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Evaluation and Prediction of the Performance

of Positive Displacement Motor (PDM)


J. LI H. XU
BJ Services Japan National Oil Corp.
R. TUDOR, L. GINZBURG C. GRIGOR
Canadian Fracmaster Ltd. Drilex Systems Inc.
G. ROBELLO
Landmark Graphics

flow rate. The performance parameters of a PDM include output


Abstract torque, rotation speed, pressure drop and mechanical power. For a
Positive displacement motors (PDM) are being used exten- given type of PDM, the rotation speed is proportional to the flow
sively due to the increased drilling of horizontal/extended reach rate pumped through the PDM, and the pressure drop across the
wells as well as the deepening of vertical wells. Knowing motor motor is proportional to the torque output(2).
performance is essential to ensure drilling success. To enhance Usually, the manufacturer-supplied operation manuals present
the technology and make the system effective, a complete per- the data in the form of pressure drop vs. torque output, and rota-
formance envelope of the motor in use is required. In the tradi- tional speed vs. pressure drop based on limited test data. These
tional way, the performance of a PDM can be described by pres- plots do not depict the actual performance, as the plotted curves
sure drop vs. torque and rotational speed. For a particular type of are different for different flow rates. In this study, new correla-
motor, the RPM curves are different at different flow rates. tions were developed to aid in presenting the true behaviour of the
Although it is very difficult to fully describe the motor perfor- performance of the motor for different operating parameters.
mance with limited testing, a good prediction is critical for
motor selection and operation. In addition, the performance of a
PDM operating with compressible fluid decreases drastically as Data Compiling Methods
compared to the operation with incompressible fluids. In this
paper, analysis of the test results for various PDMs from differ- A databank of PDM test data from different PDM manufactur-
ent PDM suppliers are presented. Correlations have been devel- er’s manuals such as Moyno(3), Drilex(4), Black Max(5), Trudril(6),
oped, based on the test data, to describe PDM performance with and the previous studies(7, 8) was developed. The test data from
incompressible fluids. these manuals were based on water test results. Two-phase flow
test results were also added to the databank from previous
studies(7-9).
The mechanical power generated by the motor can be calculat-
Introduction ed as a function of torque (T) and rotational speed (N):
Drilling with coiled tubing is a very complex process. In gener-
al, the coiled tubing unit consists of surface equipment and down- TN
hole equipment. Most downhole tools and equipment associated Pmech =
9550 ........................................................................................(1)
with coiled tubing drilling may be summarized in the following
categories: drill bit, PDM, and bottom hole assembly (BHA) for
The hydraulic power is given as the product of pressure drop
non-directional and directional drilling. For a particular well, the
(∆P) and flow rate (Q) through the motor:
proper combination of a bit and a downhole motor must be select-
ed. To optimize the drilling process, a variety of parameters have
to be fully understood, such as rate of penetration, which can be ∆PQ
Phydraulic =
modelled with a solid mechanism model(1), and the performance 60 ..................................................................................(2)
of a PDM which can be predicted with a suitable correlation.
The PDM based on the Moineau principle is considered in this For a given configuration of PDM, a certain force is required to
study. A PDM consists of a by-pass valve, power section, trans- overcome the initial resistance to rotation in the power section.
mission assembly and bearing assembly. In the power section, a When the bit is at the bottom of the well and weight is applied, an
helical rotor with one or more lobes is placed eccentrically inside additional force is required to overcome the resistance caused by
a stator having one cavity more than the rotor lobes. This differ- the bit/formation interface. Additional pressure is then required to
ence between the rotor/stator lobe configurations creates the cavi- continue rotation, and the torque output is developed as a result of
ties. Under pressure, the drilling fluid will drive the rotor in an the application of the differential pressure across power section of
eccentric rotation, which is then translated into concentric rotation PDM. Therefore, for a given configuration of PDM, the four para-
through the transmission assembly and further transferred to the meters such as torque, rotational speed, pressure drop and flow
drill bit. rate can be expressed in a general form of:
In general, the performance of a PDM depends on the cross-
section of the flow area between the rotor and stator, rotor-stator
f 1 (T , N, ∆P,Q) = 0
lobe ratio, stage length (or lobe spiral pitch), number of stages and ............................................................................(3)

