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USING ISOCHRONOUS LOAD-SHARING PRINCIPLES

WITH GAS AND STEAM TURBINE GENERATORS

©istockphoto.com/allkindza
By Krishnanjan Gubba Ravikumar,
Brandon Bosley, Ty Clark, and Julio Garcia

A liquefied natural gas facility in the United States is being expanded


to allow the liquefaction of natural gas and exportation of liquefied natural gas while
keeping intact its existing import facilities. This means it will add more loads and
steam-based generation to its existing gas turbine generator (GTG) portfolio. The
upgraded system will feature six GTGs and two steam turbine generators (STGs)
in an islanded plant with no grid connection. This article reveals the fundamentals

Generation Control Systems


Digital Object Identifier 10.1109/MIAS.2018.2875127
Date of publication: 19 December 2018

36 IEEE Industry Applications Magazine œ March/April 2019 1077-2618/19©2019IEEE


of how the plant performs isochronous load sharing Generation Control Systems
in an islanded power system with various makes and The objective of a GCS is to maintain the system’s frequen-
sizes of generators (steam and gas turbines) and details cy and voltage during everyday operations and provide
the decentralized generation control system interface support during system events. A GCS combines low- and
methodology with automatic speed governors and volt- high-speed functions to ensure safe and optimal control
age regulators. Also presented are some topics that are of the machines to maintain system stability. Control func-
crucial for industrial power systems—particularly in tions such as base loading, droop control, and isochronous
islanded configurations—as well as the transient simu- load sharing allow the GCS to maintain and regulate fre-
lations performed in a controlled lab environment that quency for any planned or unplanned system events. Simi-
analyze system stability and help finalize the generator larly, functions such as voltage control, power factor (PF)
modes of operation. control, and volt-ampere-reactive (VAR) sharing allow the
proper regulation of reactive power within a system. Com-
Overview of the Expansion pared with larger grids, islanded power systems require rel-
One of the key requirements for islanded power system atively faster-acting control systems during system events to
stability is the ability to monitor and control all of the compensate for the reduced overall system inertia. Figure 2
generators that maintain voltage and frequency. Gen- shows a high-level architecture and distributed controller
eration control systems (GCSs) typically perform slow- connections in a case with two STGs.
and high-speed rebalancing actions, depending on the
control objective [1]. This article discusses a decentral- Frequency Control System
ized (distributed) GCS applied to an islanded power A frequency control system (FCS) regulates the generators
system with a mix of STGs and GTGs from various to maintain the system’s frequency when an accelerating or
manufacturers, while advancing the concepts originally decelerating torque develops, e.g., during a machine step-
presented in [2]. load response for either accepting or rejecting a change in
The previously mentioned gas facility features six load. Such a torque also develops during or after system
GTGs in an islanded configuration with no grid con- events, e.g., faults and unexpected load/generation trips.
nection. Five of the GTGs are from the same manufac- Figure 3 shows the frequency, electrical power, and
turer with different ratings, although all of the GTGs mechanical power responses of an industrial frame tur-
operate at 13.8-kV nominal voltage and can operate in bine and generator for a small-load step response [3]. The
an isochronous load-sharing mode. The plant also has step change in electrical power along with the time lag
four synchronous motors. A new expansion will add between the generator and turbine output are also dis-
two generators to the system that are driven by high- played in Figure 3.
speed steam turbines equipped with gears. The new The basic, underlying equation that relates to mechani-
expansion will also add one 26-MW and two 20-MW cal power, electrical power, and speed is
variable-frequency drive-operated motors. Figure 1
shows a simplified one-line diagram of the facility’s dW m
JW s = Pa = Pm - Pe,(1)
power system without any load representation. dt

GTGs
9.42 MW

9.42 MW

9.42 MW

GTGs STGs GTG


25.312 MW 25.312 MW 65 MW 65 MW 15.605 MW

13.8 kV
13.8 kV (60 Hz) 13.8 kV 13.8 kV
(60 Hz) Bus A Bus B (60 Hz) Bus D (60 Hz) Bus C

FIGURE 1. A simplified one-line diagram.

