JournalThe International, Interdisciplinary Society Devoted to Ocean and Marine Engineering, Science, and Policy Volume 47 Number 6 November/December 2013

Diving Technologies and Techniques for the 21st Century Volume 47, Number 6, November/December 2013 Diving Technologies and Techniques for the 21st Century Guest Editor: Michael Lombardi

Front Cover: J.F. White Contracting Company diver test pilots the Exosuit Atmospheric Diving System (photo by M. Lombardi). Back Cover: Background image–Scientific diver Jeff Godfrey (UConn) explores the vertical Mesophotic In This Issue coral ecosystem using a mixed-gas (photo by M. Lombardi, courtesy of National Geographic 5 64 Society/Waitt Grants Program). Thumbnail images, Guest Editor’s Introduction Manufacturing Imperfection Sensitivity clockwise from top left: PVC structure for mounting camera for benthic surveys (photo by Barrett Brooks); Michael Lombardi Analysis of Spherical Hull HUD system from Sieber et al. paper, this issue; Figure 4 for Manned from Clark paper, this issue; Rebreather prototype from 7 Bhaskaran Pranesh, Dharmaraj Sieber et al. paper, this issue; Portable inflatable habitat Sathianarayanan, Sethuraman Ramesh, deployed to augment lengthy (photo by Long-term Methods for High-Definition and Gidugu Ananda Ramadass M. Lombardi, courtesy National Geographic Society/Waitt Image Maps of Benthic Surveys Grants Program). Laurie Penland, Barrett Brooks, 73 and Edgardo Ochoa A New Generation of ADS Capabilities 16 James F. Clark A Diver’s Automatic Control 80 Device and Its Prototype Development Take Me Back Down: The Best “Over Darko Valenko, Zdenko Mezgec, the Counter ” Remedy for DCIs Martin Pec, and Marjan Golob Joseph Dituri 27 83 Compact Recreational Rebreather with Book Review Innovative Gas Sensing Concept and Low Work of Loop Design Arne Sieber, Andreas Schuster, Sebastian Reif, Michael Kessler, Index to Volume 47 Thomas Lucyshyn, Peter Buzzacott, Text: SPi and Peter Enoksson Cover and Graphics: 84 Michele A. Danoff, Graphics By Design 42 Author Index Head-up Display System for The Marine Technology Society Journal 86 (ISSN 0025-3324) is published by the Marine Technology Closed-Circuit Society, Inc., 1100 H Street NW, Suite LL-100 With Antimagnetic Wireless Subject Index Washington, DC 20005 Data Transmission 93 Subscription Prices (all prices include shipping): Arne Sieber, Andreas Schuster, MTS members can purchase the printed Journal for Sebastian Reif, Dennis Madden, 2013 Reviewers for MTS Journal $32 domestic and $110 international. Non-members and library subscriptions are $435 online only (includes 13 years and Peter Enoksson of archives); $460 for online with print (includes 13 years of archives); $135 print only within the U.S. and Canada, 52 $200 print only international. Single-issue (hardcopy) is An Experimental Deployment of a $20 plus $7.50 S&H (domestic), $24.50 S&H (international); Pay-per-view (worldwide): $15/article. Portable Inflatable Habitat in Open Postage for periodicals is paid at Washington, DC Water to Augment Lengthy In-Water and additional mailing offices. Decompression by Scientific Divers POSTMASTER: Michael Lombardi, Winslow Burleson, Please send address changes to: Jeff Godfrey, and Richard Fryburg Marine Technology Society Journal 1100 H Street NW, Suite LL-100 Washington, DC 20005 Tel: (202) 717-8705; Fax: (202) 347-4305

Copyright © 2013 Marine Technology Society, Inc. PAPER A New Generation of ADS Capabilities

