Ohe Fitting Guideline
Ohe Fitting Guideline
Ohe Fitting Guideline
MINISTRY OF RAILWAYS
TECHNICAL SPECIFICATION
FOR
25 kV A.C. OHE FITTINGS
0.0 SCOPE:
2. SERVICE CONDITIONS:
2.1 The fittings shall be suitable for outdoor use in moist tropical
climate and areas subjected to heavy rainfall and severe lightening
in India. The limiting weather conditions which the fittings have to
withstand in service are indicated below:
(i) Maximum temperature of air in shade 450c
(ii) Minimum temperature of air in shade 00c
(iii) Maximum temperature attainable by an 65.50c
object exposed to sun
(iv) Maximum relative humidity 100%
(v) Average annual rainfall Raining from
1750 to 6250 mm
(vi) Maximum number of thunder 85
storm days per annum
(vii) Maximum number of dust storm 35
days per annum
(viii) Number of rainy days per annum 120
(ix) Basic wind pressure 200 kgf/m2
(x) Altitude not exceeding
1000 m
3. REFERENCE SPECIFICATIONS:
Reference has been made to the following Indian, International
and ‘RDSO’ Standards in this Specification.
4.1 The fittings shall be free from defects which are likely to be
detrimental to their performance in service.
4.2 Aluminium bronze, tin bronze and aluminium alloy cast fittings
shall preferably be made by pressure die-casting process. The
castings made out of other processes like gravity die-casting
shell moulding/investment casting by lost way method shall also
be acceptable so long as fittings/test bars meet all the necessary
mechanical and Electrical properties specified in relevant
Specifications. Sand casting for these cast fittings are not
acceptable.
4.3 Steel/Stainless steel bolts, nuts and washers shall conform to
RDSO Specification No. TI/SPC/OHE/Fasteners/0120. Non-
ferrous bolts/nuts shall not be used.
4.4 All parts of the fittings shall be manufactured by the
manufacturer in his works. Components such as fasteners,
washers and Split pins which form part of the fittings shall be
obtained from the approved manufacturers with the specific
approval of the Central Organization for Railway Electrification.
The supplier of the assembly shall ensure that such bought out
components conform to the relevant specification.
4.5 PROTECTION AGAINST CORROSION:
5.1.2 Non-ferrous cast fittings for different type, category and rating,
if manufactured out of same melt shall be considered as one
lot.
5.1.5 Chemical analysis test for Ferrous OHE fittings shall be conducted
on boring of anyone of the sample fittings drawn from the lot
instead of complete fittings/part of the fittings. Boring can be
sent for Chemical test instead of sending complete fittings/part
of the fittings.
5.2 Castings-
If the weight of the fittings is not more than one kg, a lot
shall consist of pieces making upto a weight of not more than
200 kg. If each fitting weighs more than one kg, a lot shall
consist of pieces making upto 500 kg for non-ferrous fittings and
1500 kg for ferrous fittings.
5.2.1 The lot size of following ferrous OHE fittings for Chemical test will
be 500 Nos (Maximum):-
The lot sizes for other ferrous OHE fittings will remain unchanged.
5.2.2 The lot size of following ferrous OHE fittings for Chemical
test will be as under:
5.5.1 The lot size of following non-ferrous copper strips for chemical test
will be 1000 Nos (Maximum):-
The lot sizes for other Non-ferrous OHE fittings will remain
unchanged.
5.5.2 The lot size for following non-ferrous copper fittings for Chemical
test will be as under:
6.0 TESTS:
6.1 Tests have been specified according to the material and functional
requirement of the fitting and are required to be conducted to
determine conformity to the material Specification and
requirements of the fitting.
6.2 Classification of test and criteria of acceptance:
The tests are divided into three groups:
i) Type tests
ii) Acceptance tests
iii) Routine tests
6.2.1 Type tests: Type test are intended to establish the general
qualities and design characteristics of the fittings and to prove its
conformity with the requirements of Specification. The type tests
are to be conducted only after all the designs and drawings have
been approved and clearance given by RDSO/Purchaser to this
effect the manufacturer shall then take up the manufacture of
the prototype for RDSO/Purchaser inspection. It is to be clearly
understood that any change required to be done in the prototype
as required by RDSO/Purchaser shall be done expeditiously. Each
test shall be made on 3 samples. If the sample fails in any of the
tests the production of further fittings shall be stopped till further
investigation and improvements in the manufacturing procedure
done.
