Documente Academic
Documente Profesional
Documente Cultură
October 2005
PIP INEG1000
Insulation Design Guide
PIP will not consider requests for interpretations (inquiries) for this Practice.
PRINTING HISTORY
December 1997
April 1999
Issued
Complete Revision
October 2005
Complete Revision
COMPLETE REVISION
October 2005
PIP INEG1000
Insulation Design Guide
Table of Contents
1. Introduction................................. 2
2. References .................................. 2
2.1 Process Industry Practices................ 2
2.2 Industry Codes and Standards.......... 2
2.3 Other References .............................. 3
Categories ......................................... 3
Closed-Cell Insulations...................... 3
Fibrous Insulations ............................ 4
Granular Insulations .......................... 5
Jacket Materials and Accessories ..... 5
Vapor Barriers ................................... 7
9. Type Codes............................... 18
9.1
9.2
9.3
9.4
General ............................................ 18
Hot Insulation Types........................ 18
Cold Insulation Types ...................... 19
Insulation Types for Traced and
Energy Transfer Jacketed
Systems ........................................... 20
9.5 AC Acoustic Control Insulation..... 21
9.6 FP Fire-Protection Insulation........ 21
Page 1 of 27
PIP INEG1000
Insulation Design Guide
1.
COMPLETE REVISION
October 2005
Introduction
1.1
Purpose
This Practice provides guidance for the design of insulation systems.
1.2
Scope
This Practice describes the types of insulation systems that are indicated by the
type code on the Piping and Instrumentation Diagrams (P&IDs), data sheets, and
other design documents. This Practice provides guidance on insulation design
criteria, insulation materials, extent of insulation, determination of insulation
thickness, and insulation material properties.
2.
References
Applicable parts of the following Practices, industry codes and standards, and references
shall be considered an integral part of this Practice. The edition in effect on the date of
contract award shall be used, except as otherwise noted. Short titles will be used herein
where appropriate.
2.1
2.2
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COMPLETE REVISION
PIP INEG1000
Insulation Design Guide
October 2005
Other References
Federal Energy Administration Report
3.
Insulation Materials
3.1
Categories
Insulation materials fall into the following three major generic categories based
on the structure of the insulation material and each has properties that give it
unique performance characteristics:
a. Closed cell
b. Fibrous
c. Granular
3.2
Closed-Cell Insulations
3.2.1
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PIP INEG1000
Insulation Design Guide
COMPLETE REVISION
October 2005
a. Cellular glass
b. Various organic materials such as rigid polymer foams,
polyisocyanurate, polyurethane, and polystyrene
c. Elastomeric foams
3.3
3.2.2
3.2.3
3.2.4
3.2.5
While the rigid foams and cellular glass have some strength, damage
resistance is not necessarily provided. The elastomeric foams are resilient
and should resist light physical abuse.
3.2.6
Fibrous Insulations
3.3.1
3.3.2
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COMPLETE REVISION
PIP INEG1000
Insulation Design Guide
October 2005
rock; fiberglass and E glass are made from inorganic glass fibers; and
ceramic fibers are made from inorganic ceramics.
3.4
3.5
3.3.3
3.3.4
3.3.5
Granular Insulations
3.4.1
3.4.2
3.4.3
3.5.2
Aluminum Jacketing
3.5.2.1 The most commonly used jacket material in chemical and
petrochemical plant applications is aluminum. The aluminum
materials are available in several thicknesses and finishes
depending on the application. The two major aluminum finishes
are stucco-embossed and smooth. Stucco-embossed aluminum
has a rough finish that is rolled into the sheet metal during
manufacture. The benefit of this finish is that minor surface
Page 5 of 27
PIP INEG1000
Insulation Design Guide
COMPLETE REVISION
October 2005
Page 6 of 27
COMPLETE REVISION
PIP INEG1000
Insulation Design Guide
October 2005
4.
Vapor Barriers
3.6.1
Insulation systems that operate below the ambient dew point temperature
must be protected from the inward permeation of moisture. Water vapor
permeability is measured using ASTM test method E96, and the results
are reported in perms. Lower perm ratings represent better resistance to
moisture penetration. Closed-cell insulation materials have low perm
ratings, while fibrous and granular materials are generally not evaluated
for permeation. Because of the low perm rating, closed-cell materials are
used for low-temperature applications.