AUTHOR ABSTRACT James F. Clark This paper presents a case study describing submerged work at Shaft 19 of the J. F. White Contraction Company, Delaware Aqueduct, which evolved to become the most complex atmospheric diving Framingham, Massachusetts (ADS) project ever undertaken. The limitations imposed by existing atmospheric systems are considered along with very significant improvements in ADS capability now being developed for both commercial and scientific diving. Background of For more than a century, ADS has offered the enticing potential of allowing men to CAT/DEL 210-G work effectively at great depths without suffering the effects of increased pressure. Unfortunately, early did not function well at depth, and pilots could be more n 2007, Depart- accurately described as observers peering through the small viewports of “diving ment of Environmental Protection I bells” outfitted with crippled appendages. The modern rotary joint was patented in (NYCDEP) awarded a $1.1 billion 1985 offering great promise, but even during the past 25 years, atmospheric diving contract to the SEW Joint Venture has remained specialized, underutilized, and largely left in the wake of remarkable (Skanska/Ecco/White) for construc- advances in and remotely operated vehicle (ROV) technology. tion of the largest drinking water treat- performed at Shaft 19 contributed to development of Exosuit™, ment facility ever built anywhere in the the next generation in atmospheric diving. Substantial improvements in mechanical world. This massive project, CAT/ suit design have been integrated with an optical fiber umbilical, computerized con- DEL 210-G, was designed to provide trol systems, and modern electronics to dramatically improve ADS capabilities. ultraviolet light disinfection for the The Exosuit itself can power multiple tools, a variety of hand pod end-effectors principal water supply to New York are presently maturing, and atmospheric diving may now be poised to assume far CityatasiteinWestchesterCounty greater significance in operations. where the Catskill and Delaware Aque- Keywords: Exosuit™, atmospheric , ADS ducts pass in close proximity. The Del- aware Aqueduct at this location is a deep rock tunnel, but during construc- jacent but deeper downtake shaft. This nized that this blow-off valve was no tion in the 1930s, the Board of Water interconnection was originally intended longer operational, and remotely oper- Supply (predecessor of NYCDEP) de- to allow gravity drainage of the up- ated vehicle (ROV) inspections per- signed a massive underground vault stream aqueduct tunnel by discharge formed during the project design phase structure as an accessible connection though the blow-off line, which could also revealed that it was not fully closed. to the aqueduct near ground level. It be controlled by a water hydraulic SEW was, therefore, directed to either was originally anticipated that water valve installed within a sump at the repair or permanently seal the blow-off treatment could be required someday base of the uptake. NYCDEP recog- system to prevent water from being in the future. After 75 years, the future shunted directly from the uptake into had arrived, and ultraviolet treatment FIGURE 1 the downtake shaft without passing was the process designated for the through the requisite ultraviolet treat- UV plant construction in 2010. main water supply to New York City ment process due to this unacceptable (Figure 1). cross-connection (Figure 2).

Underwater Inspection Operational Difficulties and Repair and Constraints At the outset of our work in 2010, a The Diving Division of J. F. White 16-inch blow-off line connected the Contacting Company was initially uptake shaft to the sidewall of the ad- tasked by SEW with the responsibility

November/December 2013 Volume 47 Number 6 73 FIGURE 2 then completely filled with grout. Depiction of shafts and interconnecting blow-off line. Phase 2: Install a special 250-lb (pressure rating) “oil field blind flange” on the intake flange of the 16-inch blow-off valve in the sump at the base of the uptake shaft. Mount a permanent bulkhead plate (5-feet square by 1-inch thick) on the curved wall of the downtake shaft to seal the discharge outlet from the blow-off line. Phase 2 sealed both ends of the blow-off line and was completed during the spring of 2011. Phase 3: Completely fill the blow-off line with 5,000 psi grout between the oil field blind flange and the downtake of developing appropriate underwater term durability, and security of the bulkhead plate. Phase 3 procedures for remediation of the water supply. Even after engineering de- was completed during the 16-inch bypass. All operations and cisions had been resolved for Shaft 19, fall of 2011. equipment had to accommodate a underwater operations had to be inte- This interrupted work schedule dictated variety of project-specificrequire- grated with other repairs within the multiple mobilizations and demobili- ments and constraints imposed by aqueduct system and coordinated with zations, but additional constraints im- NYCDEP. These challenges ultimately changing environmental conditions posed by NYCDEP also affected our influenced developments of a new gen- affecting water quality. underwater protocols. eration of Remediation of the blow-off sys- ■ Work hours were generally restricted (ADS) with improved capacity for scien- tem was undertaken in phases with between 2200 and 0600, 6 days per tific as well as commercial operations. the schedule restricted to intervals of week excluding Sundays. Opera- When work commenced at Shaft reduced water demand between October tions also had to respond on a 19, there appeared to be a possibility and May. daily basis to DEP interruptions de- that the blow-off valve could be re- Phase1: Exposeandinspectblow- termined by ambient or paired or perhaps actuated once to be off valve so that NYCDEP work in progress at other locations. fully closed and sealed. The valve was and consulting engineers ■ Available deck space at Shaft 19 was situated in a small sump beneath sedi- could develop remediation very limited, and numerous other ment, debris, and cast iron gratings at criteria. Phase 1 was per- topside construction activities had the bottom of the uptake shaft elbow; formed during the spring to be accommodated. The deck therefore, it was difficult to gain access and fall of 2010 and re- area was actually an “island” sur- and perform an evaluation. Once this sulted in a determination rounded by a 60-foot-deep ex- valve had been inspected, NYCDEP that the blow-off line cavation and accessible only by needed time to fully assess remediation would be permanently footbridge or crane lift for signifi- alternatives with respect to cost, long- sealed at both ends and cant loads.

