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SPE 164666

Permanent Magnet Motor application for ESP Artificial Lift


Ahmed Refaie, Hesham A. M. Abdou, Ahmed Seleim, Giovanni Biasin, Agiba Pet. Co.
and Walid Reda, Dmitriy Letunov, Novomet Company

Copyright 2013, Society of Petroleum Engineers


This paper was prepared for presentation at the North Africa Technical Conference & Exhibition held in Cairo, Egypt, 1517 April 2013.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
The majority of Western Desert wells (Agiba Petroleum Company) are completed with artificial lift systems and several kind
of pump: ESP, Sucker Rod, PCP (about 40 ESP, 250 Sucker Rod and 10 PCP). A new technology - Permanent Magnet Motor
(PMM) - has been developed for ESP motors as alternative to conventional asynchronous induction motor in the last years.
PMM is synchronous motor in which the stator manufacturing technique is similar to that of conventional asynchronous
motor, but rotor has permanent magnets (instead of copper winding). PMM has more benefit of conventional induction motor:
high efficiency (90-94%) vs. induction motors up to 86%; smaller size and weight; wider ranges of rotation frequency
regulation (100-1000, 1000-4200 and 3000-6000 r.p.m.); reduced energy consumption and rating of surface equipment (Power
Saving); stable torque over wide operation range; Power factor is near to 1; lower specific heat release due to higher
efficiency. Also indirect benefits are: a) low heat release (minimum cooling fluid velocity 0.05 ft/s); b) less size for cable and
lower power rating for transformer and VSD; c) decreased reactive power; d) improved system Power factor. All Agiba ESP
wells are equipped with conventional induction motor. In the middle of June of 2012 Agiba performed a trial installation of
Novomet PMM replacing an ESP unit with induction motor on well North Nada 1 x (oil well - Qg =315 BFPD, Qn=173
BOPD) of North Nada field. The installation was successful achieving the expected results and benefits in term of low power
consumption. Successful key point: keeping electrical system stability and minimize the number of shutdowns; minimum cost
for power consumption and production.

Introduction
Today when the Artificial Lift share in the global Oil Production industry is growing up the Electrical Power consumption and
its cost becomes of a major concern for Oil and Gas Operators. In this regard High Efficient and/or Power Saving techniques
more and more become of current interest. Electrical Submersible Pump (ESP) in its turn as a most focused part of Artificial
Lift and as a technically sophisticated system requires efficiency improvements in the first place.
As ESP manufacturer Novomet Group conducted several in-house tests (in Russia) of equipment power consumption
measurements and losses. The conclusions of these tests are the following:
The share of average total net power is 39% (useful power). The rest 61% are losses that turn into heat and warm up
the environment; in other words it is being wasted;

Energy losses occur mostly in two different parts of ESP (Fig.1):


-

Submersible pump (transfers mechanical energy into hydraulic energy) 29% of 61%,

Submersible motor (transfers electrical energy into mechanical energy) 13 % of 61%.

The remaining 19% of total losses are distributed in cable, transformer, switchboard (VSD) and filters.
Power losses distribution per component is showed in Fig.1

SPE 164666

(%)

Powerlosses%byESPsystemcomponent
50
45
40
35
30
25
20
15
10
5
0

29

13
19
8

PowerLosses
10
6

4
3

3
2

NetPower
2
1

Figure 1. ESP power losses by ESP component


Therefore the enhanced efficiency of the Pump and Motor is the technical measure which may bring the major result. In
technical terms the enhancement of the efficiency may be achieved in two ways either using one of them or combination:

Optimum designing of the pump operating point during equipment selection for the well;
Designing of the ESP system with a higher efficiency itself.