7. MATERIAL SPECIFICATION:
7.1 Aluminium Bronze: Aluminium bronze alloy used for the
fittings shall conform to IS: 3091-1999. The relevant extracts of
the specification are given in Appendix ’A’.
7.2 Malleable cast iron: The malleable cast iron fittings shall
conform to Grade BM: 340 of IS: 14329-1995. Relevant extracts
of the specification are given in appendix- ‘B’.
7.3 Tin-bronze: The tine bronze fittings shall conform to the IS:
306-1997. The relevant extracts are given in Appendix ‘C’.
7.4 Aluminium alloy: The aluminium alloy fittings shall conform to
Grade 4600 of IS: 617-2003. The extracts are given in Appendix
‘D’.
7.5 Forged steel: The material of forged steel fittings shall conform
to class 2 of IS: 2004-1991, unless otherwise specified. The
relevant extracts are given in Appendix ‘E’.
7.6 Fabricated steel: The material of fabricated steel fittings unless
otherwise stated on the drawings shall conform to Grade A of IS:
2062-2011. The relevant extracts are given in Appendix ‘F’.
7.7 Copper strip fittings: The material of fittings formed by copper
strip shall conform to IS: 1897-2008. The relevant extracts are
given in Appendix ‘G’.
7.8 Aluminium or aluminium alloy strips/sheets: The material of
strips shall conform to Grade 52000, condition H2 of IS: 737-
2008. The relevant extracts are given in Appendix ‘H’.
7.9 Spheroidal Graphite Cast Iron (SGCI) OHE Fittings: The material of
SGCI fittings shall conform grade SG 400/15 of IS: 1865-1991 &
Chemical Composition, Physical Properties including Hardness shall
conform to the relevant extracts are given in Appendix ‘L’.
Note:
“Electrical Resistivity test specified under Para-9of IS:1897-2008
shall not be applicable for catenary dropper clip(RI-1192) and
bridle wire dropper clip(RI-1194)”
7.9 Due to non-availability of flat size M12x35 mm, the flat size
M12x38 mm can be used in lieu, for following fittings:-
8.1 Fittings for clamping the conductors, which are in tension, at the
ends & their mid-span splices are called end clamps and tension
joints respectively and are covered in this group.
8.4 The fitting may be bolted type, cone type, wedge type or
compression type, as specified in purchaser’s drawing.
8.5 Tests:
8.5.1 Type Tests:
a) Visual inspection (see Cl.11.1)
b) Dimensional verification (see Cl.11.2)
c) Chemical composition test (see Cl.11.3)
d) Physical properties test (see Cl.11.4)
e) Failing load test (see Cl.11.5)
f) Radiographic test (only for castings) (see Cl.11.6)
g) Electric resistance test
(For splices only) (see Cl.11.8)
h) Temperature rise test
(For splices only) (see Cl.11.9)
i) Galvanising test (for ferrous
Fittings only) (see Cl.11.10)
j) Dye penetration test (see Cl.11.12)
k) Hardness test (for MCI & SGCI fittings) (see Cl.11.14)
9.1 Non-Tension Joints: The fittings used on the overhead conductors for
electrical continuity which are not subjected to tension are classified as
non-tension joints. Such fittings include parallel groove clamps and
terminal clamps of jumper assemblies.
9.4 Non-tension joint fittings are generally of bolted type, though there
may be some fittings of crimped type or soldered type. All fittings are
subjected to the tests as specified in relevant paras of this specification.
