicationsand must never be put under a mechanical tension load.

14.2.The ends of the ACCC conductor are cut flush with the core left in place.14.3.Thoroughly wire brush the top layer of aluminum strands with Penetrox A13 along the

brushed length of the aluminum strands. Rebrush the surface with additional Penetroxallowing the inhibitor to penetrate the spaces between the strands.

14.4.For the first end of the jumper, slide the conductor into the barrel of the jumper.14.5.Crimp using a 60 ton press with the prescribed die size (see Table 2). The crimps need to

overlap in the area marked on the aluminum jumper. The direction of the crimping mustalways start at the four bolt connector end of the fitting and crimp out towards the exposedconductor.

14.6.For the second end of the jumper, slide the conductor into the barrel of the jumper and,using a marker pen, mark the conductor where it sticks out of the fitting. Pull the


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conductor back 1 inch. Crimp using a 60 ton press with the prescribed die size (see Table2). The crimps need to overlap in the area marked on the aluminum jumper. The directionof crimping is reversed and will start at the conductor end of the fitting and crimp downtowards the four bolt pad. This technique is known as back pressing. Back pressingmust never be used for deadends or conductor splices where a mechanical load tension isgoing to be applied on the conductor.


Connector Notes:

Compression fittings are used for dead-ends and splices. (See ACCC Cable Dead-end and SpliceInstallation Guidelines.) Because the aluminum strands are annealed TW, installation ofcompression dead-ends or splices may cause conductor distortion and minor birdcaging. Thesecan often be repaired satisfactorily by reshaping with a small wooden block or a piece of rubberhose. Installation techniques can also be modified to minimize the potential for birdcaging to form.It is suggested that the location of any grips (20 hoists) and/or grounding clamps be safelyattached as far downstream from the end of the dead-end as possible in order to allow formaximum travel of the extruded trapezoidal aluminum strands. FAILURE TO FOLLOW THESEINSTRUCTIONS COULD RESULT IN A POOR CONNECTION.

15. ANCILLARY HARDWARE:15.1.For assistance with appropriate ancillary hardware selection, such as dampers,

suspension clamps, and armor-rod, please contact CTCs engineering department or yourpreferred hardware supplier.

15. CONDUCTOR SAGGING:

15.2.ACCC cable is sagged the same as conventional ACSR (Aluminum Conductor SteelReinforced).

15.3.Standard sight, return wave, transit, and dynometer methods are applicable for saggingthe ACCC conductor.


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16. LEGAL NOTICES:

PLEASE READ THESE LEGAL NOTICES CAREFULLY.

Disclaimer: This guide provides suggestions for methods, equipment and tools that have beenfound practical based on field testing of CTCBrandACCC cable and accessories. ACCCcable requires some specific shipping, handling, storage and installation procedures. Unliketraditional ACSR cables that have a steel core,ACCCcable consists of a composite core strengthmember surrounded by one or more layers of conductor. Due to the structure of theACCCcable,

theACCCcable cannot be handled in accordance with some of the techniques used to installother overhead transmission line conductors. These guidelines are meant to provide proceduresthat will help provide a high quality, trouble-free installation so that theACCCcable, once installed,will perform its intended function. Failure to follow these guidelines may cause a hazardouscondition or result in premature line failure.

The information contained herein or related hereto is intended for evaluation by technically skilledpersons, with any use thereof to be at their independent discretion and risk. Such information isbelieved to be reliable, but the accuracy or completeness thereof is not guaranteed. The userassumes all risks and liability whatsoever in connection with such use.

WARNING: A potential for electrical shock exists when using cables energized with electrical

power. Use appropriate safety procedures.

COMPOSITE TECHNOLOGY CORPORATION SHALL NOT BE LIABLE TO THE USER OR ANYOTHER PERSON UNDER ANY LEGAL THEORY, INCLUDING BUT NOT LIMITED TONEGLIGENCE OR STRICT LIABILITY, FOR ANY INJURY OR FOR ANY DIRECT, INDIRECT,INCIDENTAL OR CONSEQUENTIAL DAMAGES SUSTAINED OR INCURRED BY REASON OFTHE USE OF ANY OF COMPOSITE TECHNOLGY CORPORATIONS PRODUCTS.

Trademarks and Copyrights

2006 by Composite Technology Corporation. All rights reserved. CTC andACCC aretrademarks of Composite Technology Corporation. Any use of Composite TechnologyCorporations copyrights or trademarks require written approval from Composite TechnologyCorporation. Such permission may be obtained from Composite Technology Corporationsheadquarters in Irvine, California.

Additional Information

Composite Technology Corporation reserves the right to make changes in specifications or otherinformation contained in this document without prior notice. Composite Technology Corporation isnot responsible for typographical errors contained herein.

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