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PERFORMANCE MEASUREMENT AND RELIABILITY OF

VRLA BATTERIES— PART II: THE SECOND GENERATION

Mr. William P. Cantor, Test Products, Inc., Shrewsbury, PA, USA


Mr. Eddie L. Davis, Edan Engineering Corp., Vancouver, WA, USA
Dr. David O. Feder, Electrochemical Energy Storage Systems, Inc., Madison, NJ, USA
Mr. Mark J. Hlavac, AMERITECH, Advanced Data Services, Chicago, IL, USA

Abstract— This paper presents the results of capacity presented an overly optimistic view of the performance of
discharge tests on approximately 15,000 VRLA cells, of the entire VRLA population. The large proportion of the
primarily AGM design, representing five different US VRLA population, used in outdoor, extreme environments
manufacturers’ “20 YEAR DESIGN LIFE” products. was not represented in these failure rate data. In those
Some data are also presented on gel design cells. Just as environments, lifetimes are significantly shorter, with
was found in the earlier paper, presented at the 1995 failures often of a more dramatic nature, such as thermal
INTELEC meeting, the cells showed significant premature runaway or actual explosion.
capacity loss beyond 2 years’ service in benign,
temperature controlled environments. The cells tested At the time of the 1995 study, several new VRLA products
generally represented designs that were too new to have had just been introduced, either from manufacturers whose
been included in the earlier study. While it had been products had not been in the original test population, or as
hoped that these newer design cells would have been a result of new designs from existing manufacturers.
modified to correct the early failures shown in those tested While those products were too “young” at that time to
in 1995, this was apparently not to be. In accord with that expect to show capacity problems, the hope and
study, as well as an extensive Swedish study of 35,000 expectation was that the manufacturers had long since been
VRLA batteries, presented at the 1995 INTELEC, the most aware of the aging effects shown by the earlier designs and
significant conclusion from all these studies is that current had taken the necessary remedial steps to insure that the
VRLA cells, regardless of manufacturer or design, newly introduced designs would, in fact, show significant
demonstrate acceptable reliability for only 2 years. improvement.