M arch/A p ri l 2019 œ IEEE Industry Applications Magazine 37


where J is the combined moment
STG-A STG-B of inertia of the generator and tur-
bine (kg # m2 ), W s is the synchro-
nous angular velocity (rad/s), W m is
the rotor angular velocity (rad/s), t
is the time (s), Pa is the accelerat-
CT Input CT Input ing power (W ), Pm is the mechanical
VT Input VT Input
power (W ), and Pe is the electrical
power (W ).
A typical FCS operates on a pro-
Open Open
Distributed Distributed portional megawatt-sharing philoso-
Controller Controller phy and tries to maintain all of the
Status Status units within their respective capabil-
VT Input VT Input ity curves. The generators within the
facility operate in two out of three
available frequency control modes.

Isochronous Load Sharing


Ethernet In isochronous load-sharing mode,
Other Substation Switch Other Substation
Generators Generators all of the ­generators within the plant
are set to isochronous mode on their
Communications Cables
speed governors. Using a common
communications backbone, the dis-
FIGURE 2. The high-level architecture of distributed controllers in a two-generator case.
CT: current transformer; VT: voltage transformer. tributed controllers connected in the
island exchange information and regu-
late the generators to maintain frequency during load imbal-
98 63 ances. In addition to maintaining frequency, controllers
97 also perform proportional, real power sharing between the
62
Frequency (Hz)

96 units based on their rated megawatt capacity.


Power (MW)

61
95
The regulation at each unit is performed by biasing
60 the speed governor using a control signal (typically an
94
93 Electric Power 59 analog bias). This bias adds into or subtracts from the
Mechanical Power 58 speed reference (nominal speed) of the governor con-
92 Speed = Frequency
trol itself. The response of the bias signal is defined
91 57
0 5 10 15 20 by a proportional-integral-derivative (PID) control that
Time (s) exists within the GCS controller.
Figure 4 shows the integration of the bias signal into
FIGURE 3. A small-load synchronous machine step response. a typical governor-controlled block diagram. The con-
ditioner block is used to limit and
scale the bias for use in the gover-
Valve/Gate nor control system. The speed bias
Pm
Turbine Pe integrator time constant, limits, and
Steam Wr gain are field-tunable parameters
∆Y – that obtain the desired response
+ + from the machine.
Integrator –K Σ Σ Speed
∆Wr Reference W0 A high-level block diagram of the
+
frequency control function within
Integrator the distributed controller is shown
in Figure 5. Depending on the type
Conditioner of control selected, different logic is
activated along with the PID loop.
Speed Bias Figure 6 shows single-unit iso-
(Analog Signal) chronous governor regulation for
different bias conditions. During a
FIGURE 4. The block diagram of an isochronous governor with integrated speed bias (analog control situation, the GCS dynami-
bias input). cally calculates the bias set points

38 IEEE Industry Applications Magazine œ March/April 2019


for each generator before dispatching controls. These set Voltage Control System
points change rapidly as the system adjusts to a newer set- A voltage control system (VCS) dispatches exciter set
tling state after a disturbance of the equilibrium. points among a group of generators to maintain the ter-
Isochronous load sharing between multiple units provides minal bus voltages within acceptable limits [1]. The VCS
the ability to reject frequency disturbances and to active- at the aforementioned facility is implemented within the
ly share the load. In cases with fast-acting speed governors same distributed controllers used for the FCS. Similar to an
that operate in isochronous load-sharing mode, generator- FCS, a VCS issues control signals to every generator to keep
shedding schemes can mostly be eliminated, assuming the
generators have enough headroom to swing.
Load-Sharing
Droop Control Logic
For stable load sharing between multiple units paralleled to
Power Control
strong sources, droop-based control allows multiple units to
Control Logic +
operate in parallel by decreasing their speed for increases Σ PID Loops* Bias
Frequency + Signal
in load. Droop control is typically observed in units that Control
are paralleled to utility grids. In islanded power systems, Control Logic
droop-only control (without isochronous operation) is not *Different PID Loops Are Activated Based
recommended because of its inability to actively maintain on the Type of Control
the system frequency during system events. It is important to
note that droop-only control can be allowed where a system, FIGURE 5. The high-level block diagram of an individual distributed
such as a GCS, is available to provide functionality similar to controller.
an isochronous control.

