85:
522:". For example, saturated steam at atmospheric pressure boils at 100 °C (212 °F). Saturated steam taken from the boiler may contain entrained water droplets, however a well designed boiler will supply virtually "dry" saturated steam, with very little entrained water. Continued heating of the saturated steam will bring the steam to a "superheated" state, where the steam is heated to a temperature above the saturation temperature, and no liquid water can exist under this condition. Most reciprocating steam engines of the 19th century used saturated steam, however modern steam power plants universally use
290:. Smeaton further lengthened the path of the gases by means of a spiral labyrinth flue beneath the boiler. These under-fired boilers were used in various forms throughout the 18th century. Some were of round section (haycock). A longer version on a rectangular plan was developed around 1775 by Boulton and Watt (wagon top boiler). This is what is today known as a three-pass boiler, the fire heating the underside, the gases then passing through a central square-section tubular flue and finally around the boiler sides.
615:. Many firetube boilers heat water until it boils, and then the steam is used at saturation temperature in other words the temperature of the boiling point of water at a given pressure (saturated steam); this still contains a large proportion of water in suspension. Saturated steam can and has been directly used by an engine, but as the suspended water cannot expand and do work and work implies temperature drop, much of the working fluid is wasted along with the fuel expended to produce it.
751:
steam-raising plant will suffer from scale formation and corrosion. At best, this increases energy costs and can lead to poor quality steam, reduced efficiency, shorter plant life and an operation which is unreliable. At worst, it can lead to catastrophic failure and loss of life. While variations in standards may exist in different countries, stringent legal, testing, training and certification is applied to try to minimize or prevent such occurrences. Failure modes include:
321:. The gas flow was then reversed into a passage or flue beneath the boiler barrel, then divided to return through side flues to join again at the chimney (Columbian engine boiler). Evans incorporated his cylindrical boiler into several engines, both stationary and mobile. Due to space and weight considerations the latter were one-pass exhausting directly from fire tube to chimney. Another proponent of "strong steam" at that time was the Cornishman,
705:
43:
630:
308:, who rightly recognised that the cylindrical form was the best from the point of view of mechanical resistance and towards the end of the 18th century began to incorporate it into his projects. Probably inspired by the writings on Leupold's "high-pressure" engine scheme that appeared in encyclopaedic works from 1725, Evans favoured "strong steam" i.e. non condensing engines in which the steam pressure alone drove the
330:
cylindrical tube about three feet wide which passed longitudinally inside the tank. The fire was tended from one end and the hot gases from it travelled along the tube and out of the other end, to be circulated back along flues running along the outside then a third time beneath the boiler barrel before being expelled into a chimney. This was later improved upon by another 3-pass boiler, the
842:(ASME) performance test code, PTC 4. A related component is the regenerative air heater. A major revision to the performance test code for air heaters will be published in 2013. Copies of the draft are available for review. The European standards for acceptance test of steam boilers are EN 12952-15 and EN 12953–11. The British standards BS 845-1 and BS 845-2 remain also in use in the UK.
655:
1079:
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allows for a greater flue gas velocity increasing the overall draught in the furnace. This method was common on steam driven locomotives which could not have tall chimneys. The third method is by simply using an induced draught fan (ID fan) which sucks flue gases out of the furnace and up the stack. Almost all induced draught furnaces have a negative pressure.