74 Marine Technology Society Journal ■ All underwater equipment had to Decant water from all sediment to support simultaneous diving opera- be removed from the submerged extraction operations was pumped tions in both the uptake and downtake shafts after each work shift. Ulti- topside for off-site disposal. shafts during grout injection. Recur- mately, a support truss (Figure 3) Fines created by concrete drilling ring phases of mob/demob for a was allowed to remain underwater had to be filtered, contained, and saturation system would have been between shifts, but it was jacked removed from the shafts. expensive, and work postponements in place with a water hydraulic sys- All grout, slurry, and decant water imposed by NYCDEP water supply tem and then additionally tethered was contained and removed from requirements would also have been ex- by four synthetic fiber lines ten- the water supply. tremely costly. These considerations sioned to strong-back beams at Our initial project responsibility was made ADS the logical choice of diving deck level. to determine the underwater proce- system, but many unique challenges ■ Work performed at Shaft 19 had to dures and equipment that could best still had to be overcome. comply with NYCDEP water qual- accomplish the blow-off remediation ity regulations: safely, economically, and on schedule. All equipment entering shafts was disinfected in accordance with Management of American Water Works Associa- ADS Operations tion standards. Designation of Manned The selection of ADS for manned No wire rope was permitted to con- Diving System diving intervention was an easy deci- tact the water surface due to con- Our initial surveys at Shaft 19 were sion principally driven by economics, tamination by lubricants. undertaken by an inspection class but the appropriate integration of Only water-powered hydraulics Falcon ROV outfitted with a five- suit, support systems, and tooling were allowed underwater due to a function manipulator. This effort proved to be immensely more com- potential for contamination with identified the difficult tasks that plex. The evolution of this process ex- even benign hydraulic oils. Only would subsequently be required to posed many practical limitations of electrically powered launch and re- gain access at the blow-off valve and atmospheric diving for unique, com- covery systems or double encapsu- then implement a repair. ROVs pro- plex, and nonrepetitive applications. lated hydraulic units were allowed vided regular inspection capabilities On behalf of SEW, the CAT/DEL on deck. and very significant diving support 210-G joint venture general contrac- ■ All diving operations had to in- throughout the course of this project, tor, we initially attempted to engage corporate provisions to prevent but we determined at the outset that an ADS provider as a full-service sub- turbidity: remote vehicles alone could not per- contractor to perform all the atmo- Underwater debris was loaded into form all the operations that would be spheric diving work. After our initial closing containers lined with filter needed. Manned diving was required, ROV inspections, it became apparent fabric. and it could have been accomplished that the ADS systems would have either by saturation diving or ADS. to be equipped with special tooling, FIGURE 3 Atmospheric diving was clearly the unique installation fixtures would preferred economic choice. have to be designed and fabricated Support truss being lowered into downtake The restricted deck area of the within a very restrictive time frame, shaft. Shaft 19 “island” could not accom- and the ADS team would also have modate most saturation systems, and to be prepared to develop engineering significant engineering costs would adaptations on site in response to un- have also been incurred for the design foreseen problems. and refit of bell handling systems with One major ADS provider offered syntheticline(wirenotallowedby suits and pilots on a day-rate basis NYCDEP). Ultimately, a second bell butdeterminedthattheycouldnot and launch and recovery systems perform the specialized engineering would also have had to be deployed required for this project. Another