Base Loading Positive Bias


Base loading is performed on a generator to follow a pre-
set megawatt command. This is sometimes referred to as 100% No Bias
maintained mode, in which the operator requests a certain
output from a few generators while others provide regula-
Speed

tion using droop and/or isochronous controls. Generators Negative Bias


are typically maintained when they are in parallel to the
utility, have smaller ratings, or do not have the built-in
ability to assist with primary frequency regulation.
Figure 7 shows the response of an STG for different 50% 100%
base load transitions. Starting at 37 MW, the machine is
stepped through various set points, and the figure shows Load
the response of the speed bias signal, generator frequen-
cy, and active power response. FIGURE 6. A single-unit isochronous governor regulation with GCS bias.

65,000 65
Generator Active Power
5–60 MW
Generator Frequency (Hz)

Speed Bias 60–37 MW


37–15 MW
kW

60

Generator Frequency
15–5 MW
Load
Reference

0 55
0 4.7 9.4 14.1 18.8 23.5 28.2 32.9 37.6 42.3 47
Time (min)

FIGURE 7. The base load tests on a single STG model using real GCS controller equipment.

M arch/A p ri l 2019 œ IEEE Industry Applications Magazine 39


them running at the desired mega- 2) PF control: In this mode, every
VAR (MVAR) output level. Although distributed controller follows the
the external interface between the A typical FCS operates operator set point on a per-
VCS and the generator exciter consists machine basis. This mode is typi-
of raise and lower control signals, on a proportional cally used when the generator is
there can be different control inner
loops within the VCS. For example,
megawatt-sharing in parallel with the utility and
needs to maintain its PF through-
during an islanded situation, the philosophy and tries out the real power operating
VCS implements a generator volt- range. During PF control, the
age control inner loop to maintain to maintain all of the controller does not try to main-
the island bus voltages rather than
implementing a VAR control loop to
units within their tain the bus voltage and does not
need to exchange information
maintain a fixed VAR output. Similar respective capability with the rest of the controllers
to isochronous operation for main- because sharing is not occurring.
taining system frequency, a VCS is curves. This mode is only recommended
requir­­ed to keep at least one unit (if when there are other machines
not more) to maintain and regulate available to provide voltage sup-
the bus voltages. port and balance the system reac-
A typical VCS operates on a proportional MVAR- tive power needs.
sharing philosophy and tries to maintain all of the units The control loop parameters for achieving the desired
within their respective capability curves. The generators PF are separate from the voltage control parameters. This
within the facility operate in two different voltage con- way, two independent loops are established and tuned for
trol modes. fast- and slow-acting controls.
1) Voltage control with VAR sharing: In this mode, the
primary objective of the VCS is to maintain the bus Island Tracking System
voltages at each generator terminal and proportion- Controlling multiple generators within an island requires
ally share the MVAR based on the unit ratings. The a smart island tracking system to correctly enable the
distributed VCS dynamically calculates the individ- control modes on the governors and exciters. Island
ual set points for each excitation system and biases detection is traditionally performed by tracking the sys-
the excitation reference to achieve the desired set tem topology using breaker statuses (52 A and 52 B). In
point. Figure 8 shows the interfacing of the bias (raise/ this application, these statuses are brought into a central-
lower pulses) with a typical generator excitation system. ized location to properly identify islands and update the
When the bias signal is an analog input, the interface distributed controllers. When provided with such infor-
is similar to what is shown in Figure 4. mation, the controllers correctly identify the groups of
generators that need to be controlled
in every island.
Vset
+ Synchronization System
– KA VR + 1 The distributed GCS controllers
Vinput Σ VE
1 + STA STE within the plant provide the abil-
+ –
Vbias VX = VE . SE (VE) ity to synchronize across individual
+ generator breakers and some of the
Σ KE critical tie breakers. Breaker closing
+
+ and generator control for synchro-
KD Ifa nization are performed automati-
Vraise cally after the user selection and
Start
+Edge initiation [4]. This important func-
Adjust + +
Timer tion helps the plant successfully
Stop Gain Σ
–Edge reconnect because the islanded

Control Signal plant itself can become further
Vlower segregated into subislands follow-
Start
+Edge ing particular events or even dur-
Adjust
Timer ing normal operating conditions.
Stop Gain
–Edge After the events are cleared and
the islands are stabilized, the auto-
FIGURE 8. The block diagram of an ac exciter with integrated voltage bias (digital bias input). matic ­synchronization system can