9.5 Tests:
9.5.1 Type Tests:
a) Visual inspection (see Cl.11.1)
b) Dimensional verification (see Cl.11.2)
c) Chemical composition test (see Cl.11.3)
d) Physical properties test (see Cl.11.4)
e) Radiographic test
(Only for castings) (see Cl.11.6)
f) Slip test (see Cl.11.7)
g) Electric resistance test (see Cl.11.8)
h) Temperature rise test (see Cl.11.9)
i) Dye penetration test (see Cl.11.12)
10.1 Fittings which are used on the cantilever assembly and the
suspension of suspension of conductors are covered in this group.
10.2 General Requirements:
The clamps and fittings shall be so designed and manufactured that the
effect of vibrations, both on the conductors/cantilever assembly and
fitting itself, are minimized.
10.3 Tests:
10.3.1 Type tests:
a) Visual inspection (see Cl.11.1)
b) Dimensional verification (see Cl.11.2)
c) Chemical composition test (see Cl.11.3)
d) Physical properties test (see Cl.11.4)
e) Failing load test (see Cl.11.5)
f) Radiographic test (see Cl.11.6)
(Only for casting)
g) Slip test
(Only for suspension clamp). (see Cl.11.7)
h) Galvanising test (for ferrous
Fittings only) (see Cl.11.10)
i) Assembly test (for contact wire
Dropper clip and swivel clips only) (see Cl.11.11)
j) Dye penetration test (see Cl.11.12)
k) Hardness test (for MCI & SGCI fittings)(see Cl.11.14)
11.5.1For Conductor End Clamps, Mid Span Tension Joints and Splices.
11.5.1.3 The tensile load shall then be increased until the conductor
either slips out of the fitting under test or snaps or one or more of the
component(s), of the fitting fracture or deform.
11.5.1.4 The fitting shall not break, slip or deform till the conductor
breaks. Should the wire or conductor slip in the fitting or any component
of the fitting fractures or deforms before the failure of conductor the
fitting shall be deemed to have failed in the load test. If the conductor
breaks at a load less than 95% of its specified breaking strength, the test
shall be repeated.
FIGURE-1
11.7.2.1 The joint shall be assembled using the connector under test on
conductors of the size with which it is to be used. The assembly shall be
mounted in a tensile testing machine and anchored in such a way that
the test load is applied in the direction of the conductor.
CONECTOR
FIGURE-3
11.9 Temperature Rise Test:
11.9.2 The temperature rise test for power connectors shall be made
with alternating current at an average frequency not below 95% of the
rated frequency.
11.9.3 The connector shall be assembled indoors on conductors of the
size and type with which it is to be used. Air shall be freely circulated
around the assembly, but no draughts shall be allowed.
11.9.4 Each test shall be made over a period of time sufficient for the
temperature to reach a constant value (for practical purposes, the
condition is attained when the variation does not exceed 1oC/hour).
Temperature measurement shall be made using either thermometer or
thermocouple.
11.9.5 The temperature-rise shall not exceed 40 degree C above the
reference ambient temperature of 45 degree C. If the ambient
temperature exceeds 45 degree C the permissible temperature rise shall
be reduced by an amount equal to excess ambient temperature.
12. Marking:
12.1 For the purpose of identification, the following marking shall
invariably be made/cast on each fittings/castings.
i) Manufacturer’s code number
ii) Railway Identification No. (R.I. No)
iv) The month and year of production shall invariably be indicated
on the fittings/castings. If it is not possible to accommodate
any particular marking on the fittings/castings, the
manufacturer shall obtain prior approval of the purchaser to
delete the markings or to make the marking by any other
suitable means.
12.2 It is desirable that a code giving the lot or melt number is also cast
or engraved on each casting to facilitate the identification of lot
number of each fittings. Alternatively, the month and year of
production may be provided during casting.
12.3 In case of fabricated fittings marking shall be punched on such
fittings prior to the galvanisation so that not only the markings are
clearly visible after galvanisation, but also there is no damage to the
galvanised surface.
12.4 A lable indicating the inspectors code number and date shall be fixed
indelibly on every fitting immediately after tests and inspection.
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APPENDIX -‘A’
A.2 The manufacturer shall supply free of charge a copy of his works
analysis of the material. Works analysis may be defined as the routine
analysis conducted by the manufacturer in order to control the quality of
material.