3.6.2
General
4.1.1
4.1.2
The insulation materials chosen depend upon the reasons that insulation
is being used. Many different criteria are important in the selection of an
insulation system. Not all the criteria mentioned in this Practice apply in
all cases. The criteria that apply to a project should be determined, and
priorities should be assigned to those criteria. In some cases, it may be
that only heat conservation or personnel protection are important. In
most projects, many criteria apply with some being much more important
than others. Because each project is unique, the criteria should be
assessed for each project, and selections should be made that are
Page 7 of 27
PIP INEG1000
Insulation Design Guide
COMPLETE REVISION
October 2005
Cold conservation
The possible reasons are aligned with the PIP type codes that are used on
P&IDs to designate the insulation type.
4.2.2
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Insulation Design Guide
October 2005
Page 9 of 27
PIP INEG1000
Insulation Design Guide
4.2.4
COMPLETE REVISION
October 2005
4.2.5
4.2.6
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COMPLETE REVISION
PIP INEG1000
Insulation Design Guide
October 2005
4.3
Location of Facilities
The location of the items to be insulated determines the ambient
conditions that should be used in calculating the insulation thickness.
Location also plays an important role in the choice of accessories such as
the jacket type and the method of securement. In high wind areas, band
spacing should be reduced to keep the jacket in place. In corrosive areas
such as close to the seacoast or corrosive chemical fumes, it may be
necessary to select a jacket material that is resistant to the specific
corrosive condition. Equipment that is located inside a building is not
exposed to weather extremes or UV light and less durable jacket
materials, or in some cases no jacket material, can be suitable.
4.3.2
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PIP INEG1000
Insulation Design Guide
COMPLETE REVISION
October 2005
Appearance
Appearance requirements sometimes determine the type of jacket or
finish material that must be used. Applications that require a
continuously high degree of cleanliness can specify a jacket material that
has a gloss white or polished stainless steel finish to facilitate both
identification and removal of surface contamination. Embossed surface
finishes on metal jacket materials can be used to make minor surface
damage less visible to casual observation; however, it is more difficult to
clean embossed jackets. Smooth finishes are more reflective, and damage
is more easily visible.
4.3.4
Leak Detection
4.3.4.1 Leak detection is a regulatory requirement for some chemical
processes. If insulating piping and equipment that contains
chemicals that fall within the leak detection classification, it is
necessary to design the insulation to permit detection of leaks at
flanges, valves, and other locations that can be prone to leakage.
4.3.4.2 Leak detection provision can be done in hot systems by not
insulating leak-prone items or by using removable reusable
insulation as specified in PIP INSR1000. This approach is not an
option for low-temperature systems because there would be no
vapor seal and condensation or ice formation can occur. Lowtemperature systems require special consideration and should be
handled on a case-by-case basis.
4.3.5
Absorption Resistance
The absorption resistance of the insulation material is an important
attribute if insulating piping and equipment that contain flammable or
explosive chemicals. If leaks occur and the insulation absorbs the
chemical, it is possible to build up enough of the flammable or explosive
chemical to achieve auto-ignition. It may be necessary to use an
appropriate closed-cell insulation that is compatible with the chemical
and does not absorb leaks. It is desirable to provide drainage to enable
the leaking chemical to escape from the insulation in a controlled
fashion.
4.3.6
Emissivity
4.3.6.1 Emissivity is a measure of a bodys ability to radiate energy. A
body that radiates a large amount of energy has an emissivity
close to 1, while a material that is a poor radiator has a low
emissivity. All materials have a characteristic emissivity. New
aluminum jacket has an emissivity of about 0.04, while PVC
jacket has an emissivity of about 0.9. The emissivity value can
change as the surface characteristics of the insulation change
with time.
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COMPLETE REVISION
PIP INEG1000
Insulation Design Guide
October 2005
5.
5.2
5.3
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PIP INEG1000
Insulation Design Guide
6.