Optimization of the operating point of the centrifugal pump in the course of its sizing for the well is now the basis for the
proper design procedure widely used in most of the oil operating companies. Application of higher efficiency ESP systems is
the most prospective measure, though not widely applied due to the higher cost of the equipment. Novomet managed to
develop pump stages with high efficiency (up to 76 %) that is a part of approach to power saving, but the most significant and
major achievement is the development of Permanent Magnet Motor (PMM). This is a different motor principle applied in ESP
system. The new motor type is much more efficient than the Asynchronous Motor (94% vs. 86%).
Power SaveTM ESP system which comprises high efficiency Pump modification and PMM can reduce absolute power
consumption by 25-30%. The distinguishing feature of the Power SaveTM ESP system is the significant reduction of number of
working stages in the pump if compared to a conventional one with induction motor. The desired head is achieved through
increased rotation speed (r.p.m.) of the PMM Motor. When comparing the PMM and asynchronous motor, the first one
has a better efficiency and lower operating current. The reduced operating current in its turn allows reducing heat losses in
the cable line and losses in the control panel and transformer. Figure 2 gives a visual differentiation between conventional ESP
and Power SaveTM ESP.

SPE 164666

Figure 2. Power Save ESP vs. Conventional ESP System


A detailed description of the above figure is reported in the next table:

Parameter
Flow rate, bbl/d
Average flow sp.gr. (60 F / 60 F)
Motor power- NPHP, HP
Efficiency of motor + protector (1), %
Power lost in motor & protector, HP
Shaft Power BHP, HP
Overall pump efficiency (2), %
ESP Hydraulic Horse Power -HHP, HP
Pump Total Dynamic Head -TDH, ft
speed rotation, r.p.m.

Conventional Design
3,145
0.85
128.6
84.1
20.4
108.2
70
75.7
3,841
2,910

Power Saving Design


3,145
0.85
105.2
93
7.4
97.8
70
68.5
3,475
4550

Table 1. Analyzing of data given in Figure 2


Where as per (1):


.
135,625.73 2 %
HHP = NPHP * 1 * 2 * 10-4
TDH = 135,625.73 * HHP / Q / sp.gr.

(135,625.73 constant conversion factor due to units used)

As size of the modified design is 0.6083 times the conventional design and its TDH is less than that obtained by the
conventional design, so it must run at r.p.m. higher than 2,910 to meet same TDH as 3,841 ft. Accordingly its r.p.m is
calculated as following using affinity law (2):
r.p.m. modified = (conventional size / modified size) x conventional r.p.m.* (TDH modified / TDH conventional)0.5
r.p.m. modified = (1 / 0.6083) x 2910 * (3475 / 3841)0.5 = 4,550

SPE 164666


Permanent Magnet Motors
In the last years a new technology - Permanent Magnet Motor (PMM) - has been developed for ESP motors as alternative to
conventional asynchronous induction motor. PMM is synchronous motor in which the stator manufacturing technique is
similar to that of asynchronous motor, but rotor has permanent magnets (instead of copper winding) made from rare-earth
alloys forcing high level of magnet induction.

Design
Motor consists of a stator (Fig.3) with three-phase winding, rotor with the permanent magnets, head and base. Winding phases
are located at 1200 to each other and Y- connected.

Figure 3. PMM Stator


Stator core comprises electric steel plates with heat resistant coating, pressed into the tubular housing. Stator winding is made
of copper wire with heat resistant coating. Stator winding has zero-point terminal (neutral) for ESP parameters control
system. Motor winding is epoxy compounded (under pressure by insulation compound) which increases its heat-conductivity.
Stator of PMM motor has conventional design and is similar to stator of asynchronous motor. Rotor is inside the stator (Fig.4)
and consists of separated rotor packs mounted on motor shaft and high load radial bearings between the packs.

Figure 4. PMM Rotor Pack


Unlike the conventional rotor the PMM rotor isnt of a squirrel cage design since it doesnt even have a copper winding at
all. Instead of the winding it has permanent magnets placed in mated slots where north and south poles create magnetic flux
which interfaces with stator winding field (Fig. 4). To ensure oil circulation motor shaft is hollow.
Permanent magnet sealing coating is performed by elements of special design excluding contact of permanent magnets with
fluid inside the motor and therefore corrosion and bulging of magnets as well.
PMM motors have precisely minimal electromagnetic clearance that positively influences on efficiency. Rotor packs do not
contain soft magnetic poles, therefore, intermediate bearings between rotors are subjected to less loads by forces of one-sided
magnet attraction and potentially have higher life time.
Rotor magnet can operate without significant loss of magnetic force at temperature up to 350 C. In the next figure the
temperature effect on create (electromotive force) EMF