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48 Journal of Canadian Petroleum Technology


As was mentioned before, the rotational speed is proportional ρQ
to the flow rate and the torque is proportional to the pressure drop. Π6 =
Dµ ............................................................................................(14)
Therefore, the product of torque and rotational speed is propor-
tional to the product of pressure drop and flow rate, and Equation
(3) can be modified as: Q/D 2
Π7 =
Dg
........................................................................................(15)
f 2 (TN, ∆PQ) = 0 ...............................................................................(4)
Π 8 = b .................................................................................................(16)
Combining Equations (1) and (2) with Equation (4) results in
the following equation: Another dimensionless group is obtained by multiplying group
Π1, Π2, and Π3.
Pmech = f 3 (Phydraulic )
............................................................................(5)
TN
Π 1* = Π 1 • Π 2 • Π 3 =
It can be inferred that the mechanical power produced by a ∆PQ .............................................................(17)
PDM is a function of the input hydraulic power. In fact, the PDM
is a device which converts the hydraulic power produced by the
Equation (17) represents the efficiency of the motor.
pumped fluid into the mechanical power to turn the bit. Based on
the test results, a similar correlation for a given type of motor can Based on Equations (12), (13), and (16), another new dimen-
be developed. Furthermore, due to TN∝∆PQ, the output torque of sionless group can be expressed as:
a PDM can be correlated with a P factor as which is related as
follows: Π4 Π5 D3
Π 2* = =
Π8 bAL .........................................................................(18)
T = f 4 (P ) ..............................................................................................(6)
This dimensionless group represents the geometric parameters
where of the motor.
The dimensionless group Π6 is equivalent to Reynolds number,
∆PQ which represents the ratio of inertia to viscous forces. Π7 is equiv-
P= alent to Froude number, which represents the ratio of inertia to
N gravity forces. In general, the gravitational acceleration, g, can be
assumed to be constant and its effect on the other dimensionless
Similarly, based on the test results, a correlation in Equation (6) groups can be ignored. Therefore, all the dimensionless groups
can be developed. In general, for different PDMs, the performance can be coupled as:
factor P is not only a function of ∆PQ/N, but also a function of the
geometric configuration of the motor.
TN D3 ρQ
Based on the study by Drilex(3), the revolutions per flowrate F ( Π 1* , Π 2* , Π 6 ) = F ( , , )=0
ratio, N/Q, was found to be inversely proportional to rotor/stator ∆PQ bAL Dµ ..................................(19)
configuration (b), cross-sectional flow area between the rotor and
stator (A) and stage length (L): The detailed expression may have different forms, and one of
the general forms can be depicted as:
N 1

Q bAL .............................................................................................(7) TN D 3 α ρQ β
= a( ) ( )
∆PQ bAL Dµ .................................................................(20)
In general, the performance of a PDM is a function of: torque,
flow rate, rotational speed, pressure drop, stator lobe number, The constants a, α and β can be estimated based on the test
cross-sectional flow area, stage length, diameter of the motor, results for different PDMs. However, one of the key parameters,
density (ρ) and viscosity (µ) of the fluid, and gravity force (g). A, cross-sectional flow area, is not available to the public. This is
The function can be expressed as: because the detailed geometric information and the profile of the
rotor/stator lobes are patented by the individual PDM manufac-
f (T ,Q, N, ∆P,b, A, L, D,ρ,µ, g) = 0 ...............................................(8) tures. Equation (20) is a universal correlation, which correlates the
performance parameters of PDMs with the geometric parameters
Based on the Buckingham Π theorem(10), the following dimen- and the physical properties of the pumped fluid. This equation is
sionless groups can be derived: very important for both the PDM’s design and the performance
prediction.
DT
Π1 =
ρQ 2 ............................................................................................(9)
Results and Discussion
ρQ 2 Correlation Between Mechanical Power and
Π2 = Hydraulic Power
D 4 ∆P .......................................................................................(10)
Based on test data in the PDM manuals, the mechanical power
D3N and hydraulic power are calculated with Equations (1) and (2).
Π3 =
Q .........................................................................................(11) Figures 1 and 2 depict the correlation between mechanical power
and hydraulic power for the Drilex PDMs. They show that the
data falls into a straight line for each individual type of PDM.
D2
Π4 = However, the data would fall into different curves if it were com-
A ............................................................................................(12) piled in plots of rotational speed vs. pressure drop and torque vs.
pressure drop, which are the most common compilations used at
D
Π5 = the present time. Similarly, the study of Moyno PDMs also shows
L ...............................................................................................(13) that the correlation between mechanical power and hydraulic