COMPLETE REVISION
October 2005
General
6.1.1
6.1.2
6.2
Not all insulation materials perform equally well with respect to these
design criteria. Each insulation type has strengths and weaknesses and
the strengths of the material selected for a specific job should be matched
to the most important design criteria for that job. For example, a low
permeation material should be chosen for a low-temperature application
in which permeation resistance is needed to prevent condensation on the
surface of the insulated item. A rigid high compressive strength material
should be chosen in situations in which mechanical abuse is likely.
ASTM Considerations
6.2.1
Water wicking
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COMPLETE REVISION
PIP INEG1000
Insulation Design Guide
October 2005
6.3
There is no ASTM test for water wicking except for aircraft-type glass
fiber blanket as published in ASTM C800. Some manufacturers test
material using the ASTM C800 procedure however, the appropriateness
of this procedure for all materials has not been demonstrated. The
relevance of the procedure to real world applications is also not clear. If
in doubt about the appropriate use of a specific insulation material
contact the owners representative for guidance.
7.
Extent of Insulation
7.1
Extent of insulation refers to what can and cannot be insulated during a project.
PIP datasheets INSH1000-D3 and INSC2001 can be used to specify the extent of
insulation for a project. The extent of insulation varies depending on the design
criteria. For example, in the case of heat conservation, flanges, valves, or other
potentially high maintenance items can be left uninsulated to facilitate leak
detection and repairs. In the case of cold conservation, piping items cannot be left
uninsulated because condensation and ice formation can occur. As a general rule,
all low-temperature surfaces should be insulated. Both heat conservation and
process stability applications should be insulated as much as possible to ensure
these criteria are met.
7.2
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PIP INEG1000
Insulation Design Guide
COMPLETE REVISION
October 2005
8.
Insulation Thickness
8.1
General
8.1.1
8.1.2
8.2
Page 16 of 27
3E Plus
8.2.1
8.2.2
COMPLETE REVISION
PIP INEG1000
Insulation Design Guide
October 2005
does not produce an accurate result. The 3E Plus users guide provides a
detailed description of the basis for the economic analysis that goes
beyond the scope of this discussion. Among the data required by 3E Plus
is climate information that requires both ambient temperature and wind
speed. Both affect heat transfer. Climate data for many locations in the
U.S. is available at www.noaa.gov, the website of the National Oceanic
and Atmospheric Administration (NOAA). The actual climatic data used
depends upon the design criteria of the project and the location of the
item to be insulated.
9.
8.2.3
8.2.4
Type Codes
9.1
General
9.1.1
9.1.2
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PIP INEG1000
Insulation Design Guide
9.2
COMPLETE REVISION
October 2005
9.2.2
9.2.3
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PIP INEG1000
Insulation Design Guide
October 2005
9.2.3
9.3
9.3.2
9.4
General Considerations
9.4.1.1 The primary consideration for using tracing or heat transfer
jacketing and associated insulation should be control of process
temperatures.
9.4.1.2 Design of insulation should be based on the operating
temperature, heat transfer jacketing temperature, or the tracer
Page 19 of 27
PIP INEG1000
Insulation Design Guide
COMPLETE REVISION
October 2005
ET Electric Traced
Electric tracing and associated insulation should be designated with the
code ET.
9.4.3
ST Steam Traced
Steam tracing and associated insulation should be designated with the
code ST.
9.4.4
SJ Steam Jacketed
Steam jacketing and associated insulation should be designated with the
code SJ.
9.4.5
9.4.6
9.4.7
9.4.8
9.5
Page 20 of 27
9.5.2
9.5.3
9.5.4
COMPLETE REVISION
PIP INEG1000
Insulation Design Guide
October 2005
9.5.5
9.6
FP Fire-Protection Insulation
9.6.1
9.6.2
9.6.3
9.6.4
Refer to API RP521, API Publication 2218, and API RP2001 for
additional information on fire protective insulation.