SPE 164666

Figure 5. Temperature effect on magnetic rotor


Stator is encapsulated and a temperature sensor is located inside winding slots, which allows measuring motor temperature
more accurately.
Conventional induction motors with rated frequency up to 3000 r.p.m. have copper rotor design with shaft and bearings in
stator counter bore. In design of motors rotating at frequency of more than 4500 r.p.m. innovative solutions are applied. Due to
these solutions and preliminary balancing of packs it is possible to get low vibration level during initial motor.
Comparison of standard design and enhanced design with vibration reduction elements installed (special form and alloy
bushings inside the bearings and balanced rotor packs) are respectively showed in Fig. 6 and Fig. 7:

Figure 6. Vibration curve for motor without elements for vibration reduction

SPE 164666

Figure 7. Vibration curve for motor without elements for vibration reduction
Motor operation is based on electromagnetic interaction between two magnetic fields: stator and rotor. The stator rotating
magnetic field is created by system of three-phase AC current for both types PMM and induction one. The rotor magnetic field
in the conventional asynchronous motor is created by the induction currents which are generated in the rotors copper winding;
then currents create EMF, which in turn generates torque. In case of PMM the rotor has its own permanent magnetic field
created by the nature of permanent magnets. So there is no additional power spent on generating the induction current inside
the rotor, and no losses/resistance in rotor copper Thus an interaction between rotor and stator magnet fields creates an
electromagnetic torque which makes the rotor rotate.



Power Losses
In a rotor winding of permanent magnet motor, unlike asynchronous motor, there are no losses (Fig.8) because these rotor
packs consist of permanent magnets itself. Concerning other types of losses such as losses in stator winding and losses in steel
it is possible to mention that they are lower because current value is also lower and less steel losses because of lower stator
length. Finally, Permanent magnet motor is equipped with a special bearing which allows reducing mechanical losses as well
(see vibration comparison curves above).

Figure 8. Power losses in motors

SPE 164666

Operation and Control


PMM has an impulse (or sine-wave if using VSD by Novomet) power supply principle which means that winding (phase), in
which current is absent, is shifted at each cycle. There are only two phases in each moment with power supplied to them; the
third one is switched off (Fig. 9). It is required to keep one phase switched off to determine EMF created by rotating magnetic
rotor field on stator phases; this allows determining what is the positioning of magnetic rotor at each moment of time. The
moment of phase shifting is defined by Rotor Position Sensor (RPS) that is installed inside VSD. The latter is tuned in such a
way to ensure that there is a phase coincidence between current and no-load voltage (position self-excitation). In other words
the idea is the following: North and South poles of PMM rotor field interact with North and South poles of stator winding
field. When they catch up the poles of stator there is switching of power supply to the next phase, to ensure rotation of the
rotor as North and South poles of stator field will be shifted. Due to the switched off phase, rotor positioning sensor (in VSD
controller) determines (measuring EMF induced by rotor in the switched off phase) the position of rotor North and South poles
and sends a signal when it is needed to switch the phase next time. Yellow points in the figure show the operation of rotor
positioning sensor.

Figure 9. PMM operation principle

Permanent magnet motor control system contains power keys (in other words power switches): IGBT transistors. They are
VSD inverter components. The control device converts sensor signals into combination of control voltages which operate
power keys in the way that at each motor cycle two keys are operated and two out of three stator phases are connected
successively to the power network, as it is mentioned above (Fig. 10). Windings U, V, W are located on stator at 120 to each
other. Winding inputs and outputs are connected thus to create rotating magnet field during keys changeover. PMM control
system is placed far from the motor itself: it is a part of top side switchboard ESP drive.

SPE 164666

Figure 10. PMM control system

Supplied voltage value in VSD inverter can be regulated that is why it is possible to sustain motor rotating torque (Fig.11) at
the required level, so that if operating conditions change, these will not affect produced flowrate. In other words frequency of
voltage can be regulated due to the measured value of speed of rotor rotation by rotor positioning sensor as control system
understands that rotor rotation speed is decreasing. Automatic increasing of voltage frequency by the system allows sustaining
motor torque at required level even if there is pump stuck due to the solids. For induction motor it is not possible as system
does not measure rotor rotation speed, thats why torque for induction motor is limited by its load capacity.