November/December 2013 Volume 47 Number 6 75 provider offered sophisticated design contractor when the water supply to team had to develop a variety of engineering, but they could not offer New York City was designated for ADS-compatible tooling and fixtures a convincing fabrication program for night shift shutdowns (2200–0600 h) to seal the blow-off piping (Phase 2) specialized underwater tooling or de- months in advance to facilitate the in preparation for the subsequent ployment of the construction oriented work. We were given, for example, grouting phase. ADS diving teams required. an interval of 6 months to design, fab- J. F. White was responsible for the R. T. (Phil) Nuytten, the principal ricate, and proof test a system for downtake support truss, downtake of Nuytco Research, Ltd., patented the mounting a 5-foot square stainless blanking plate, and alignment frame. modern rotary joint (Nuytten, 1985), steel bulkhead plate on the curved These fixtures were adjustable to ac- and he is widely recognized as the wall of the downtake shaft. This bulk- commodate discontinuities in the innovator most responsible for devel- head was intended to seal the 16-inch shaft, actuated by water hydraulic oping effective atmospheric diving blow-off line at the downtake shaft jacks or rams, and designed to position systems. We naturally contacted during grout injection. This might the blanking plate within a 0.025-inch Nuytco for ADS services; however, not have been difficult even at 400 ffw tolerance each time it was brought into they already had submersible opera- except for unusual constraints: position on the wall of the down- tions scheduled within the same time ■ The blanking plate had to be re- take shaft. The blanking plate and its frame. They could not deliver their moved and reinserted on a daily alignment frame were removed at the regular subsea products while addi- basis until eight preliminary mech- conclusion of each work shift until 8 of tionally fulfilling SEW demands for anical anchor studs could be prop- the total 30 stainless anchor studs (1 × field operations combined with the de- erly torqued to secure the bulkhead 16 inch) had been installed and sign, development, and fabrication of during normal aqueduct flow. We torqued to secure it permanently in po- multiple ADS tooling systems. were unable to install and torque sition. As the support frame was being It soon became apparent that there eight studs during a single work lowered during the beginning of each wasnosolesourceprovideroffering shift (8 hours between opening work shift, the ROV could set it on the comprehensive ADS capabilities and closing concrete shaft covers); the support truss and the ADS would within the time frame required by therefore, a triangular support make hose connections for the water SEW and NYCDEP. We, therefore, truss was allowed to remain under- hydraulic lines (Figures 3 and 4). developed an operational partnership water between shifts after being Concurrently, Nuytco Research by which the J. F. White Dive Division jacked in place with a water hy- developed the oil field blind flange teamed with Nuytco Research to pro- draulic system and additionally and practiced installing it by ADS on vide ADS capabilities and SeaView tethered by four synthetic fiber lines a full-scale valve mock-up in their test Systems to provide ROV support ser- tensioned to strong-back beams at tank. This mechanism was simple in vices to complete the underwater op- deck level. concept but required considerable erations at Shaft 19. This cooperative ■ The 1,200-lb blanking plate had practice and coordination with very effort resulted in successful project per- to be positioned during each shift skilled ADS pilots to seal the blow- formance for SEW and also directly within a tolerance of 0.025 inch, off flange during a single work shift contributed to development of the and all studs had to be drilled paral- (Figure 5). Exosuit™. lel, with axial run-out along the stud SeaView Systems developed and less than 0.010 inch despite the cur- fabricated electrically powered tooling vature of the concrete shaft wall. for core drilling, stud installation, and Performing ADS ■ The shaft wall was core drilled to torqueing the bulkhead nuts. This Operations accept 1 × 16-inch stainless steel machinery was designed around their Although the underwater work at mechanical anchor studs utilizing proprietary “backbone system” for Shaft 19 was only a minute component a custom-built electrical drill sys- integrated topside electronic control, of the overall SEW construction effort, tem, which also collected and ex- and each tool was configured to be it was critical in nature, and the sched- tracted drill fines. handled and engaged by ADS. The ule was very demanding. There was ab- In the 6-month interval following the topside electronics could adjust rota- solutely no flexibility available to the Phase 1 inspections, our underwater tion speed, torque, quill feed pressure,