545:
641:
in the late 1820s for use in steam road carriages. This boiler was ultra-compact and light in weight and this arrangement has since become the norm for marine and stationary applications. The tubes frequently have a large number of bends and sometimes fins to maximize the surface area. This type of
606:
In a
Stephensonian firetube locomotive boiler, this entails routing the saturated steam through small diameter pipes suspended inside large diameter firetubes putting them in contact with the hot gases exiting the firebox; the saturated steam flows backwards from the wet header towards the firebox,
590:
type (absorb heat via a fluid i.e. gas) and some are a combination of the two. So whether by convection or radiation the extreme heat in the boiler furnace/flue gas path will also heat the superheater steam piping and the steam within as well. While the temperature of the steam in the superheater
407:) were not absolutely safe, nor was the cast iron hemispherical boiler initially used by Richard Trevithick. This construction with small plates persisted until the 1820s, when larger plates became feasible and could be rolled into a cylindrical form with just one butt-jointed seam reinforced by a
497:
Forced draught: draught is obtained by forcing air into the furnace by means of a fan (FD fan) and duct-work. Air is often passed through an air heater; which, as the name suggests, heats the air going into the furnace in order to increase the overall efficiency of the boiler. Dampers are used to
493:
is less dense than the ambient air surrounding the boiler. The denser column of ambient air forces combustion air into and through the boiler. The second method is through use of a steam jet. The steam jet or ejector oriented in the direction of flue gas flow induces flue gases into the stack and
750:
When water is converted to steam it expands in volume 1,600 times and travels down steam pipes at over 25 m/s. Because of this, steam is a good way of moving energy and heat around a site from a central boiler house to where it is needed, but without the right boiler feed water treatment, a
312:
and was then exhausted to atmosphere. The advantage of strong steam as he saw it was that more work could be done by smaller volumes of steam; this enabled all the components to be reduced in size and engines could be adapted to transport and small installations. To this end he developed a long
774:
uses a once-through type contra-flow generator, consisting of a continuous tube. The fire here is on top of the coil instead of underneath. Water is pumped into the tube at the bottom and the steam is drawn off at the top. This means that every particle of water and steam must necessarily pass
599:
offer a "continuously expanding space" and the pressure remains the same as that of the boiler. The process of superheating steam is most importantly designed to remove all droplets entrained in the steam to prevent damage to the turbine blading and/or associated piping. Superheating the steam
501:
Balanced draught: Balanced draught is obtained through use of both induced and forced draft. This is more common with larger boilers where the flue gases have to travel a long distance through many boiler passes. The induced draft fan works in conjunction with the forced draft fan allowing the
566:
A greater quantity of steam can be generated from a given quantity of water by superheating it. As the fire is burning at a much higher temperature than the saturated steam it produces, far more heat can be transferred to the once-formed steam by superheating it and turning the water droplets
517:
The next stage in the process is to boil water and make steam. The goal is to make the heat flow as completely as possible from the heat source to the water. The water is confined in a restricted space heated by the fire. The steam produced has lower density than the water and therefore will
329:
developed around 1812 by
Richard Trevithick was both stronger and more efficient than the simple boilers which preceded it. It consisted of a cylindrical water tank around 27 feet (8.2 m) long and 7 feet (2.1 m) in diameter, and had a coal fire grate placed at one end of a single
798:
set at 1,200 lb (544 kg) provides added protection. The fire is automatically cut off by temperature as well as pressure, so in case the boiler were completely dry it would be impossible to damage the coil as the fire would be automatically cut off by the temperature.
642:
boiler is generally preferred in high pressure applications since the high pressure water/steam is contained within narrow pipes which can contain the pressure with a thinner wall. It can however be susceptible to damage by vibration in surface transport appliances. In a
398:
The 1712 boiler was assembled from riveted copper plates with a domed top made of lead in the first examples. Later boilers were made of small wrought iron plates riveted together. The problem was producing big enough plates, so that even pressures of around
889:
The Steam Engine, Comprising an
Account of Its Invention and Progressive Improvement; with an Investigation of Its Principles ... Detailing Also Its Application to Navigation, Mining, Impelling Machines, &c. ... Illustrated by ... Plates, and ... Wood
518:
accumulate at the highest level in the vessel; its temperature will remain at boiling point and will only increase as pressure increases. Steam in this state (in equilibrium with the liquid water which is being evaporated within the boiler) is named "
167:
325:. His boilers worked at 40–50 psi (276–345 kPa) and were at first of hemispherical then cylindrical form. From 1804 onwards Trevithick produced a small two-pass or return flue boiler for semi-portable and locomotive engines. The
209:
at a rate which can vary according to the pressure above the boiling water. The higher the furnace temperature, the faster the steam production. The saturated steam thus produced can then either be used immediately to produce power via a
934:
390:, outright winner of the trial. The design formed the basis for all subsequent Stephensonian-built locomotives, being immediately taken up by other constructors; this pattern of fire-tube boiler has been built ever since.