I. BACKGROUND In this paper, the authors examine capacity test results


from approximately 15,000 VRLA cells which were not
At the 1995 INTELEC, one of the authors presented included in the earlier study. This study includes a
detailed information regarding the field performance of significant percentage of cells whose designs were too new
approximately 24,000 VRLA cells, as measured by actual to be included in the earlier tests. In addition, cells of
discharge capacity testing. The cells in that study ranged some of the earlier designs, with either design or
from one to nine years in age and represented the products manufacturing improvements are included in the test
of nine different battery manufacturers, from the USA, UK results.
and the Pacific Rim countries[1].
At the time of the 1995 presentation, it was stated that the
In that study, >15,000 cells failed to meet their 80% most useful outcome of that presentation would be to
capacity requirement, out of a total test population of stimulate fundamental rethinking of the processes, design
>23,000, for a 68% overall failure percentage. Failure concepts, manufacturing techniques and behavior in actual
rates among the nine manufacturers, ranged from 27% to usage of the VRLA technology. At that meeting, both in
86% for cells 3–7 years in age. some of the technical presentations and also in the Battery
Workshop, these concepts began to emerge. In papers
Of greatest concern was the startling increase in failure presented subsequent to the 1995 meeting, these concepts
rates with age, at only 25–50% of the cells’ nominal design have matured, gained wider acceptance and will likely be
life. Cells 1–2 years old had low failure rates, but by the presented in even greater detail and clarity at this 1998
third year the failure rate had increased to 35% and then INTELEC Conference[2][3][4][5][6].
grew rapidly to 79% at 6 years. Of equal concern, these
results represented performance, under the most benign, It is hoped that the test data presented in this paper will
temperature controlled environmental conditions, and thus assist in highlighting the urgency of the problems,
stimulate discussions and, in concert with the radically products of five major US manufacturers, all representing
new concepts which describe the oxygen recombination designs claimed to have a 20 year design life. The
processes, ultimately lead to an improved life expectancy. majority of the cells tested were in utility or
telecommunications stationary reserve, central office,
In the earlier paper, one of the authors noted that in a prior transmission and cellular applications. Some were in UPS
publication [7] he had pointed out that the very attributes applications in which the discharge rates were generally
which led to the claimed advantages of the VRLA design, higher, i.e., 15 minute or one hour rates, to either 1.75 or
i.e. reduced maintenance due to elimination of: water 1.67 end of discharge voltages. In all cases, these tests
addition; measurement of specific gravity; measurement of represented cells being operated in benign temperature
individual cell voltages; etc.; actually resulted in a environments, subjected to minimal discharge frequency.
designed-in Penalty Of Ignorance, that is, the inability to The majority of the cells ranged in age from a few months
determine the condition of the battery on float and to 5–6 years service, with some tested after 8–9 years
knowledge of its ability to provide the reserve needed, if service. The actual discharge tests were performed by
called upon to perform. three different testing organizations. Their actual test
procedures are described below.
User recognition of this problem led initially to the need to
find an alternate technique, other than direct measurement Discharge testing procedures in this study were performed
of string and cell capacity, generally recognized as by highly qualified personnel employed by reputable
technically challenging, often requiring specialized testing organizations utilizing state of the art test
equipment and presenting an economic penalty that might equipment. All test equipment and data acquisition
easily offset the overall perceived advantages of the VRLA equipment was calibrated in accordance with NIST
technology. Ohmic measurement techniques, initially standards. The load test equipment was configured for
conductance or impedance measurement of individual constant current discharge with strict control and
cells, were proposed as a possible solution. In order to regulation of the discharge rate.
determine the relationship between these techniques and
the actual capacity or capacity degradation of VRLA cells, Prior to discharge, the following parameters were
it was obviously necessary to perform a significant number measured on each cell: float voltage, internal ohmic values,
of ohmic measurements in conjunction with actual intercell connection resistance, and temperature. Ambient
discharge capacity tests on a statistically valid sample of temperature, plant load current, cell model, and
VRLA cells, at various stages of their life[8][9][10][11]. manufactured dates were also recorded.
In the 1995 study, ohmic measurement techniques
(conductance or impedance) correctly identified the 15,000 In preparation for discharge, each battery string was
failed cells, with an accuracy of 98%. removed from service and connected to the load bank. For
the majority of the testing, each cell was connected to a
The results, as described in the 1995 paper, confirmed the monitor to record individual cell voltages during the test.
validity of the ohmic techniques and their ability to detect Overall voltage, individual cell voltages, and current were
cells with low capacity. However, perhaps, far more recorded during the test to characterize the coup-de-fouet
importantly, it exposed a major problem cutting across the and to determine each individual cell’s capacity.
entire VRLA spectrum. The actual capacity data
demonstrated a shocking, totally unexpected, cell capacity After the discharge was completed, the battery was
premature failure rate at only a small fraction of the returned to service. Techniques were developed to match
expected design lives of the cells in question. Whether the voltage between the battery and the system to allow a
designed for 10 or 20 years, none of the cells tested safe reconnection. For the majority of systems, minimal
appeared to be capable of reliable capacity lifetimes even at temperature corrections were required because the sites
5 years. Further, since these data represented tests on were environmentally controlled. Calculations of
approximately 25,000 cells, the products of 9 different discharge capacity were made in accordance with IEEE
manufacturers and spanning two orders of magnitude in Standard 1188[12] and utilization of the manufacturer’s
capacity, it clearly indicated a major problem cutting published data.
across the entire technology in use at that time.
The battery data submitted by Test Products, Inc. was
II. CAPACITY TESTING PROGRAMS obtained through dc system evaluations of
telecommunication, utility, and UPS systems.
In this study, discharge capacity tests were performed,
primarily at the 2–5 hour rate to 1.75 vpc end of discharge Edan Engineering acquired its cell failure data as part of a
voltage on a wide variety of cell types, representing the test program to compare cell capacity to internal ohmic
measurements. The results of this test program were failure rates increase drastically, ranging from 88% to
presented at BATTCON98[13]. The batteries included in 100% by the 9th year. As shown by the test results, these
this test program were used in substation, generating cells cannot be considered suitable 20 year designs.
station, and communications centers in the electric power
industry. These results are similar to the overall data shown in Table
3 and Figure 6 of the 1995 paper (shown here as Table 2
III. TEST RESULTS and Figure 2), and compared directly in Table 3 and Figure
3. In each case, the failure rates show acceptably low
Overall, capacity tests were performed on more than values in the first 2 years, but then increase rapidly to
14,000 cells, of the AGM design representing products of totally unacceptable values in subsequent years. Whether
five manufacturers and cell sizes from 50 AH to 4,800 AH the failure rates are 27% in the 3rd year, as in this study, or
(a small sample of some 660 cells of the gel design were 35% as in the 3rd year of the 1995 study, these are clearly
also tested and will be discussed later). The combined unacceptable failure rates, and both studies are based on
overall results are shown in Table 1 and depicted significant 3rd year sample sizes (approximately 2,000 cells
graphically in Figure 1. Failure to provide 80% of rated in this study and 675 cells in the 1995 paper). In the 3–7
capacity, the industry norm, are shown, as well as failure to year population, Table 3 shows 61% failures in an overall
provide either 60% or 50% of rated capacity. Table 1 and population of 8,017 cells for the 1995 data. For this paper,
Figure 1 show essentially zero failures for the first two Tables 1 and 3 show 40% failures for the 3–7 year
years, then rapidly increase to 50% in the 4th year. There population of 5,027 cells, with 19% failures at 60%
is a drop in the 5th and 6th years, but the failure rates are capacity and 15% failures at 50% capacity.
still significant and unacceptably large. After year 6, the