76 Marine Technology Society Journal FIGURE 4 from the outset of this project that Lessons Learned ADS operations could be more quickly Blanking plate with alignment frame being Lessons learned during the under- lowered into downtake shaft. adapted to unforeseen conditions than water construction at Shaft 19 may an ROV. This proved true when well be applicable to similar pro- NYCDEP determined that a bronze jects as well as deep water (1,000 fsw) grate and debris within the blow-off science. If a project cannot be com- discharge line had to be removed rather pleted solely by ROVs and the work- than grouted in place. We were directed ing duration or depths encountered with only 24 hours of notice to remove are too great for bounce diving, a the grate at 405 ffw within the down- choice will probably be made between take shaft. This became a relatively saturation diving and ADS. The de- simple construction site mechanical cision will be determined by consid- problem because we had only to de- ering all the interrelated operational velop tooling that could be manipulated factors. by the ADS. Our blanking plate align- Mobilization for ADS diving is per- ment frame was quickly modified so haps an order of magnitude less expen- that the ADS could control an abrasive sive than a saturation spread, but that blade saw (Figure 6). disparity must be balanced against The deep diving work at Shaft 19 project duration and underwater work was successfully completed, and ADS requirements. was undoubtedly the best choice for Atmospheric diving suits can offer this underwater intervention. Our manned performance with respect to ADS costs are estimated between range of motion, manipulation, and FIGURE 5 25% and 35% of saturation diving dexterity that is perhaps 50–85% the when considering only the multiple ADS practicing in mock-up replicating sump capacity of a working gas or saturation mobilizations and time delays imposed and blow-off valve. diver. ADS capabilities improve to- by NYCDEP. Special engineering ward the higher end of that range costs associated with bell deployment into the active water supply would when special tooling can be developed further favor ADS. Even multiple work- and tested in advance. classROVscouldnothaveoperated ADS can successfully perform effectively in the limited visibility of many basic diver functions, but an at- Shaft 19 as the combination of ADS mospheric diving operation has to be with ROV support. supported with tooling developed for the anticipated tasks and adapted to function with the suit. Tooling for at- FIGURE 6 mospheric diving must be carefully planned as it is for ROV operations. Abrasive saw tested topside by ADS pilot, quill travel distance, and position by The tool must be integrated with the Doug Bishop. use of a touch-screen computer inter- atmospheric suit; it is not as simple as face. The SeaView rotary torque tool handing a new underwater tool to a gas was also deployed to actuate mecha- diver and expecting effective perfor- nisms on the sump blanking plate and mance. Tools can be standardized for the oil field blind flange. repetitive work, but unusual tasks un- Work-class ROVs can perform dertaken for construction or science very complex tasks, but the support will likely require special tooling and tooling and control systems must be pilot training to handle each specific developed in advance. We believed application.