May 2001, Volume 40, No. 5 49


FIGURE 1: Correlation between mechanical power and hydraulic FIGURE 2: Correlation between mechanical power and hydraulic
power for small Drilex PDMs. power for large Drilex PDMs.

power can be expressed as a straight line for each individual


motor.
Figures 1 and 2 also indicate that, for different types of motors,
the lines are different. This is because Equation (5) does not
account for the effect of geometry and lobe configuration on the
PDM performance. Based on plots such as Figures 1 and 2, the
mechanical output could be determined directly if the pressure
drop across the motor and the fluid circulation rate were given.
These plots also indicate which type of motor has a higher opera-
tional efficiency. For example, in Figure 2, the D625SS has a
higher efficiency than the D950TPS4, because the D950TPS4
needs a higher input hydraulic power for the same output mechan-
ical power.
Based on the detailed study in this paper, it was shown that the
correlation between mechanical power and hydraulic power
would be presented by a straight line for the individual type of FIGURE 3: Correlation between mechanical power and hydraulic
motor, providing that the data was collected when the motor was power for Black Max PDM 31/8 in. 7:8 4-stage circulated only with
operating under less than full load conditions. Under more than water. (The hydraulic power is calculated based on the inlet
full load conditions, the torque is no longer directly proportional pressure for solid lines, Q = 208 lpm. The hydraulic power is
to the pressure drop and the rotational speed is no longer directly calculated based on pressure drop.
proportional to the flow rate. Equations (21) and (22) are valid
only for instances when the motor is operating on or below its full
sure. This can be explained by the fact that the motor was tested
load. This is explained by the fact that, under the full load operat-
with its integrated parts, which include the power section, trans-
ing condition, a higher torque would result in a higher-pressure
mission assembly, output shaft/bearing assembly and bit box. The
drop, which will cause fluid to escape through the sealing gaps
pressure drop used to calculate the hydraulic power is the pressure
between the rotor and stator. Therefore, in order to produce the
drop across the whole motor assembly rather than that across the
same amount of incremental mechanical power, a higher input
power section. In most drilling operations, the only measurable
hydraulic power is needed.
pressure drop is the pressure drop across the whole motor assem-
bly. Because of this, the straight line for the Pmech and Phydraulic cor-
Q2 relation is no longer valid.
N2 = N1
Q 1 .......................................................................................(21) Figure 3 also shows mechanical power vs. hydraulic power at
various backpressures and a constant fluid rate of 208 lpm. The
∆P2 hydraulic power was calculated in two different ways. One calcu-
T2 = T1 lation was based on the pressure drop across the whole motor
∆P1 .......................................................................................(22)
assembly (curves marked with *). Another hydraulic power calcu-
lation was based on the pressure at the inlet of the motor (the solid
Further investigation of the data provided in the motor manuals line curves). Based on the pressure drop across the motor calcula-
of Drilex and Moyno shows that, for some types of motors, plots tion, the data with different backpressures falls into the same
of torque vs. pressure drop across the motor power section are dif- curve. However, hydraulic power calculations based on the PDM
ferent with different flow rates. It is not clear why this type of per- inlet pressure and pump rate of 208 lpm fall into completely dif-
formance variance occurs. However, if it does, the correlation ferent curves. The authors believe that it is feasible to use inlet
between mechanical power and hydraulic power is no longer lin- pressure based calculations to obtain the input hydraulic power. If
ear. It is also true for the correlation between the torque and P fac- the pressure drop across the motor was used to calculate the
tor. When the torque vs. pressure drop across the power section hydraulic power, the plot of mechanical power vs. hydraulic
does not fall into a single curve at a various circulation rates, the power would fall into the same curve. This means that the effi-
torque vs. P factor also does not fall into a single curve. ciency of the motor is the same no matter how much backpressure
Figure 3 represents the mechanical power vs. hydraulic power is applied. In fact, a higher backpressure results in a higher inlet
for a Black Max 79.4 mm (31/8 in.) 7:8 4-stage motor with water pressure to produce the same amount of the output mechanical
as the pumped fluid(8). The figure indicates that the data does not power. Therefore, with a higher backpressure, the motor is operat-
fall into a single line for different flow rates at the same backpres- ed in a lower efficiency mode. Figure 3 shows that the curve with