<80% Capacity <60% Capacity <50% Capacity


Age Number Number Percent Number Percent Number Percent
(years) of Cells Failed Failed Failed Failed Failed Failed
0–1.9 5,990 47 0.1% 2 0.03% 0 0%
2–2.9 3,347 254 8% 67 2% 18 0.5%
3–3.9 1,919 517 27% 101 5% 79 4%
4–4.9 1,234 605 49% 222 18% 149 12%
5–5.9 912 262 29% 112 12% 71 8%
6–6.9 331 65 20% 32 10% 15 5%
7–7.9 368 323 88% 258 70% 233 63%
8–8.9 167 166 99% 129 77% 105 63%
9–9.9 96 96 100% 96 100% 96 100%
Total 14,364 2,335 16% 1,019 7% 766 5%

Table 1: Cell Failures by Age— All Manufacturers

100%

80%
Failure Rate

60%

40%

20%

0%
0–1.9 2–2.9 3–3.9 4–4.9 5–5.9 6–6.9 7–7.9 8–8.9 9–9.9
Age (years)

80% Failures 60% Failures 50% Failures

Figure 1: Cell Failures by Age— All Manufacturers


Age Number <80% <70% <60% <50%
(years) of Cells Capacity Capacity Capacity Capacity
1–2 851 7% 5% 3% 2%
3 675 35% 25% 17% 11%
4 600 42% 17% 11% 6%
5 5,400 55% 38% 24% 22%
6 1,164 79% 67% 56% 41%
7 120 39% 36% 33% 30%
9 60 55% 15% 10% 0%
Total 8,870

Table 2: Table 3 From 1995 INTELEC Paper[1]

80%

70%

60%
Failure Rate

50%

40%

30%

20%

10%

0%
1-2 3 4 5 6 7 9
Age (years)

<80% <70% <60% <50%

Figure 2: From Table3/Figure2 of 1995 INTELEC Paper[1]


1995 Data 1998 Data
Number Percent Number Percent
Age (years) Number <80% <80% Number <80% <80%
of Cells Capacity Capacity of Cells Capacity Capacity
0–2 851 60 7% 9,337 301 3%
3 675 236 35% 1,919 517 27%
4 600 252 42% 1,234 605 49%
5 5,400 2,970 55% 912 262 29%
6 1,164 920 79% 331 65 20%
7 120 468 39% 368 323 88%
8 0 0 0% 167 166 99%
9 60 33 55% 96 96 100%
Total 8,870 4,939 56% 14,364 2,335 16%

Table 3: Cell Failure Data— 1995 Versus 1998 Results

100%

80%
Failure Rate

60%

40%

20%

0%
0-2 3 4 5 6 7 8 9
Age (years)