Figure 11. PMM vs. AM torque curves


Summary

As a short summary of what above mentioned, here-below the main benefits of PMM versus conventional induction motor:
-

High efficiency (90-94%).vs. induction motors up to 86% because of motor design (rotor construction and decreased
losses) and PMM system control;
Smaller size and weight at the same power output (excellent solution for offshore applications) due to the increased
efficiency and lower current consumed;
Wider ranges of rotation frequency regulation: 100-500 r.p.m., 500-1500 r.p.m. due to the 14 poles configuration and
1500-4500 r.p.m., 3000-6000 r.p.m. due to the 4 poles (the higher number of poles motor has the lower speed it
rotates);
Reduced energy consumption and reduced rating of surface equipment (Power Saving) due to the lower consumed

SPE 164666

current and lower power losses in the system: cable, transformer, VSD. Losses in cable, transformer and variable
speed drive are reduced as well because of lower current and lower rating itself.
Lower heat release due to the less consumed current and decreased losses value (losses generate the heat), which
allows operating in the well with lower cooling fluid velocity (0.05 ft/s) without shroud.
Less consumed current also let using smaller cable size, minimizing the cost of the system
Stable torque over wide operation range because of the control system voltage (r.p.m.) regulation;
Power factor is near to 1 as there is no reactive resistance in rotor copper as rotor consists of permanent magnets


Field trials in Egypt


Agiba petroleum company has two main production areas in Egypt: onshore in Western Desert area and offshore in Ashrafi
area, for a total production of about 56,000 BOPD and a total of about 300 wells. Western desert included five locations
Meleiha, Zarif, Aghar, Faras and Raml. The main location is Meleiha field with about 250 wells (70% of total Agiba wells).
The majority of Western Desert wells are completed with artificial lift systems and several kinds of pumps: ESP, Sucker Rod,
PCP (about 40 ESP wells, 250 Sucker Rod wells and 10 PCP wells).
In the middle of June of 2012 Agiba performed a trial installation of Novomet PMM replacing an ESP unit with induction
motor in well North Nada 1 x. North Nada 1x is an oil well (Qg = 315 BFPD, Qn =173 BOPD).
The installed equipment is the following:
Pump: NHV380, FLT, AR1, CR1, STD, 405stg
Motor: PMM (460 series): N460PM100, 2230V, 3600 r.p.m., SGL, CR2, UHT
In the next figure the pump performance curves:
Pump performance curves
Novomet NHV 380 405 stgs (9675 ft)
r.p.m.: 3143
HZ: 54.0
sp.gr.: 1.0 (60 F / 60 F)
Developed pressure: 4189.3 psi

Figure 12. Pump NHV380, FLT, AR1, CR1, STD, 405 stg performance curves
The parameter requested for design of Novomet installation is reported here-in under:
Operating
frequency,
HZ
54

Flow rate,
BFPD
350

Water
Cut,
%

Pump
setting
depth,
ft

45

8800

Top of
perf., Solids
ft
8912

No

GOR,
SCF/STB

Pf,
psi

WHP,
psi

100

1300

200

P.I.,
Casing O.D. BHT,
Viscosity,
Sp.gr.
BFPD/psi
, inch
F
cP
0.3

9 5/8

Table 2. Initial operating conditions for N. NADA 1X with PMM

220

0.89

0.2

10

SPE 164666

The installation successfully achieved expected results and benefits in terms of low power consumption as documented in the
next table:
ESP operating parameters (comparison table)
Parameter
Production rate, bbl/d
Wellhead pressure, psi
Pump head/stage, ft
Required hp/stage, HP
Pump efficiency, %
Rated current, A
Operating current, A
Voltage, V
Apparent Power, KVA
Motor PF, %
Active Power, kW
Reactive Power, kVAR
Motor Efficiency, %
Motor Power Losses - MPL, kW (HP)
Heat released due to MPL, kBTU/hr
Useful motor power - shaft power, kW (HP)
ESP Hydraulic Horse Power - HHP, HP
Equipment length, ft
Motor OD, inch
Motor shroud application
Fluid cooling velocity, ft/s
Overall ESP efficiency may be used, %
Run life, days