484:
leaving the furnace, as well as chimney height. All these factors make effective draught hard to attain and therefore make mechanical draught equipment much more economical. There are three types of mechanical draught:
790:
As the hot gases pass down between the coils, they gradually cool, as the heat is being absorbed by the water. The last portion of the generator with which the gases come into contact remains the cold incoming water.
381:
surrounded by water spaces and a boiler barrel consisting of two telescopic rings inside which were mounted 25 copper tubes; the tube bundle occupied much of the water space in the barrel and vastly improved
334:
which had a pair of furnaces in separate tubes side-by-side. This was an important improvement since each furnace could be stoked at different times, allowing one to be cleaned while the other was operating.
218:
to a higher temperature; this notably reduces suspended water content making a given volume of steam produce more work and creates a greater temperature gradient, which helps reduce the potential to form
278:
which retained some heat. A voluminous coal fire was lit on a grate beneath the slightly dished pan which gave a very small heating surface; there was therefore a great deal of heat wasted up the
574:
unit, however to a different end. The steam piping (with steam flowing through it) is directed through the flue gas path in the boiler furnace. This area typically is between 1,300–1,600
154:, industrial installations and power stations will usually have a larger separate steam generating facility connected to the point-of-use by piping. A notable exception is the steam-powered
646:
sectional boiler, sometimes called a "pork chop boiler" the water is contained inside cast iron sections. These sections are mechanically assembled on site to create the finished boiler.
684:) that actual boiling ceases to occur, the boiler has no liquid water - steam separation. There is no generation of steam bubbles within the water, because the pressure is above the
418:
Once-through monotubular water tube boilers as used by Doble, Lamont and
Pritchard are capable of withstanding considerable pressure and of releasing it without danger of explosion.
941:
637:
Another way to rapidly produce steam is to feed the water under pressure into a tube or tubes surrounded by the combustion gases. The earliest example of this was developed by
354:
devised a two-pass boiler of which the second pass was formed by a bundle of multiple tubes. A similar design with natural induction used for marine purposes was the popular
814:
Steam boilers are used where steam and hot steam is needed. Hence, steam boilers are used as generators to produce electricity in the energy business. It is also used in
304:
An early proponent of the cylindrical form was the
British engineer John Blakey, who proposed his design in 1774. Another early proponent was the American engineer,
185:. However it needs to be treated separately, as to some extent a variety of generator types can be combined with a variety of engine units. A boiler incorporates a
338:
Railway locomotive boilers were usually of the 1-pass type, although in early days, 2-pass "return flue" boilers were common, especially with locomotives built by
607:
then forwards again to the dry header. Superheating only began to be generally adopted for locomotives around the year 1900 due to problems of overheating of and
84:
1064:
BS 845-2: "Methods for assessing thermal performance of boilers for steam, hot water and high temperature heat transfer fluids. Comprehensive procedure. (1987)
1055:
BS 845-1: "Methods for assessing thermal performance of boilers for steam, hot water and high temperature heat transfer fluids. Concise procedure" (1987)
839:
794:
The fire is positively cut off when the pressure reaches a pre-determined point, usually set at 750 psi (5.2 MPa), cold water pressure; a
696:
production. The term "boiler" should not be used for a supercritical pressure steam generator, as no "boiling" actually occurs in this device.
688:
at which steam bubbles can form. It passes below the critical point as it does work in a high-pressure turbine and enters the generator's
685:
676:
pressure. In contrast to a "subcritical boiler", a supercritical steam generator operates at such a high pressure (over 3,200
266:
produced by condensation of the steam, the requirement was for large volumes of steam at very low pressure hardly more than 1
370:
134:
A boiler or steam generator is used wherever a source of steam is required. The form and size depends on the application: mobile
722:
Feed water for boilers needs to be as pure as possible with a minimum of suspended solids and dissolved impurities which cause
872:
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64:
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for parboiling and drying. Besides many different application areas in the industry for example in heating systems or for
663:
489:
Induced draught: This is obtained one of three ways, the first being the "stack effect" of a heated chimney, in which the
453:
910:
Young, Robert: "Timothy
Hackworth and the Locomotive"; the Book guild Ltd, Lewes, U.K. (2000) (reprint of 1923 ed.) p.326
55:
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of 1849 had a longitudinal welded seam. Welded construction for locomotive boilers was extremely slow to take hold.