50 Journal of Canadian Petroleum Technology


FIGURE 4: Correlation between torque and P factor for small FIGURE 6: Correlation between torque and P factor for small
Drilex PDMs. Moyno PDMs.

a higher backpressure (7 MPa) is on the top and the curve with a stall condition when the P factor is larger than a certain value. For
lower backpressure (1.4 MPa) is at the bottom when the inlet pres- example, in Figure 4, when the P factor is larger than 8, the motor
sure is used to calculate the hydraulic power. This indicates that D350HF is close to the stall condition. For different motors, the
the motor is operating in a lower efficiency mode when the back- critical P factor values are different. Figure 4 shows that the criti-
pressure is increased. Therefore, it is preferable to use the inlet cal P factor values for motors D170 and D170HF are only about
pressure to calculate the hydraulic power rather than the pressure 1. In the drilling operation, if the pressure drop, flow rate and
drop across the motor when the efficiency of the motor is evaluat- rotational speed are measured in real time, then the P factor can be
ed at the different backpressures.

Correlation Between Torque and


Performance Factor
As was discussed previously, for a given type of PDM, the
torque of a motor is correlated with the P factor. Figures 4 to 9
show the correlation between the P factor and output torque. It
should be mentioned here that the P factors in Figures 4 to 7 were
calculated based on the pressure drop across the power section,
while the P factors in Figures 8 to 9 were calculated based on the
pressure drop across the whole motor assembly, since this was the
available data. As is shown in Figures 4 to 7, for different types of
motors, the data falls into different curves. This can be explained
by the fact that the correlation expressed in Equation (6) does not
account for the effect of the geometry and the lobe configuration
on the motor performance. However, for an individual motor, the
torque vs. P factor data falls into a single curve no matter what the
fluid flow rates are.
Figures 4 to 7 also indicate that, when the P factor is larger than
a certain value, the torque does not change significantly with the FIGURE 7: Correlation between torque and P factor for large
change of the P factor. This means that the motor is close to the Moyno PDMs.

FIGURE 8: Correlation between torque and P factor for Black


FIGURE 5: Correlation between torque and P factor for large Max 31/8 in. 7:8 4-stage PDM pumped with water at different
Drilex PDMs. backpressures.

May 2001, Volume 40, No. 5 51


FIGURE 9: Correlation between torque and P factor for Black
Max 31/8 in. 7:8 4-stage PDM pumped with commingled fluid at FIGURE 10: Correlation between the full load torque and
different back pressures with N2/H20 = 15/0.1. rotational speed/flowrate.