November/December 2013 Volume 47 Number 6 77 Next-Generation ADS ■ During our work at Shaft 19, we pilot. The Exosuit utilizes a newly All diving at Shaft 19 was performed often had six synthetic tether lines designed rotary joint, which re- with the designed by Phil deployed in addition to the ADS duces friction under pressure by Nuytten in 1985 but now utilizing umbilical, ROV umbilical, water approximately 50% as compared technology nearly 25 years old and per- hydraulic supply line, and then an to previous ADS. Every pilot move- haps past its prime. Nuytco Research electrical power supply to each ment of the suit legs, arms, or hand had been gradually developing a new tool. The ability to power tools di- pods is more precise and less tiring. generation ADS, designated as the Exo- rectly from the Exosuit will be a sig- This flexibility will clearly assist po- suit, for a number of years prior to our nificant advantage for construction sitioning of the suit when working work for SEW in 2010 and 2011. ADS as well as scientific applications on bottom or in restricted areas. performance at Shaft 19 was so success- where suction motors for biological ■ Fiber Optics: The Exosuit umbili- ful that J. F. White placed an order for collection, drills for coral coring, or cal includes optical fiber in addition the first Exosuit. At the time of this special tooling for archaeological to power conductors and strength writing, this first Exosuit has passed specimen preparation could be di- members. This fiber provides data pressure testing certification to 1,400 fsw rectly powered from the Exosuit. transmission for high-definition and has been delivered to J. F. White. ■ Topside Control: Most modern video, , and other digital sensor It incorporates modern developments thruster-powered ADS have been systems. Voice transmission over in electronic control and optical fiber controlled with foot pedals leaving fiber is superior to copper, and un- data transmission with multiple me- the hand pods available for other like older suits, cabin life support chanical improvements gained during tasks. The Exosuit can be flown in data can be monitored directly by operational experience at Nuytco. this manner, but it can also be in- the topside supervisor without in- ■ Thrusters: Exosuit thrusters have dependently piloted by topside terrupting pilot attention to the approximately twice the bollard pull control. It could be utilized as an task at hand. of thrusters on the older Newtsuit. ROV equipped with its standard The Exosuit also incorporates many This added power can be a signifi- high-definition cameras if that de- small modifications that would go un- cant advantage working in a ployment proved advantageous, noticed by a general observer, but or applying to tooling. The but perhaps, more importantly, an they will be immensely appreciated maneuverability and positioning incapacitatedpilotcouldbeflown by pilots and will become obvious capability of the Exosuit is further around obstructions to safely clear during an assessment of work perfor- improved because forward and re- the umbilical for retrieval to the mance. The pilot’s range of vision verse thruster power is controlled surface. An inexperienced ADS through the new face dome is excep- by the speed and direction of rota- pilot with appropriate safety train- tional, slight modification of the torso tion, not by a variable pitch propel- ing but little suit time could also eases pilot entry into the arms, and ler as in older suits. This new ADS be flown by topside control to a hand pods have been improved and can be more easily flown by less particular work site. A skilled ar- include threaded mounting lugs to ac- experienced pilots and more accu- chaeologist, for example, could be commodate special tooling. In com- rately controlled by skilled divers. flown to a site where he would bination, these and other advances ■ Power Ports: The Exosuit includes only have to manipulate the ADS qualify the Exosuit as a new generation four additional power supply hand pods or specialized tooling of ADS, but they also set the stage ports, each capable of delivering ap- to evaluate a critical specimen. for development of additional capabil- proximately 1 hp. Additional thrus- ■ Suit Flexibility: Atmospheric div- ities (Figures 7 and 8). ters could be added to the suit to ing capabilities were very limited accommodate special circum- until invention of the rotary joint stances, but these ports also provide (Nuytten, 1985). Modern ADS New ADS Capabilities the capacity to run additional elec- then became practical for under- Nuytco Research is presently devel- tric tooling directly by a suit whip, water work, but friction in a joint oping a free- untethered not a separate power umbilical from exposed to pressure can limit suit version of the Exosuit. This capability the surface. dexterity and tire the working would be derived from the reduced

78 Marine Technology Society Journal FIGURE 7 FIGURE 9 hensor mechanism depicted above has been invented by Bhargav Gajjar of Newtsuit in operation. Prototype prehensor developed by Nuytco Research. Vishwa Robotics in Cambridge, MA.

Author: James F. Clark J. F. White Contraction Company 10 Burr Street, Framingham, MA 01701 Email: [email protected]

Reference FIGURE 8 Nuytten, R.T. 1985. U.S. Patent No. 4,549,753 entitled “Rotary Joint”; 29OCT85. Exosuit performing acceptance tests. FIGURE 10

Anthropomorphic ADS prehensor invented by Vishwa Robotics.

friction offered by ’s new replicating a human hand would pro- joint design and could benefit specific vide immense advantage underwater. scientific or military applications. Nuytco Research has been developing J. F. White and Nuytco Research their prehensor hand as depicted are both presently evaluating the ad- below, and concurrently, several vantages of mating an Exosuit with a other designs are emerging from robot- tether management system mounted ic and biomedical laboratories. It is aboard a small submersible. This com- probably a safe prediction that im- bination would be free of any umbili- proved hand mechanisms will be cal to the surface; incorporate the working underwater within the next capacity for self-rescue; and offer a few years (Figures 9 and 10). very capable platform for , science, or salvage. Atmospheric suits are usually Acknowledgments equipped with manipulators resem- The author wishes to express his bling pliers that can open, close, and appreciation to Nuytco Research, lock a grip. This limited dexterity Ltd., of , BC, and SeaView often slows a pilot’s work as compared Systems, Inc., of Dexter, MI, for to a gas diver and creates the need for their effort and cooperation during the special adaptive tooling. The develop- Shaft 19 project and other underwater ment of a manipulator more closely endeavors. The anthropomorphic pre-

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