1995 1998

Figure 3: Cell Failure Data— 1995 Versus 1998 Results

Tables 4–8 show the detailed failure rates, for products by speculate that the older population may have been
each of the manufacturers. The same data are shown “ethnically cleansed” of many of the failed cells. In
graphically in Figures 4–7. Of the five manufacturers addition, field repair attempts by water addition have likely
shown, only two had test data included in the 1995 paper. contributed to this improvement as well[14]. In any case,
In that paper, manufacturer A had 15,627 cells within the the failure rates are clearly unacceptable by year 3.
3–7 year age band, with an overall failure rate of 69%. In
this year’s paper, the same manufacturer’s data are shown Table 5 and Figure 5 show the new data for manufacturer
in Table 4 and Figure 4. This shows an overall failure rate D. In the 1995 paper, the 3–7 year data for manufacturer
of only 23%, but the 5,500 cell population is heavily D showed a failure rate of 75% out of an overall population
weighted by minimal failures in the 2,892 cell 1st and 2nd of 288 cells. Table 5 shows an overall failure rate of only
year populations. Removing those years, and comparing 6% in a 2,640 cell population. Again removing the 2,052
on the same 3–7 year basis as in the earlier paper, results 1st to 3rd year cells, results in a population of 588 cells from
in 987 failures in a 2,358 cell population, for a failure rate, 3–6 years old, with 129 failed cells, for a failure rate of
from 3–7 years of 41%. Adding in the 8th and 9th year data 22%. Although this failure rate is significantly lower than
results in an overall population of 2,621 cells, with 1,249 in the previous study, it is still unacceptably high for a
failures, for an overall 3–9 year failure rate of 48%. While product claimed to have a 20 year design life.
this may seem to be a slight improvement, we might
<80% Capacity <60% Capacity <50% Capacity
Age Number Number Percent Number Percent Number Percent
(years) of Cells Failed Failed Failed Failed Failed Failed
0–1.9 2,264 40 2% 2 0.1% 0 0%
2–2.9 228 3 1% 0 0% 0 0%
3–3.9 840 323 38% 14 2% 1 0.1%
4–4.9 588 151 26% 14 2% 4 1%
5–5.9 324 129 40% 44 14% 15 5%
6–6.9 238 61 26% 32 13% 15 6%
7–7.9 368 323 88% 258 70% 233 63%
8–8.9 167 166 99% 129 77% 105 63%
9–9.9 96 96 100% 96 100% 96 100%
Total 5,513 1,292 23% 589 11% 469 9%

Table 4: Manufacturer A Failure Rates

100%

80%
Failure Rate

60%

40%

20%

0%
0–1.9 2–2.9 3–3.9 4–4.9 5–5.9 6–6.9 7–7.9 8–8.9 9–9.9
Age (years)
80% Failures 60% Failures 50% Failures

Figure 4: Manufacturer A Failure Rates


<80% Capacity <60% Capacity <50% Capacity
Age Number Number Percent Number Percent Number Percent
(years) of Cells Failed Failed Failed Failed Failed Failed
0–1.9 1,992 7 0.4% 0 0% 0 0%
2–2.9 60 18 30% 12 20% 12 20%
3–3.9 24 13 54% 8 33% 6 25%
4–4.9 24 18 75% 15 63% 13 54%
5–5.9 540 98 18% 42 8% 35 6%
Total 2,640 154 6% 77 3% 66 3%

Table 5: Manufacturer D Failure Rates

80%

60%
Failure Rate

40%

20%

0%
0–1.9 2–2.9 3–3.9 4–4.9 5–5.9
Age (years)