With Induction
motor @50Hz
315
150
20.4
0.138
50
26
19
1,730
56.87
88
50.04
27.01
83
8.5 (11.4)
29.03
41.5 (55.7)
27.85
54.1
5.62
Yes
0.79 (in 7 shroud)
30.4
180

With PMM motor@54Hz


315
170
23.88
0.12
52
24.7
16
1870
51.76
91
47.10
21.46
92
3.8 (5.1)
12.86
43.3 (58.1)
30.21
61.9
4.6
No
0.067 (in 9 5/8 casing)
29.2
> 260
(still running)

Table 3. Results of save in power for ESP application at Agiba field


The installation gave also the following indirect benefits:
a)

Lower heat release, that enables to operate without shroud even with 460 series of motor in 9 5/8 Casing (minimum
cooling fluid velocity 0.07 ft/s);
b) Less current consumption (16 amps instead of 19 amps) and less size for cable and lower power rating for transformer
and VSD;
c) Decreased reactive power in the ESP electrical system (please see Table 3 above);
d) More system stability and less vibration due to reduced reactive power;
e) Improved system Power factor (please see Table 3 above);
f) Less fuel consumption for the generators or turbines 10 % reduction of diesel/gas consumption;
The ESP unit is still running ad under monitoring and observation in order to evaluate the overall benefit of the installation.

Summary and conclusions


1.
2.

3.

An alternative to conventional asynchronous induction motors has been developed. Its efficiency factor is
significantly higher than of conventional motor (from 88 up to 94% depending on motor series).
Power consumption is considerably low and high efficiency is observed due to the improvement of power factor
(from 0.88 up to 0.91) that significantly decreases the reactive power and heating of electrical system.
The expected results have been achieved: power consumption was reduced by 10 %.
Less power consumption allows increasing of the number of ESP wells by 10-15 % without change of power supply
system.

Acknowledgment
The author would like to thank Novomet R&D department namely, Santalov A.M., Khotsyanov I.D., Koshelev S.N. and
Novomet Egypt Workshop Manager Sergey Stolbov for provision of information related to the design and control operating
system of PMM and consultations during technical paper preparation. Also many thanks to ENI Milano, Italy-COMP

SPE 164666

11

department, namely Salvatore Pilone and Salvatore Spagnolo for the help and technical support during the installation phase
and revision of the paper. Thanks are convoyed to Eng. Ishak S. Attia, Agiba Petroleum Company for his technical support
and team leading.
References
1- http://www.gemi.org/waterplanner/calc-horsepower.asp
2- The Engineering ToolBox, http://www.engineeringtoolbox.com/affinity-laws-d_408.html
Nomenclatures
AM = Asynchronous Motor
AC = Alternating Current
API = American Petroleum Institute degree = [141.5 / sp.gr. (60 F / 60 F)] 131.5
bbl/d = Barrels Per Day
BHT = Bottom Hole Temperature
BHP= Brake Horse Power
BFPD = Barrel Fluid Per Day
BOPD = Barrel Oil Per Day
BTU = British Thermal Unit
cP = CentiPoise
EMF = Electromotive Force
ESP = Electric Submersible Pump
ft = foot
ft/s = foot per second

F = degree Fahrenheit

C = degree Celsius
GOR =Gas to Oil Ratio
HHP = Hydraulic Horse Power
HP = Horse Power
IGBT = Insulated Gate Bipolar Transistor
kVA = kilo Volt Ampere
kVAR = kilo Volt Ampere Reactive
kW = kilo Watt
NPHP = Nameplate Horse Power
MPD = Mid of Perforation Depth
O.D. = Outside Diameter
PCP = Progressive Cavity Pump
P.I. = Productivity Index, BFPD/psi
Pf = formation pressure, psi
PMM= Permanent Magnet Motor
psi = Pound force per square inch
Qgross = Gross fluid flow rate
Qnet = Net oil flow rate
P.I. = Productivity Index
r.p.m. = revolution per minute
RPS = Rotor Position Sensor
SCF = Standard Cubic Foot
STB = Stoke Tank Barrel
sp.gr. = Specific Gravity
TDH = Total Dynamic Head
VSD = Variable Speed Driver
WHP = Well Head Pressure
P, W = loss in power, Watt
= Efficiency, %
Subscripts
g = gross
n = net