A.3 Casting shall be clean, sound and free from harmful inclusions. Any
castings may subsequently be rejected due to manufacturing defects, not
withstanding the fact that it had been previously passed for Chemical
Composition and Mechanical properties.
A.4 The material when tested in accordance with IS: 2654-1977** shall
have the tensile properties given in Table-3.
TABLE-3:
TENSILE PROPERTIES OF ALUMIANIUM BRONZE INGOTS AND CASTINGS.
A.5.1 Three cast to shape test pieces (fig.4) shall made for each lot.
The test bar shall be identified with lot and date of melt.
FIGURE-4
A.5.3 One test piece shall be tested. If the mechanical properties are
met by this one test, the lot shall be accepted. If the first test piece fails
to conform to the specified requirements, the two remaining test pieces
shall be tested, and if either of them fails to meet the specified
requirements, the whole lot shall be rejected.
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APPENDIX- ‘B’
B.2 Micro-structure.
B.2.1 The material shall be free from primary graphite and shall not
contain free cementite or pearlite in a from or amount detrimental to the
physical properties of machinability of the casting.
B.3.2 Test bars shall be cast in green or sand moulds of the same
materials as the moulds used for the castings they represent. They shall
be cast in the same time and from the same melt as the casting they
represent.
B.3.3 Test bars shall in all cases undergo the melleabilising heat
treatment being together with the casting they represent.
B.3.4 In the event of any further heat treatment being given to the
castings, to meet the requirements provided under B-4, the test bars
shall be suitable heat treatment along with the casting they represent.
B.3.5 Tensile test bars shall be cast to the dimensions specified in
figure-5. The dimensions of the shanks may be modified to suit the jaws
of the testing machine.
FIGURE-5
B.3.6 The cast tensile test bars may be dressed or cleaned and shall
be tested in the un-machined condition.
B.4 Mechanical tests:
B.4.1 Tensile test: A tensile test bar, cast as for as practicable to the
dimensions shown in figure-5 shall when tested in accordance with IS:
1608-2005 without machining the gauge length, give results not less
than those specified in table-4. Since the test bars are in un machined
state. They may not be quite circular, in which case the tensile strength
shall be calculated on the mean diameter at the middle of the gauge
length by taking two measurements at right angles, one of which shall be
maximum diameter.
TABLE-4: TENSILE PROPERTIES OF BLACK MEART MALLEABLE IRON
CASTINGS.
SECTIONAL DIAMETER TENSILE 0.2% ELONGATION
THICKNESS OF TEST STRENGTH PROOF (L0=3D)
REPRESENTED BAR (mm) N/mm2 STRESS
(min.)
(mm) (D) (Kgf/mm2) N/mm2
2 percent
(Kgf/mm )
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APPENDIX- ‘C’
CONSTITUENTS PERCENT
(castings)
Tin 9.5-10.5
Zinc 1.5-3.0
*Lead, Max. 1.5
Nickel, Max. 1.0
Iron, Max. 0.15
Aluminium, Max. 0.01
Silicon, Max. 0.02
Bismuth. Max. 0.03
Total impurity Max.(include iron, Aluminium, Arsenic, 0.50
Antimony, Silicon, Bismuth)
Copper Remainder
FIGURE-6
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APPENDIX-‘D’
Tensile Steangth
Sand cast, N/sq mm (kgf/sqmm) 165(16.5)
Chill cast, N/sq mm (kgf/sqmm) 190(19.0)
Elongation (percent)(on 5.65_/¯So or 50 mm gauge length
Sand cast 5
Chill cast 7
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*IS: 504-2000: Method of Analysis of Aluminium and its Alloys.
D-2 Sample for Mechanical Tests of Castings.
D-2.1 The metal for the test sample shall be taken from the crucible
or ladle from which, the castings are poured and shall not be
subjected to any further treatment other than adjustment of the
temperature to that suitable for pouring.
D-3.3 Should a test piece break outside the middle half of the gauge
length, test may at the option of the supplier be discarded and another
test made.