80% Failures 60% Failures 50% Failures

Figure 5: Manufacturer D Failure Rates

Table 6 and Figure 6 show results for one of the Table 7 shows another product too new to be included in
manufacturers (here named manufacturer “K”) whose the earlier paper, and here named “L”. In the 477 cell
product was too new to be included in the earlier paper and population, no cell is older than 2 years, so that the zero
which had presumably included material and design failures seem reasonable. For these, we can only say
corrections to the problems shown by the earlier designs. “WAIT ‘TIL NEXT YEAR”!
Here, in a population of almost 2,700 cells, the overall
failure rate was 27%, more or less in qualitative agreement Table 8 and Figure 7 show data from another manufacturer
with both the overall group and manufacturer A’s product. (M) who has been in manufacture for some time, but for
However, closer examination on a yearly basis indicates a whom no discharge test data were available for the earlier
far more serious problem. While year 1 is trouble free, in paper. While the overall population of some 3,000 cells
the 2nd year failures reach 10%, then rapidly climb to seems significant, 2,996 or 98% are in UPS service and
54%, 72% and then 73% in the 3rd, 4th, and 5th year. The 2,276 are less than 3 years old. Only 48 cells are 4 years
sudden drop to zero in year 6 is likely a statistical anomaly, or older. Of these, 7 tested as failures to the 80% criterion,
considering the small sample size. for a 15% failure rate, but the population size is not
statistically significant.
<80% Capacity <60% Capacity <50% Capacity
Age Number Number Percent Number Percent Number Percent
(years) of Cells Failed Failed Failed Failed Failed Failed
0–1.9 810 0 0% 0 0% 0 0%
2–2.9 830 86 10% 35 4% 5 0.6%
3–3.9 335 181 54% 79 24% 72 21%
4–4.9 598 433 72% 192 32% 131 22%
5–5.9 48 35 73% 26 54% 21 44%
6–6.9 69 0 0% 0 0% 0 0%
Total 2,690 735 27% 332 12% 229 9%

Table 6: Manufacturer K Failure Rates

80%

60%
Failure Rate

40%

20%

0%
0–1.9 2–2.9 3–3.9 4–4.9 5–5.9 6–6.9
Age (years)

80% Failures 60% Failures 50% Failures

Figure 6: Manufacturer K Failure Rates

<80% Capacity <60% Capacity <50% Capacity


Age Number Number Percent Number Percent Number Percent
(years) of Cells Failed Failed Failed Failed Failed Failed
0–1.9 408 0 0% 0 0% 0 0%
2–2.9 69 0 0% 0 0% 0 0%
Total 477 0 0% 0 0% 0 0%

Table 7: Manufacturer L Failure Rates


<80% Capacity <60% Capacity <50% Capacity
Age Number Number Percent Number Percent Number Percent
(years) of Cells Failed Failed Failed Failed Failed Failed
0–1.9 116 0 0% 0 0% 0 0%
2–2.9 2,160 147 7% 20 1% 1 0.05%
3–3.9 720 0 0% 0 0% 0 0%
4–4.9 24 3 13% 1 4% 1 4%
5–5.9 0 0 0% 0 0% 0 0%
6–6.9 24 4 17% 0 0% 0 0%
Total 3,044 206 6% 21 2% 2 0.1%

Table 8: Manufacturer M Failure Rates

20%

16%
Failure Rate

12%

8%

4%

0%
0–1.9 2–2.9 3–3.9 4–4.9 5–5.9 6–6.9
Age (years)

80% Failures 60% Failures 50% Failures

Figure 7: Manufacturer M Failure Rates

While all of the above data refer to AGM type VRLA cells, size, since the individual populations would have been too
a limited amount of data has been collected on gel type small to have any statistical significance. However, the
VRLA designs. The data, shown in Table 9 and Figure 8, failure rates are similar to those found in an earlier
represent the products of three US manufacturers and publication by two of the authors[10], in which 2-year old
include several different sizes of each. As a result, no gel cells were found to have failed in 11 of 38 6-volt
attempt was made to segregate the data by manufacturer or monoblocs, for a 29% failure rate.
<80% Capacity <60% Capacity <50% Capacity
Age Number Number Percent Number Percent Number Percent
(years) of Cells Failed Failed Failed Failed Failed Failed
0–1.9 16 0 0 0 0% 0 0%
2–2.9 0 0 0 0 0% 0 0%
3–3.9 0 0 0 0 0% 0 0%
4–4.9 96 4 4% 0 0% 0 0%
5–5.9 212 25 12% 8 4% 0 0%
6–6.9 72 24 33% 24 33% 2 3%
7–7.9 120 24 20% 24 20% 24 20%
8–8.9 24 0 0% 0 0% 0 0%
9–9.9 48 0 0% 0 0% 0 0%
10–10.9 72 24 33% 0 0% 0 0%
Total 660 101 15% 56 8% 26 4%

Table 9: Gel Cell Failure Rates

40%
Failure Rate

30%

20%

10%

0%
0–3.9

4–4.9

5–5.9

6–6.9

7–7.9

8–8.9

9–9.9

10–10.9
Age (years)