9.6.4
Page 21 of 27
PIP INEG1000
Insulation Design Guide
COMPLETE REVISION
October 2005
Calcium
Silicate Pipe
& Block
C533-95
(R2001),
Type 2
Expanded
Perlite Block
and Pipe
C610-99
Flexible
Elastomeri
c Cellular
C 534-03,
Grade 1
Flexible
Elastomeric
Cellular
C 534-03,
Grade 2
Max Temp, F
1200
1700
1200
220
350
Min Temp, F
N.A.
N.A.
80
-70
-40
Density, lb/ft3
15.0 (max)
22.0 (max)
10.0 (min)
14.0 (max)
consult
manufacturer
consult
manufacturer
100
100
60
N.A.
N.A.
2%, max,
(C411,
1200F)
2%, max,
(C411,
1700F)
2%, max,
length
2%, max, width
8%, max, thick
(C356,
1200F)
5%, max,
(C356, 220F)
7%, max,
(C356, 350F)
4x dry weight
4x dry weight
50% by weight,
@600F
(C610)
0.20% by vol.
(C209)
0.20% by vol.
(C209)
N.A.
0.10 perm-in.
(E96,
desiccant
method,
50% RH,
73F)
0.10 perm-in.
(E96,
desiccant
method,
50% RH, 73F)
consult
manufacturer
consult
manufacturer
Material Properties
Compressive strength,
min., psi
(C165, unless noted)
Dimensional Stability
Absorption, max.
Water Vapor
Transmission/
Permeability, max.
N.A.
N.A.
Surface burning
characteristics (E84):
Flame spread
Smoke developed
Apparent thermal
conductivity (k),
Btu-in./h-ft2-F, at
mean temperature (F)
Page 22 of 27
0.45
200
0.54
200
0.55
200
0.25
-20
0.25
-20
0.50
300
0.58
300
0.60
300
0.26
0.26
0.55
400
0.61
400
0.66
400
0.28
75
0.30
75
0.60
500
0.64
500
0.74
500
0.30
120
0.32
120
0.66
600
0.67
600
0.80
600
0.31
150
0.34
150
0.71
700
0.70
700
0.88
700
0.42
300
0.73
800
0.75
900
0.77
1000
COMPLETE REVISION
PIP INEG1000
Insulation Design Guide
October 2005
Mineral
Fiber Pipe
C547-03
Type I,
Grade A
Grade B
Mineral
Fiber Pipe
C547-03
Type II, III
Grade A
Grade B
Mineral
Fiber Pipe
C547-03
Type IV,
Grade A
Grade B
Mineral
Fiber
Blanket
C592-04
Type I
Max Temp, F
250
850
1200
1000
850
Min Temp, F
-40
N.A.
N.A.
N.A.
N.A.
Density, lb/ft3
consult
manufacturer
consult
manufacturer
consult
manufacturer
consult
manufacturer
10.0 (max)
Compressive
strength, min., psi
(C165, unless noted)
N.A.
N.A.
N.A.
N.A.
N.A.
Dimensional Stability
7%, max,
(C356,
250F)
2%, max,
(C356, 850F)
2%, max,
(C356,
1200F)
2%, max,
(C356,
1200F)
4%, max,
(C356, 850F)
Absorption, max.
0.20% by vol.
(C209)
2% by weight
(C1104)
2% by weight
(C1104)
2% by weight
(C1104)
5% by weight
(C1104)
Water Vapor
Transmission/
Permeability, max.
0.10 perm-in.
(E96,
desiccant
method,
50% RH,
73F)
N.A.
N.A.
N.A.
N.A.
Surface burning
characteristics (E84):
consult
manufacturer
Flame spread
25
25
25
25
Smoke developed
50
50
50
50
Material
Properties
Apparent thermal
conductivity (k),
Btu-in./h-ft2-F, at
mean temperature
(F)
0.25
-20
0.25
100
0.25
100
0.25
100
0.25
75
0.26
0.31
200
0.31
200
0.31
200
0.27
100
0.28
75
0.40
300
0.37
300
0.37
300
0.34
200
0.30
120
0.51
400
0.45
400
0.45
400
0.43
300
0.31
150
0.64
500
0.54
500
0.54
500
0.55
400
0.65
600
0.65
600
0.70
500
0.77
700
0.77
700
Page 23 of 27
PIP INEG1000
Insulation Design Guide
COMPLETE REVISION
October 2005
Material
Properties
Mineral
Fiber
Blanket
C592-04
Type II
Mineral
Fiber Board
& Block
C612-04
Type IA
Mineral
Fiber Board
& Block
C612-04
Type IB
Mineral
Fiber Board
& Block
C612-04
Type II
Mineral
Fiber Board
& Block
C612-04
Type III
1200
450
450
850
1000
Max Temp, F
Min Temp, F
N.A.