*IS: 1816-1979 Method for tensile test for light metals and their alloys.
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APPENDIX- ‘E’
Note: When the steel is Aluminium killed or killed or killed with both
Aluminium and Silicon, the requirement of minimum Silicon
content shall not apply. For Aluminium killed steel the total
Aluminium content shall be within 0.02 to 0.05 percent.
*IS: 1762 (Pt-I) - 1974: Code for designation of Steels- based on the
letter Symbols.
IS: 228: Method for Chemical Analysis of steel.
E-1.2 Check Analysis: The purchaser may specify check analysis
on finished forgings. The number of samples on which the
analysis has to be carried out shall be at the rate of one sample
per cast per section.
Note: Variations shall not be applicable both over and under the
specified limits in several determinations in a heat.
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APPENDIX- ‘F’
Structural Steel- Extracts from IS: 2062-2006.
F.2.1.3 The gauge lengths other than 5.65_/So may also be used in
which case the elongations shall be read from IS: 3803 (Pt-1) – 1989*.
Grade Designation Tensile Yield strength Min. MPa Elongation Bend test
strength (Kgf/mm2) percent (Internal
Min. 2<20 20-40 >40 Min (In DIA) Min.
MPa mm mm mm gauge
length)
(Kgf/mm) 5.65_/So
A Fe410W A 410 250 240 230 23 3t
(42) (25.5) (24.5) (23.5)
B Fe410W B 410 250 240 230 23 2t for less
(42) (25.5) (24.5) than or
(23.5) equal to 25
mm
thickness.
3t for more
than 25 mm
thick
products.
C Fe410W C 410 250 240 23 2t
(42) 230
(25.5) (24.5)
(23.5)
‘t’ is the thickness of the material.
F.2.2.3For bend test, the test piece at room temperature shall withstand
bending through 180 Deg. to an internal diameter not greater than that
given in Table-10.
F.3 Relevant extract from IS: 1608-2005:
FIGURE-8
Note-2: Test pieces with diameters other than these given in this table
may be used provided that the gauge length Lo=5.65_/So.
Note-1: Not withstanding the above, test pieces having a gauge length
equal to 5.65 so are permitted.
Note-1: Dimensions of the ends of the reduced section of test pieces should
not differ in width by more than 0.1mm.
Note-2: For rectangular section test pieces machined on the four faces,
same tolerances as for diameter of circular section test pieces shall apply.
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APPENDIX-‘G’
G.2.1 The material when tested in accordance with IS: 3260-1965# and
IS: 2654-1977+ shall have the Physical Properties as given in Clause 7.2 &
7.3 respectively.
FIGURE-9
G.3.2 The Test Pieces shall not crack when bent once through the
appropriate angle as specified below:-
BEND TEST
Thickness Condition Bend Test
Transverse or Longitudinal
Angle in Degree Radius
Upto and Annealed(O) 180 Close
including 10 Half hard(HB 180 t
mm Hard(HD) 90 t
t is the thickness
G.3.3 The Test pieces shall be of conventent length and the width
shall be as follows:
Thickness Width
G.4.2 Test pieces of full thickness of the material with a gauge length
4_/Area or 50 mm shall be used. The longitudinal axis of the test piece
shall be in the direction of rolling.
TABLE-15: TENSILE PROPERTIES OF STRIP
Thickness Temper Upto and including 300 Over 300 mm upto and
mm width including 1000 mm
width
Over Upto & Tensile Elongation Tensile Elongation
mm including Strength % on Strength % on
mm kgf/mm² 4√Area or kgf/mm² 4√Area or
(Min.) 50 mm (Min.) 50 mm
Gauge Gauge
Length(Min.) Length(Min.)
0.50 2.50 Annealed(O) 21.0 35.0 21.0 35.0
Half 25.0 10.0 25.0 10.0
hard(HB
Hard(HD) 31.5 - 29.0 -
2.50 10.0 Annealed(O) 21.0 35.0 21.0 35.0
Half 25.0 15.0 25.0 15.0
hard(HB
Hard(HD) 30.0 - 28.0 -
G.5.1 The standard values at 20°c for the Electrical Resistivity of annealed
high conductivity copper shall be taken as 0.01724 ohm mm 2 /m. The
Electrical Resistivity of strip shall be measured in accordance with IS:
3635-1966*. The Electrical Resistivity values are given in Table-16.