40 IEEE Industry Applications Magazine œ March/April 2019


control the governor and exciters automatically to match In addition to the generator and load-protection systems,
the phase, voltage, and frequency error between the the plant has a primary contingency-based load-shedding
islands. Once the closing criterion is met (along with system, a backup frequency-based load-shedding system,
the availability of operator permissives), the controller and an intertie tripping system based on available genera-
that has access to the generator breaker provides the tion and overload conditions.
close command.
Testing Using a Real-Time Hardware Simulator
Communications Architecture To verify and validate the GCS performance, the authors
Modern power management systems are a complete inte- developed a computer simulation model of the plant in
gration of protection, control, and automation devices [1]. a commercial real-time hardware simulator. The simulator
GCSs are no different when it comes to how to monitor provides the ability to connect the actual controllers (real
and control generators. Communications play a vital equipment) under test in a closed-loop fashion with the
role in both centralized and decentralized architectures. plant model. This allows for the exchange of measurement
Because of the necessity of measuring local quantities and control signals in real time to evaluate the true perfor-
and making a wide-area decision, various intelligent mance of the GCS functions. Figure 9 shows a block dia-
electronic devices (IEDs) send measurements to a central- gram of the simulator testing setup.
ized controller, or controllers located at the generators The model contains detailed plant information, includ-
constantly exchange critical information pertinent to each ing generator electrical and mechanical parameters, actual
generator. With the criticality of the application, such governor and excitation models and parameters (obtained
communications networks need to be dedicated and iso- from the manufacturer), network impedances, detailed load
lated from noncritical traffic to avoid network overloads, models (e.g., static, induction, and synchronous motors),
lost data packets, and failure [5]. A dedicated bandwidth and voltage- and frequency-protection systems. This level
is crucial for guaranteeing round-trip times for high- of detail allows for accurate testing of the controller perfor-
speed functions [6]. mance for various system events and conditions.
The facility applies a distributed GCS with controllers Before performing the closed-loop tests, the authors
located at each generator. These controllers are connected validated every component in the model and the full model
via copper Ethernet connections to locally managed Eth- itself. Generator validation tests included load rejection,
ernet switches within the substations. The substations load acceptance, full-speed no load, and exciter step tests
are further connected through a
combination of single- and mul-
timode fiber connections to form DI
an isolated, star-connected net-
Hardwire Currents and
work. Each distributed controller
Analogs Voltages
provides two physical network Real-Time Distributed
connections for redundancy. This Simulator Simulator AO AO AI Controller
Amplifier
forms an A network and a B net- Hardwire I/O Cards (Each
Digitals Generator)
DO DI
work across the system, each
with dedicated Ethernet switches. IEC 61850
TCP
GOOSE
Coordination With the
Protection and Control AI DI
Interface
System PLC
Proper coordination of all the
protection and control systems is UDP
critical for ensuring smooth plant Interface DI AI DO AO
UDP PLC Card Card Card Card
operation. The GCS was designed
considering the plant load-shed-
ding system, intertie tripping Operator
Island
system, and generator and load- UDP Set Points
Detection
protection systems; this ensures System
Island Identification
optimal control of the system fre-
quency and voltage at all times. Bias Signals
Improper coordination often
leads to unnecessary tripping and FIGURE 9. A block diagram of the simulator testing setup. PLC: programmable logic controller;
could have a detrimental effect on I/O: input/output; DI: digital input; AO: analog output; DO: digital output; AI: analog input; TCP:
the stability of the system. Transmission Control Protocol; UDP: User Datagram Protocol.

M arch/A p ri l 2019 œ IEEE Industry Applications Magazine 41


Before performing integrated system tests, the authors
used the model to tune and test every generator by using
Test A (0.8*) their GCS controllers. This provided the starting-point
61 Test B (1.2*) PID values for each distributed controller. A large variety
Frequency (Hz)