12

SPE 164666

Author (s) Biography


Giovanni Biasin, is Deputy Production Manager in Agiba Petroleum Company, Egypt. He has a degree in Electronic Engineer
from Politecnico of Milano (Italy-1993). Also he achieved Professional qualification within the national engineering albo
(Italy-1994). His working experience in oil sector started about twenty years ago with ENI where he gained a solid experience
as Petroleum Production Optimization Engineer first and as Production manager in the last years. He has about ten year
experience in field development through artificial lift systems, first in Libya - development of El Feel field - than in Egypt in
Petrobel - one of the biggest producers and referred company - and finally in Agiba - one of the company with the widest kind
of artificial lift system implemented.
Ahmed Mahmoud Seleim, is a petroleum engineering assistant general manager, Agiba Petroleum Company, Egypt. He
earned B.Sc. in Petroleum Engineering from Al Azhar University, 1991. He joined Agiba in 1992 and started in the petrolelum
engineering department, ten he was appointed Senior Petroleum Engineer being in charge of all Agiba operating issues related
to production. After that he serves as a Head of Production section group for Agiba field. Currently, he carries out duties of all
production issues including artificial lift in the petroleum engineering department.
Hesham A. M. Abdou, is a general manager in operations department, Agiba petroleum Company, Egypt. He holds B.Sc.
Degree in petroleum engineering, from Al-Azhar University (1982), awarded degrees of M. Sc. (1996) & Ph.D. (2002) in
mechanical power engineering from Cairo University. His oil field experience is more than twenty seven years, in workover
operations for oil and gas wells and so water injector and source wells, in addition to oil & gas production facilities and
artificial lift systems. He instructed in faculty of engineering, Banha University and faculty of mining and petroleum
engineering, Suez Canal University. Currently, he instructs part time in both British University in Egypt (BUE) and Mataria
faculty of engineering, Helwan University.
Ahmed Refaie, is a petroleum enginner, Agiba petroleum Company, Egypt. He earned B.Sc. in Petroleum Engineering from
Al Azhar University, 2005. He joined Agiba in 2006. Currently, he carries out duties of artificial lift in the petroleum
engineering department and is deeply involved in design and follow up activity.
Dmitiry Letunov, is based in Cairo and serves as Business development/ESP Application Engineer for all Novomet activities
in Egypt since 2012. Before that he was based in Russia as a Head of overseas projects support department and was in charge
of technical and general support provision to all international activities. As far as his background is concerned, he is reservoir
evaluation and management engineer with experience in drilling monitoring, sidetracking, casing running and well completion
operations. Previously (before Novomet), he was with the company called PetroAlliance, where he served as drilling
monitoring engineer and was responsible for geological control of drilling, rock sampling, casing running control, evaluating
and supervising for gas content analysis and control. In his current position of the Business development/ESP Application
Engineer in Egypt, he is in charge of Customers technical support, equipment sizing and selection, commercial issues and
business development.
Walid Reda, is a Country Manager for Novomet Group of Companies in Egypt, one of the Oil & Gas market leaders in
manufacturing Oilfield equipment. In this role, he continues to advance the process of management for Strategic Accounts,
and helps to define the key projects and initiatives for resource commitment and New Business Development. Always active
and willing to work at the leading edge in all things he does in a creative and professional manner. He is a visionary leader
who "walks the talk". Before joining Novomet, Mr. Walid was a Marketing & BD Manager for QUINN PUMPS in EGYPT.
He also served as Sales Manager at Baker Hughes Corporation in the Submersible Pumping Division. During the past fifteen
years, Mr. Walid was most known for his ability to build self directed teams that cultivate the types of cultures that break
down traditional business barriers to engagement. He works with the employees to create environments and conditions that
will allow individuals to align their strengths to the organizations vision and Objectives. Mr. Walid has a Bachelors Degree
in Engineering from Ain shams University and attended the joint MBA program of Alexandria University (Egypt) with
Georgia State University (USA).

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