calculated and the torque can be determined. Therefore, the motor in the Drilex motor manual(3) correlates the N/Q with the geomet-
can be operated in an optimum mode by monitoring the P factor. ric parameters of the motor as:
It is interesting to note that, in Figure 8, all of the data fall into
a single curve for different test conditions. However, with differ- N 10−3
ent flow rates, the critical P factor values at which the motor is =
close to the stall condition are different. For a flow rate at 208 Q bAL ...........................................................................................(24)
lpm, the critical P factor is about 14, but for a flow rate of 416
lpm, the motor is close to stall condition when the P factor is Combining Equations (23) and (24) results in the following
about 40. However, as is shown in Figures 4 to 7, the critical P equation:
factor is the same at different flow rates for a particular type of
motor. This is because, as was mentioned previously, the P factors
T FL = 391685 • ( bAL ) 0.9722 ..............................................................(25)
were calculated in two different ways between Figures 4 to 7 and
8 to 9.
Figure 9 indicates that the backpressure has a significant effect If the geometric parameters, b, A, and L for a PDM are given,
on the performance of the PDMs when they are being pumped Equation (25) can be used to predict the full load torque.
through with a commingled fluid. With the same gas/water flow
rates, increasing of the backpressure results(7, 8) in lower torque
output and consequently the motor will stall. Previous studies Conclusions
came to the same conclusion. However, as is shown in Figure 8,
the backpressure effect on the torque output was ignored when the In this study, correlations were developed to describe the per-
motor was pumped through with water. formance of PDMs while pumping incompressible fluids. The
conclusions are:
General Correlation 1. When a motor is operated under a load less than the full
load, the correlation between mechanical power and
Based on the above discussion, the correlation expressed with hydraulic power across the PDM power section can be
mechanical power vs. hydraulic power, and torque vs. P factor, described with a simple linear equation. For different types
does not account for the effect of geometry and lobe configura- of PDMs, the linear equation is different.
tion. It also does not account for rheological properties, such as 2. A new performance factor called P factor is defined. The P
density and viscosity. Therefore, for different types of motors, the factor aids in describing PDM performance under different
curves are different. Comparison of different correlations indi- operating conditions. The critical value of the P factor helps
cates that it is useful to evaluate the efficiency and output the operator to prevent stalling the motor.
mechanical power with the correlation of mechanical power vs.
hydraulic power. With the plot of P factor vs. torque, the operator 3. Based on the geometric information, Equation (25) can be
can control the motor in an optimum operation mode. However, it used to predict the full load torque for all types of PDMs.
would be more important and convenient for the design and oper- Due to patented geometric information, Equations (19) and
ation of PDMs if a more general correlation could be developed, (20) cannot be fully developed in this study. However, the PDM
such as that expressed by Equation (20). However, due to patented manufacturers could further develop these equations. With such
geometric information, this equation cannot be fully developed in an equation, the performance of a PDM could be described by
this study. geometric parameters of the motor and rheological properties of
Figure 10 shows full load torque vs. rotational speed per flow the circulation fluid.
rate, N/Q, for a variety of motors. The data was collected from In this study, most of the test data was collected using water as
different motor manuals or handbooks(2-8). The figure shows that the pumped fluid. The performance of PDMs with
the data falls into a straight line on the log-log plot, and the data commingled/aerated fluids and pure gas needs to be investigated
can be correlated with the following equation: more in the near future.

N −0.9722
T FL = 474.61 • ( )
Q .................................................................(23)
Acknowledgements
The authors would like to express their appreciation to BJ
Equation (23) is valid for all types of motors and is indepen- Services, EnerTech-Landmark Graphics, and Japan National Oil
dent of motor geometry and lobe number. The equation developed Corp., for the opportunity to present this paper. As well, Drilex