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APPENDIX-‘H’
A. Chemical composition:
(Values given are in percent, Maximum unless shown otherwise)
H.2.1 Tensile Test and proof stress- Tensile test shall be carried out and
proof stress determined thereby in accordance with a IS: 1816-1979. The
values obtained shall comply with the requirements given in Table-17.
H.2.2 Bend Test: The bend test piece less than 15 mm wide of
convenient length and cut with its longer axis transverse to the direction of
rolling. The longer edges shall be carefully rounded and smoothened
longitudinally, so that the cross section of the test piece has approximately
semi-circular ends.
H.2.2.1The test piece may be bent by hand to a U-form and the piece thus
obtained shall subsequently be closed in a vice until the inner surface of
the test piece are twice the thickness (of strip) apart.
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IS: 1816-1979: Method for tensile test for light metals & their Alloys.
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APPENDIX-‘J’
List for fittings on which dye penetration test is required to be carried out as
routine test.
5. Clevis 5041
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APPENDIX ‘K’
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APPENDIX ‘L’
SPECIFICATI
S.N. C% Si % Mn % S% P% Mg % Cu%
ON /Grade
L.2 Micro-structure.
L.2.1 The micro structure of the material shall be as per IS: 7754:1975
L.3.1 Provision of test bars-All test bar shall be cast separately. They shall
be suitably marked so that the castings they represent could be identified.
L.3.2 Test bars shall be cast in green or sand moulds of the same materials
as the moulds used for the castings they represent. They shall be cast in
the same time and from the same melt as the casting they represent.
L.3.3 Test bars shall in all cases undergo the melleabilising heat treatment
being together with the casting they represent.
L.3.4 In the event of any further heat treatment being given to the
castings, to meet the requirements provided under L-4, the test bars shall
be suitable heat treatment along with the casting they represent.
L.3.5 Tensile test bars shall be cast to the dimensions specified in figure-
10. The dimensions of the shanks may be modified to suit the jaws of the
testing machine.
L.3.6 The cast tensile test bar shall be dressed or cleaned and shall be
tested in the machined condition as per clause No. 10.1.2 of IS: 1865-
1991.
L.3.6 The cast tensile test bars may be dressed or cleaned and shall be
tested in the un-machined condition.
L.4 Mechanical tests:
L.4.1 Tensile test: A tensile test bar, cast as far as practicable to the
dimensions shown in figure-5 shall when tested in accordance with IS:
1608-2005 without machining the gauge length, give results not less than
those specified in table-4. Since the test bars are in Un- machined state.
They may not be quite circular, in which case the tensile strength shall be
calculated on the mean diameter at the middle of the gauge length by
taking two measurements at right angles, one of which shall be maximum
diameter.
TABLE-4: TENSILE PROPERTIES OF SGCI CASTINGS.
GRADE SECTIONAL DIAMETER TENSILE 0.2% ELONGATION
DESIGNATI THICKNESS OF TEST STRENGTH PROOF (L0=3D)
ON REPRESENTED BAR (mm) N/mm2 STRESS*
(min.)
(See (mm) (D) (Kgf/mm2) N/mm2
percent
IS:1965- (Kgf/mm2)
1991)+
SG 400 All size 15 400(40.8) 250 15
(25.5)
* 0.2% Proof Stress 250 N/mm2 shall not be applicable in case of
acceptance test.
L.5 Hardness test:
L.5.1 Casting of grade SG-400 produced according to this standard
shall have hardness between 130-180 HB. In case of higher side of
Hardness up to 200 HB should also be acceptable with meeting the
physical properties as IS: 1865-1991.
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* IS: 228-1959: Methods for chemical analysis of the steel.
** IS: 1608-2005: Method for tensile testing of steel products.
+ IS: 4843-1968: Code for designation of ferrous castings.
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