Test C (1.5*) of tests was conducted using the closed-loop simulator


60.5 Test D (2.2*) and actual distributed controllers for various generation-
60 loading conditions. Some of the tests included generation
tripping, load tripping, large-load startups, inadvertent
59.5 loss of interties, single-phase and three-phase faults at
various plant locations, loss of excitation and prime mover,
59 arc-flash events triggering the opening of multiple break-
0 5,000 10,000 15,000 20,000 25,000
ers within the system, and closely timed events (i.e., back-
Time Samples (Each Sample Is 16.667 ms)
to-back contingencies).
*Values in Parentheses Indicate Ratio of Proportional
Gain to Integral Gain
The following is the test sequence for every simula-
tion run.
1) Adjust generation and load, and initiate simulation
FIGURE 10. The frequency-control PID tuning of a single STG for a
large-load (21.3 MW) trip. using a typical load flow.
2) Trigger the event either by applying faults and clearing
them or directly opening breakers.
for each unit. Similarly, transformers, lines, and loads were 3) Analyze the system response in terms of frequency and
validated to ensure correct representation. Finally, the bus voltages in every island.
authors validated the overall system for load flow cases 4) Record the minimum and maximum frequencies, the
and performed a few dynamic performance tests that minimum and maximum voltages, and the interaction
included observing the system response for events such as of the GCS with local protection or control systems.
generator tripping and intertie tripping. 5) Verify the controller performance and record any obser-
In addition to closed-loop validation tests, the model vations, including round-trip times expected versus
also allowed tuning of the various PID loops within the actual control action, and so on.
GCS to achieve an optimal performance. Figure 10 shows 6) Confirm the behavior of protection systems based on
an example of tuning performed on a single STG for a the nature of the test case.
load-tripping condition, along with the response of a sin- As an example, Figure 11 shows the response of the
gle STG for different proportional and integral gains of its system generators (all operating in isochronous load-
distributed controller. sharing mode and voltage-control VAR sharing) for a

Frequency Line-to-Neutral Bus Voltage


Fault
Applied

Reactive Power (Two STGs)


Real Power (Two STGs)

Real Power (Existing GTGs) Reactive Power (Existing GTGs)

FIGURE 11. Simulation data showing the effect of a three-phase fault on a helper motor.

42 IEEE Industry Applications Magazine œ March/April 2019


three-phase fault on a helper motor running at 11.3 MW. ●● For most of the event conditions, the new STGs pro-
The event resulted in the motor tripping and a loss of load vide enough dynamic stability support to run the older
on the system. This test shows that the minimum and units above 50% capacity to meet emission-complian­­
maximum system frequencies and generator bus voltages ce requirements.
are well within the allowable limits and that the system ●● The generators are tuned well enough to survive low
quickly settles at a new steady state. load-loss events even when the load-shedding system
Overall, the authors performed approximately 100 is unavailable.
different simulation tests during project development and ●● Due to the controller design limitations, operate as many
factory acceptance testing. These simulations provided quali- units as possible in isochronous load-sharing mode to
tative conclusions and results regarding the system per- avoid the possibility of inadvertently putting a fixed-load
formance and evaluated the controller performance itself. unit in a single island.
The benefits ranged from fine-tuning the GCS to recom-
mending effective system operational modes for various Field Testing and Commissioning
plant-operating scenarios. The authors recently commissioned this system, tying
Some of the key benefits of using simulations are as together the Greenfield and Brownfield systems. Pre-
follows: commissioning checks and tests were completed before
1) Provide a safe environment to develop and tune system tests were executed. The tests ranged from basic
the various loop variables prior to the integration generator startup to system level for verifying load shar-
and commissioning of the actual hardware. ing among all of the generators.
2) Help develop a realistic starting point for all tuning Detailed procedures were developed to verify the
prior to real-world tuning during commissioning. system’s operation, including presynchronization checks,
3) Provide an environment for plant owners (operations preliminary checks on distributed control systems, STG
and engineering) to develop “what-if” case scenarios control panel checks, and existing GCS upgrade checks.
to examine various possibilities (faults, process upsets, The following is an example testing sequence implement-
and so on). ed for one of the STGs.
4) Allow operations to avoid risky combinations of gen- 1) excitation automatic voltage regulator and protective
eration, knowing that the islanded facility is not as relay trip test checks
robust as other combinations that might provide more 2) preload bank checks
upset-ride-through capabilities. 3) load bank “dead bus” synchronization checks to verify
Some of the lessons learned in terms of system opera- ••interfacing between the distributed controller and
tions include the following: the turbine control system
●● To provide the highest chance of survival during some ••hardwired and Ethernet control signals between
events, always operate one of the two STGs in isochro- the distributed controller and the centralized island
nous load-sharing mode. tracking system
●● For an STG in fixed load control, do not operate the unit ••distributed controller mode transitions using load
close to its maximum megawatt value (results in faster bank dynamic tests
instability during system events). ••generator and load bank breakers closing
●● Operate at least one of two existing 25 MW units in 4) “live bus” checks to verify
isochronous load-sharing mode to provide stability ••synchronization using distributed controllers with
during islanding situations. no impact on existing generation
●● Revise the underfrequency set points of the exist- ••synchronization and load sharing using distributed
ing plant to avoid nuisance tripping during certain controllers with an impact on existing generation.
island conditions. After the individual generator checks, system tests
●● To avoid overloading the intertie lines during certain were carried out using modular and integrated testing
operating topologies, always operate one STG in iso- approaches for the distributed controllers. Modular tests
chronous load-sharing mode. focused on the ability of the distributed controllers to suc-
●● Design fast load-shedding systems with appropriate cessfully control the generators, whereas the integrated
power-measurement filter-time constants to avoid tests focused on STG performance during load sharing.
all known failure modes. Examples include untrust- System performance was analyzed to ensure that stability
worthy transducer measurements during voltage was maintained.
transients and meter-data aliasing when polling data The lab test results provided significantly improved
from IEDs. initial conditions for various modular and integrated tests.
●● The distributed GCS is tuned to operate well with the As an example, Figure 12 shows the step response of a
load-shedding and generator protection systems, thus single STG tested using load banks.
avoiding any unnecessary oscillations. Final tuning Figure 13 shows the STG response for a synchroniza-
may be required during onsite commissioning. tion and base-loading condition. A single STG was started