N.A.
N.A.
N.A.
N.A.
Density, lb/ft3
12.0 (max)
8.0 (max)
8.0 (max)
8.0 (max)
10.0 (max)
Compressive
strength, min., psi
(C165, unless noted)
N.A.
N.A.
0.17
(Category 2
only)
0.17
(Category 2
only)
0.08
(Category 2
only)
Dimensional Stability
4%, max,
(C356,
1200F)
2%, max,
(C356, 450F)
2%, max,
(C356,
4500F)
2%, max,
(C356,850F)
2%, max,
(C356,
1000F)
5% by weight
(C1104)
5% by weight
(C1104)
5% by weight
(C1104)
5% by weight
(C1104)
5% by weight
(C1104)
N.A.
N.A.
N.A.
N.A.
N.A.
Flame spread
25
25
25
25
25
Smoke developed
50
50
50
50
50
Absorption, max.
Water Vapor
Transmission/
Permeability, max.
Surface burning
characteristics (E84):
Apparent thermal
conductivity (k),
Btu-in./h-ft2-F, at
mean temperature
(F)
Page 24 of 27
0.25
75
0.26
75
0.26
75
0.25
75
0.25
75
0.27
100
0.28
100
0.27
100
0.27
100
0.27
100
0.34
200
0.36
200
0.34
200
0.35
200
0.35
200
0.42
300
0.46
300
0.42
300
0.44
300
0.44
300
0.53
400
0.55
400
0.55
400
0.64
500
0.70
500
0.70
500
0.75
600
0.90
600
0.86
700
COMPLETE REVISION
PIP INEG1000
Insulation Design Guide
October 2005
Mineral
Fiber Board
& Block
C612-04
Type IVB
Mineral Fiber
Board &
Block
C612-04
Type V
Cellular Glass
Block
C552-03
Grade 1,
Types I, II, III
Max Temp, F
1200
1200
1800
800
Min Temp, F
N.A.
N.A.
N.A.
-450
Material
Properties
Density, lb/ft
12.0 (max)
12.0 (max)
20.0 (max)
6.12 (min)
8.62 (max)
Compressive
strength, min., psi
(C165, unless noted)
0.35
(Category 2
only)
0.35
(Category 2
only)
6.94
(Category 2
only)
60
(capped per
C240)
Dimensional Stability
2%, max,
(C356,
1200F)
2%, max,
(C356,
1200F)
4%, max,
(C356, 1800F)
N.A.
5% by weight
(C1104)
5% by weight
(C1104)
5% by weight
(C1104)
0.5% by weight
(C552)
N.A.
0.005 (max),
in.thk./hft2in. Hg
(E96, water
method,
73F to 90F)
Absorption, max.
Water Vapor
Transmission/
Permeability, max.
N.A.
N.A.
Flame spread /
smoke
developed varies
for Type II and III
fab methods
Surface burning
characteristics (E84):
Flame spread
25
25
25
Smoke developed
50
50
50
Apparent thermal
conductivity (k),
Btu-in./h-ft2-F, at
mean temperature
(F)
(block only)
(consult manuf.