115:. Although the definitions are somewhat flexible, it can be said that older steam generators were commonly termed
803:
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control the quantity of air admitted to the furnace. Forced draught furnaces usually have a positive pressure.
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286:, heating surface was considerably increased by making the gases heat the boiler sides, passing through a
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expands the volume of steam, which allows a given quantity (by weight) of steam to generate more power.
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horizontal boiler into which was incorporated a single fire tube, at one end of which was placed the
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386:. Old George immediately communicated the scheme to his son Robert and this was the boiler used on
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of 600 feet (183 m) a second with less than two quarts of water in the tube at any one time.
472:, air needs to be supplied both through the grate, and above the fire. Most boilers now depend on
894:
638:
603:
When the totality of the droplets is eliminated, the steam is said to be in a superheated state.
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190:
968:
Guidelines for
Selecting Resin Ion Exchange or Reverse Osmosis for Feed Water Demineralisation
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BS EN 12952-15: "Water-tube boilers and auxiliary installations. Acceptance tests." (2003)
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480:. This is because natural draught is subject to outside air conditions and temperature of
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449:
362:
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206:
158:, where separately-generated steam is transferred to a receiver (tank) on the locomotive.
147:
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of all kinds: power (kW) = steam
Production (kg h)/Specific steam consumption (kg/kW h).
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42:
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through every part of the generator causing an intense circulation which prevents any
262:
installed beneath the power cylinder. Because the engine's power was derived from the
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681:
404:
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120:
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from forming on the inside of the tube. Water enters the bottom of this tube at the
761:
Pressure vessel failure of the boiler due to inadequate construction or maintenance.
935:"University of Rochester - Investigation of Steam Turbine Extraction Line Failures"
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806:, such as the Pritchard and Lamont and Velox boilers present the same advantages.
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The source of heat for a boiler is combustion of any of several fuels, such as
377:, a scheme for a multi-tube one-pass horizontal boiler made up of two units: a
587:
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232:
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17:
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typically use a smaller boiler that forms an integral part of the vehicle;
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suspended therein into more steam and greatly reducing water consumption.
838:
The preeminent code for testing fired steam generators in the USA is the
776:
668:
Supercritical steam generators are frequently used for the production of
490:
544:
780:
758:
Insufficient water in the boiler causing overheating and vessel failure
734:. The most common options for demineralization of boiler feedwater are
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202:
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The steam generator or steam boiler is an integral component of a
165:
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104:
83:
658:
Supercritical steam generator - note the absence of a boiler drum
469:
437:
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287:
194:
127:) but, at pressures above this, it is more usual to speak of a
88:
An industrial boiler, originally used for supplying steam to a
441:
36:
555:
gives the following equation determining the efficiency of a
502:
furnace pressure to be maintained slightly below atmospheric.
692:. This results in slightly less fuel use and therefore less
456:(HRSGs) use the heat rejected from other processes such as
468:
In order to create optimum burning characteristics of the
1046:
BS EN 12953-11: "Shell boilers. Acceptance tests." (2003)
258:
of 1712, the boiler was little more than large brewer's
227:
can then either be evacuated or made to pass through an
350:
A significant step forward came in France in 1828 when
60:
582:). Some superheaters are radiant type (absorb heat by
197:. The generated heat is transferred to water to make
873:"Simmonds's Colonial Magazine and Foreign Miscellany"
452:
is also used as a heat source for generating steam.
119:
and worked at low to medium pressure (7–2,000
591:is raised, the pressure of the steam is not: the
940:. Arlington, VA. pp. 25–26. Archived from
994:Doble Steam Cars, Buses, Lorries, and Railcars
875:. Simmonds and Ward – via Google Books.