M arch/A p ri l 2019 œ IEEE Industry Applications Magazine 43


cle presents the details of VCSs,
Generator Frequency (Hz) highlights the necessity of autosyn-

Generator Output (MW)


60
Generator 5 chronization systems, and identifies
58 Generator
Frequency the benefits of testing using a real-
56 Active Power
4 time simulator for controller valida-
54 tion, understanding power system
52 Distributed Controller 3
Speed Bias (%)
dynamics, and finalizing generator
50 2 modes of operation.
0 1,000 2,000 3,000 4,000 5,000
Time Samples (Each Sample Is 400 ms) Acknowledgments
The authors would like to acknowl-
FIGURE 12. The generator step tests in load-sharing mode. edge the support of Ashish Upre-
ti and Bharath Nayak during the
closed-loop testing. and the manu-
facturer’s support with the setup of
180 55
Speed Bias the distributed controllers for con-
Angle Difference (°)

135
53 trolled lab testing.

Speed Bias (%)


90 Terminal Voltage
45 51
0
Breaker
Author Information
–45 Angle 49
Closing Krishnanjan Gubba Ravikumar
–90 Difference Generator 47 (krishnanjan_gubba_ravikumar@
–135 Active Power
–180 45 selinc.com) is with Schweitzer Engi-
0 15 30 45 60 75 90 105 120 135
neering Laboratories, Inc., Pullman,
Time (s)
Washington. Brandon Bosley is
with Kiewit Engineering and Design
FIGURE 13. The STG synchronization and base load test. Co., Lenexa, Kansas. Ty Clark is
with Dominion, Glen Allen, Virginia.
up and synchronized to a live bus into which other GTGs Julio Garcia is with Kiewit Engineering and Design Co.,
were connected. Lenexa, Kansas. Ravikumar is a Senior Member of the
While there were issues identified and recorded during IEEE. Clark is a Member of the IEEE. This article first
commissioning, the authors were satisfied with the overall appeared as “Generation Control System Using Isochro-
system performance. A majority of the issues identified nous Load Sharing Principles with Gas and Steam Tur-
were related to the distributed controller’s performance bine Generators” at the 2017 IEEE IAS Petroleum and
in terms of alarming, receiving, and sending data through Chemical Industry Technical Conference. This article
industry-standard protocols and its ability to control the was reviewed by the IAS Petroleum and Chemical
generators within the required times. It was evident that Industry Committee.
the tuning and interfaces established during the real-time
simulator testing significantly reduced the time needed References
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44 IEEE Industry Applications Magazine œ March/April 2019

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