for pipe)
k
0.25
75
0.27
100
0.24
75
0.25
100
0.45
75
0.20
-150
0.45
100
0.22
-100
0.34
0.44
200
0.30
300
0.36
200
0.47
200
0.24
-50
300
0.49
300
0.27
0.55
400
0.42
400
0.52
400
0.30
50
0.70
0.85
500
0.53
500
0.55
500
0.31
75
600
0.63
600
0.59
600
0.33
100
1.00
700
0.75
700
0.63
700
0.40
200
0.67
800
0.48
300
0.58
400
Page 25 of 27
PIP INEG1000
Insulation Design Guide
COMPLETE REVISION
October 2005
Material Properties
Cellular Glass
Block
C552-00
Grade 2,
Types I, II, III,
IV
Rigid Cellular
Polyisocyanurate
C591-01
Grade 2
Type IV
Rigid Cellular
Polyisocyanurate
C591-01
Grade 2
Type II
Rigid Cellular
Polyisocyanurate
C591-01
Grade 2
Type III
800
300
300
300
Max Temp, F
Min Temp, F
-450
-297
-297
-297
Density, lb/ft
6.80 (min)
9.74 (max)
2.0 (min)
2.5 (min)
3.0 (min)
Compressive strength,
min., psi
(C165, unless noted)
60
(capped per
C240)
21
35
45
Dimensional Stability
N.A.
0.5% by weight
(C552)
0.5% by vol.
(C272, Proc. A)
0.7% by vol.
(C272, Proc. A)
0.8% by vol.
(C272, Proc. A)
Water Vapor
Transmission/
Permeability, max.
0.005 (max),
in.thk./hft2in. Hg
(E96, water
method,
73F to 90F)
4.0 perm-in.
(E96, desiccant
method, 73F)
3.5 perm-in.
(E96, desiccant
method, 73F)
3.0 perm-in.
(E96, desiccant
method, 73F)
Surface burning
characteristics (E84):
Flame spread /
smoke
developed varies
for Type II and III
fab methods
consult
manufacturer
consult
manufacturer
consult
manufacturer
(block only)
(consult manuf. for
pipe)
(block only)
(consult manuf. for
pipe)
(block only)
(consult manuf. for
pipe)
Absorption, max.
Flame spread
Smoke developed
Apparent thermal
conductivity (k),
Btu-in./h-ft2-F, at
mean temperature (F)
(block only)
(consult manuf.
for pipe)
Page 26 of 27
0.26
-150
0.13
-200
0.13
-200
0.14
-200
0.27
-100
0.15
-150
0.15
-150
0.16
-150
0.29
-50
0.17
-100
0.17
-100
0.18
-100
0.31
0.19
-50
0.19
-50
0.20
-50
0.34
50
0.18
0.18
0.19
0.35
75
0.17
50
0.17
50
0.18
50
0.37
100
0.18
75
0.18
75
0.19
75
0.44
200
0.22
150
0.22
150
0.23
150
0.52
300
0.24
200
0.24
200
0.26
200
0.63
400
COMPLETE REVISION
PIP INEG1000
Insulation Design Guide
October 2005
Rigid Cellular
Phenolic
C1126-00
Type II
Grade 2
Max Temp, F
257
Min Temp, F
-290
Material
Properties
Density, lb/ft
Rigid Cellular
Phenolic
C1126-00
Type III
Grade 1
Rigid Cellular
Phenolic
C1126-00
Type III
Grade 2
257
257
257
-40
-290
-40
2.0 (min)
2.0 (min)
3.0 (min)
3.0 (min)
18
18
18
18
Compressive
strength, min., psi
(C165, unless noted)
Dimensional Stability
8.0% by vol.,
foam core
(C209)
8.0% by vol.,
foam core (C209)
1.0 perms
(faced)
0.15 perm-in.
(core)
(E96, desiccant
method)
foam core,
no facings
foam core,
no facings
foam core,
no facings
foam core,
no facings
Flame spread
25
25
25
25
Smoke developed
50
50
50
50
(foam core)
(foam core)
(foam core)
(foam core)
0.10
-250
0.10
-250
0.11
-200
0.11
-200
0.12
-150
0.12
-150
0.13
-100
0.13
-100
0.13
-50
0.13
-50
40
Absorption, max.
Water Vapor
Transmission/
Permeability, max.
Surface burning
characteristics (E84):
Apparent thermal
conductivity (k),
Btu-in./h-ft2-F, at
mean temperature
(F)
0.13
0.13
40
0.21
0.13
75
0.15
110
0.13
40
0.13
40
0.21
0.23
75
0.13
75
0.23
75
0.25
110
0.15
110
0.28
110
0.18
150
0.28
150
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