80% Failures 60% Failures 50% Failures

Figure 8: Gel Cell Failure Rates

While there can be some questions raised as to the manufacturing processes and controls to ensure that
statistical significance of some of the aging failures, for reliability.
some individual manufacturers, and especially for the gel
technology, there can be no doubt as to the overall Unfortunately, the above statements represent the “GOOD
message. Despite all claims to the contrary, there is no NEWS”. The “BAD NEWS” is that the largest use of
evidence, either from the 1995 paper or from these data, VRLA products is in outdoor, uncontrolled temperature
that any of these designs will achieve their 20 year design cabinets. Here we have no quantitative test data, primarily
life, even in benign temperature environments. The data since the user has come to expect such a short life in these
strongly indicate that the AGM VRLA 20 year design outdoor environments, that he generally replaces the
life product can only be considered as a reliable 2 year batteries automatically after no more than 2–3 years.
design. Since significant failures begin to occur in the Under these circumstances, the user cannot justify the
third year, any claim to reliability beyond the two year age economics of performing capacity discharge tests. In
has to be contrasted against our long-term experience with addition, in many cases he cannot justify either the use of
flooded cell reliability. That reliability has resulted from ohmic techniques to detect failures, nor in many cases can
our understanding of its failures modes and their he justify the cost of monitors with remote access,
dependence upon the interrelationships among the especially since in their attempts to lower the cost of the
metallurgical, electrochemical, and mechanical field monitors, some manufacturers have produced
interactions that govern flooded cell float behavior and life, products of questionable accuracy in their ability to detect
coupled with the development of the necessary significant cell failure for these outdoor installations.
0 and 5 years. Figure 9 shows their results, taken from
An obvious question which arises, is whether these results Figure 1 of their paper. While the results show some
are a peculiarly US-only phenomenon such that VRLA differences, depending on the overall voltage of the battery
cells made elsewhere are all performing in accordance with plants involved, their results are certainly in close
their expected design lives. As noted earlier, the data agreement with the overall results of both our 1995 study
presented in the 1995 paper included cells made and used and this study. Further, the authors note that because of
in the UK, Europe and in the Pacific Rim countries. Those the frequency of failures, two makes of AGM designs were
data showed the same characteristics as the US cells in the withdrawn from the Swedish market. While this has not
1995 study, as well as those in this study. Further, in a yet been publicly stated in the US, there are statements
paper also presented at the 1995 INTELEC, Selanger and which have been made as to the intentions of some
his co-authors report on a study of the capacity/age/failure telecoms to ban all further purchases of VRLA products,
rates of some 35,000 VRLA cells, in Telecom, Utility and for outdoor applications. For controlled environment use,
Defense usage[15]. In overall summary, they reported that flooded cells of proven reliability are considered a more
failure rates for gel cells are approximately 5% and for desirable option and are increasingly being considered and
AGM approximately 20% for batteries between the ages of selected, where space and use conditions permit.
Defect
Fraction

70%

60%

50%

40% 24 V
48 V
30% 110 V

20%

10%

0%
0 1 2 3 4 5 6
Age (years)

Figure 9: Battery Defect Fraction (Figure 1 of 1995 INTELEC Paper[15])

IV. CONCLUSIONS
4. While no quantitative data are available, it is
1. Capacity test data on some 15,000 AGM “20 year acknowledged that in the major Telecom outdoor
Design Life” cells indicate significant and cabinet usage, exposed to high temperature
unacceptable failure rates beyond the second year of environments, VRLA cells are routinely “junked” after
life, under benign environmental conditions. no more than 2–3 years, without further testing, which
has generally been considered uneconomic by the
2. These results are in general accord with those reported users.
previously for a 25,000 cell population.
5. At this time, it seems appropriate to classify the
3. These results are also in close agreement with a VRLA products as demonstrating acceptable
significant Swedish study of some 35,000 VRLA cells reliability for only 2 years. Beyond 2 years, cell
reported at the 1995 INTELEC. failure rates quickly reach unacceptable levels.

6. It is hoped that more recent understanding of the


behavior and failure modes of VRLA batteries on float,
which will be presented at this conference, will result
in improvements in life and reliability of the
technology.
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[13] E. Davis, D. Funk, and W. Johnson, Proceedings of


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