8:
712:used in demineralization of boiler feedwater
933:Mischissin, Stephen G. (7 February 2012).
548:A superheated boiler on a steam locomotive
611:of the moving parts in the cylinders and
840:American Society of Mechanical Engineers
974:. Purolite International. November 2003
863:
822:production, steam boilers are used in
570:The superheater works like coils on an
193:in order to burn the fuel and generate
996:. "Light Steam Power" Isle of Man, UK
170:Type of steam generator unit used in
7:
923:p 46. Virtue and Company Ltd, London
886:TREDGOLD, Thomas (1 January 1827).
231:, the role of which is to warm the
25:
1007:"Boiler Water Treatment Services"
274:). The whole boiler was set into
54:to comply with Knowledge (XXG)'s
1077:
755:Overpressurization of the boiler
371:Liverpool and Manchester Railway
41:
162:As a component of a prime mover
897:– via Internet Archive.
852:Glossary of boiler terminology
650:Supercritical steam generators
633:Diagram of a water-tube boiler
476:equipment rather than natural
454:Heat recovery steam generators
282:. In later models, notably by
235:before it reaches the boiler.
1:
804:forced circulation generators
664:Supercritical steam generator
294:Cylindrical fire-tube boilers
250:Haycock and wagon top boilers
27:High pressure steam generator
223:. Any remaining heat in the
148:steam-powered road vehicles
103:is a device used to create
1116:
899:Blakey Cylindrical Boiler.
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29:
214:, or else may be further
152:stationary steam engines
67:may contain suggestions.
52:may need to be rewritten
172:coal-fired power plants
90:stationary steam engine
32:Boiler (disambiguation)
992:Walton J.N. (1965-74)
871:Simmonds, Peter Lund.
713:
659:
634:
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411:; Timothy Hackworth's
212:turbine and alternator
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893:. J. Taylor. p.
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394:Structural resistance
243:Further information:
181:when considered as a
169:
87:
1086:at Wikimedia Commons
526:which allows higher
356:Scotch marine boiler
30:For other uses, see
708:Large cation/anion
388:Stephenson's Rocket
369:, treasurer of the
156:fireless locomotive
919:Bell, A.M. (1952)
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639:Goldsworthy Gurney
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619:Water tube boilers
578:(2,372–2,912
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346:Multi-tube boilers
323:Richard Trevithick
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1082:Media related to
686:critical pressure
625:Water-tube boiler
584:thermal radiation
524:superheated steam
464:Solid fuel firing
375:George Stephenson
340:Timothy Hackworth
332:Lancashire boiler
201:, the process of
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766:Doble boiler
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740:ion exchange
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613:steam chests
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534:Superheaters
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403:(344.7
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315:wrought iron
313:cylindrical
306:Oliver Evans
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300:Flued boiler
284:John Smeaton
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221:condensation
179:steam engine
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107:by applying
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73:January 2022
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61:You can help
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978:23 February
951:23 February
921:Locomotives
824:agriculture
609:lubrication
540:Superheater
528:steam cycle
446:natural gas
367:Henry Booth
352:Marc Seguin
216:superheated
183:prime mover
109:heat energy
1019:PTC 4-2008
858:References
816:rice mills
730:and water
595:or moving
588:convection
553:L.D. Porta
482:flue gases
428:Combustion
422:Combustion
319:fire grate
270:(6.9
233:feed water
229:economiser
785:flow rate
738:(RO) and
732:carryover
724:corrosion
690:condenser
644:cast iron
276:brickwork
65:talk page
1094:Category
846:See also
802:Similar
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491:flue gas
399:50
365:of 1829
138:such as
834:Testing
728:foaming
597:pistons
593:turbine
478:draught
379:firebox
280:chimney
203:boiling
191:furnace
187:firebox
117:boilers
820:cement
746:Safety
742:(IX).
409:gusset
310:piston
264:vacuum
260:kettle
97:boiler
63:. The
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781:scale
444:, or
239:Types
199:steam
113:water
105:steam
980:2015
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890:Cuts
770:The
470:fire
438:coal
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288:flue
195:heat
146:and
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