52 Journal of Canadian Petroleum Technology


Slim Hole Service/Baker Hughes is commended for providing
experimental data for larger sized PDMs. Authors’ Biographies
NOMENCLATURE Jeff Li is an engineer in the Coiled Tubing
Research and Engineering division with BJ
A = the cross-sectional flow area between the rotor and Services in Calgary. Previously he worked
stator, m2 with Canadian Fracmaster as a staff engi-
a, α, β = constants in Equation (20) neer in the Coiled Tubing Department. He
b = the lobe number of the stator holds B.Sc. and M.Sc. degrees in the
D = motor outside diameter, m People’s Republic of China. He also holds
g = gravitational acceleration constant, 9.81 m/s2 M.Sc. and Ph.D. degrees in mechanical
L = stage length, one complete cycle or revolution of the engineering from the University of
helical shape of the rotor, m/cycle Saskatchewan. Mr. Li is a member of SPE,
P = the performance factor defined in Equation (6) the Petroleum Society, and ICoTA.
Pmech = mechanical power output at rotor, kW
Phydraulic = hydraulic power, kW Robin Tudor is currently district manager
N = rotary speed, RPM in Estevan at Canadian Fracmaster Ltd. He
Pb = backpressure, MPa holds a B.Sc. in electrical engineering from
Q = flow rate, litres/min (lpm) the University of Alberta. He has been
T = torque, N.m employed by Canadian Fracmaster since
T FL = full load torque, N.m 1989 and worked in fracturing, cementing
ρ = density of circulated fluid, kg/m3 and coiled tubing drilling services. Mr.
µ = viscosity of circulated fluid, Pa.s Tudor is a member of the Petroleum
Π1-Π7 = dimensionless parameters defined in Equations (9) to
Society, SPE, CADE, and ICoTA.
(18)
Π1*-Π2*
Leyb Ginzburg is currently an underbal-
SI Metric Conversion Factors anced drilling engineer with Tesco
Corporation. Before joining Tesco he spent
ft. – lb. × 1.356 E + 00 = Nm seven years with Canadian Fracmaster; the
gal (US) × 3.785 E - 03 = m3 last three years as a staff engineer in the
HP × 7.457 E - 01 = kW Coil Tubing Department. He holds a B.Sc.
in. × 2.54 E + 00 = cm degree in civil engineering from Riga
psi × 6.8948 E - 03 = MPa Polytechnics, Latvia. His interests include
UBD as well as coiled tubing applications
for underbalanced drilling and conventional
REFERENCES well treatment and stimulation. He has
1. XU, H., A Method for Modelling Rate of Penetration of Drill Bits worked on a numerous projects in Western Canada. He is a mem-
Using Electric and Mud Logging Data; Ph.D. Thesis, Heriot-Watt ber of the Petroleum Society, APEGGA, and SPE.
University, Scotland, April 1995.
2. Drilling Data Handbook; edited by G. Gabolde and J. Nguyen, Gulf
Robello Samuel is a principal technologist
Publishing Company, P.O. Box 2608, Houston, TX, 77252-2608,
1991. in the Research and Development division
3. Motor Technology; Drilex Slim Hole Services, 15151 of Landmark Graphics. He is presently
Sommermeryer, Houston, TX, 77041, 1991. serving as a reviewer for SPE Drilling
4. Moyno Motor Products; Moyno Oilfield Products, 363 N. Sam Engineering, associate technical editor for
Houston Parkway E., Suite 520, Houston, TX, 77060, 1996. the American Society of Mechanical
5. Operations Manual and Motor Specifications; 2nd edition, Black Engineers (ASME) Journal of Energy
Max Downhole Tool Ltd., 1802 – 4th Street, Nisku, AB, T9E 7T8, Resources Technology, and member of The
1995. Steering Committee for ASME—
6. Motor Handbook; 2nd edition, Trudril Downhole Motor Technology,
Petroleum Division Conferences. He is also
Edmonton, AB, May 1996.
7. LI, J., TUDOR, R., and COX, R., Positive Displacement Motor Test the chairman of the SPE multilateral
With Two-Phase Flow; paper SPE/ICoTA 38425, presented at the drilling Technical Interest Group (TIG). He worked at Oil and
2nd North American Coiled Tubing Roundtable, Montgomery, TX, Natural Gas Corporation (India) from 1983 to 1992 as a drilling
April 1– 3, 1997. engineer. He holds B.S., M.S. (mechanical engineering) degrees
8. LI, J., TUDOR, R., SONEGO, G., and VARCOE, B., Performance from Madras University, M.S. and Ph.D. (petroleum engineering)
of Positive Displacement Downhole Motors Under Two-Phase Flow; degrees from Tulsa University. Specialized research areas include:
Petroleum Society paper 97-73, presented at the 48th Annual wellbore hudraulics, and cuttings transport; downhole tools;
Technical Meeting of the Petroleum Society, Calgary, AB, June 8 – drilling optimization models.
11, 1997.
9. ROBELLO, G., MISKA, S., and LI, J., Analysis of Positive
Displacement Motor (PDM) Operating on Incompressible and H. Xu (photograph and biography not available)
Compressible Fluid System; Oil and Gas Journal, August 1998.
10. GERHART, P.M. and GROSS, R.J., Fundamentals of Fluid Charlie Grigor is the manager of technical
Mechanics; Addison Wesley Publishing Company, 1985. services thru-tubing for Smith Services,
Red Baron Group in Houston. He holds a
Provenance—Original Petroleum Society manuscript, B.Sc. in engineering technology from
Evaluation and Prediction of the Performance of Positive Robert Gordon’s Institute of Technology in
Displacement Motor (PDM) (98-104) first presented at the 49th Aberdeen, Scotland. Previously, he was
Annual Technical Meeting, June 8 – 10, 1998, in Calgary, with Drilex and Baker Hughes.
Alberta. Abstract submitted for review December 22, 1998; edito-
rial comments sent to the author(s) May 11, 2000; revised manu-
script received December 4, 2000; paper approved for pre-press
February 23, 2001; final approval May 1, 2001.

May 2001, Volume 40, No. 5 53

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