HIGH ALTITUDE VEHICULAR EMISSION CONTROL PROGRAM
VOLUME VIII. PILOT TRAINING PROGRAM
RESULTS FOR MOTOR VEHICLE
EMISSION CONTROL
PREPARED FOR:
STATE OF COLORADO
DEPARTMENT OF HEALTH
COLORADO 80220
ENVIRONMENTAL PROTECTION AGENCY
REGION VIII
DENVER, COLORADO 80203
su
/COLORADO
STATE
UNIVERSITY
atl/;
AUTOMOTIVE
TESTING
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HIGH ALTITUDE VEHICULAR EMISSION CONTROL PROGRA
VOLUME VIII. PILOT TRAINING PROGRAM
RESULTS FOR MOTOR VEHIj
EMISSION CONTROL
PREPARED FOR:
STATE OF COLORADO
DEPARTMENT OF HEALTH
DENVER, COLORADO 80220
ENVIRONMENTAL PROTECTION AGENCY
REGION VIII
DENVER, COLORADO 80203
csu
('COLORADO
STATE
UNIVERSITY
ATL
'AUTOMOTIVE
TESTING
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INTERIM REPORT ON PILOT TRAINING PROGRAMS
FOR
MOTOR VEHICLE EMISSIONS CONTROL
(Agreement No. C-290-760)
STATE OF COLORADO
Submitted to Don Sorrels, Chief
Motor Vehicle Emissions Control Section
Air Pollution Control Division
Colorado State Department of Health
by
B. D. Hayes & B. D. Lee
Project Investigators
DEPARTMENT OF INDUSTRIAL SCIENCES
COLORADO STATE UNIVERSITY
FORT COLLINS, COLORADO 80521
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TRAINING PROGRAM ON MOTOR VEHICLE EMISSIONS CONTROL FOR
STATE OF COLORADO
Page
1. Project Investigators and Team Members 3
11. Project Objectives as Identified in
Contract Agreement #C-290-760, Colorado
State Department of Health 4
111. Proposed Approach to Establish and
Deliver a Motor Vehicle Emissions
Training Program for Investigators,
Inspectors and Motor Vehicle Repair-
men 5-6
IV. Progress Report on Contract Agree-
ment #C-290-760 7
V. Sequence and Time Schedule of Pilot
Training Programs, Automotive
Teacher Training Programs and State-
wide Implementation of Programs
VI. Estimate on Cost for Pilot Training
for Twenty-five Automotive Teachers,
Training Program for Additional
One Hundred and Twenty-five Automo-
tive Teachers, and Equipment Necessary
for Training Sites Throughout the
State 9-11
Vll. Additional Factors for Consideration
in the Implementation of an Effec-
tive and Efficient Statewide Motor
Vehicle Emissions Control Program 12
Appendix:
A Model for Delivery System 13-14
B State of the Art 15-17
C Conclusions and Recommenda-
tions from Automotive Test-
ing Laboratories, Inc. on
Idle Test Data 18-26
D Outlines for Instructional
Program for State Investiga-
tors, State Inspectors and
Motor Vehicle Repairmen 27-35
E Fifteen Selected Participants
for Pilot Training Program
for State Inspectors 36-37
F Potential Training Sites for
Inspectors and Repairmen
Statewide 38-42
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PROJECT INVESTIGATORS AND TEAM MEMBERS
B. D. Hayes, Professor and Head
Department of Industrial Sciences
Colorado State University
Fort Collins, Colorado
B. D. Lee, Associate Professor
Automotive Coordinator
Department of Industrial Sciences
Colorado State University
Fort Collins, Colorado
Brian Iler, Instructor
Automotive Area
Department of Industrial Sciences
Colorado State University
Fort Collins, Colorado
Doug Graham, Instructor
OJT Coordinator
Automotive Testing Laboratories, Inc.
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PROJECT OBJECTIVES
1. Investigation of training programs for state inves-
tigators, state inspectors, and motor vehicle repair-
men .
2. Develop and conduct pilot training programs and measure
the effectiveness of such programs for state investi-
gators and state inspectors.
3. Develop orientation and basic maintenance procedures
on air pollution control systems installed by manufac-
turers and instruct state investigators and state in-
spectors.
4. Prepare and submit to the Colorado State Department of
Health, on completion of pilot training programs, a
written final report setting forth the cost of such pro-
grams and the effectiveness thereof, and prescribing
the conclusions and recommendations resultant from hav-
ing conducted the training program and completed the
training requirements pursuant to enacted Senate Bill
No. 393.
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PROPOSED APPROACH TO ESTABLISH AND DELIVER A MOTOR VEHICLE
EMISSIONS CONTROL TRAINING PROGRAM FOR STATE OF COLORADO
FOR STATE INVESTIGATORS, STATE INSPECTORS AND MOTOR VEHICLE
REPAIRMEN
In order to implement an effective and efficient pro-
gram on motor vehicle emissions control, it is necessary to:
identify the needs; develop a delivery system consisting of
the appropriate component parts; produce and test adequate in-
structional materials; and educate and train personnel in-
volved in carrying out the total program.
In line with these requirements, the Department of In-
dustrial Sciences at Colorado State University, under a con-
tract with the Colorado State Department of Health, and a
complimentary Contract from Region Vlll of the Environmental
Protection Agency concerning a pilot training program for
automotive repairmen, and other support agencies in the State,
recommends the following procedures and delivery system
(see appendix A) in establishing and implementing a train-
ing program on motor vehicle emissions control.
1. Review of requirements for the motor vehicle
emissions control for state investigators,
state inspectors and repairmen.
2. Review of "State of the Art" in Colorado con-
cerning service stations, equipment and per-
sonnel.
3. Review data collected by Automotive Testing
Laboratories, Inc. concerning the field test
of randomly selected automobiles on idle test
emissions.
4. Review the instructional materials now avail-
able concerning motor vehicle emissions con-
trol.
5. Compile the results of these reviews and analyze
the implications for needed instructional
materials and programs on motor vehicle emissions
control.
6. Compile and develop instructional materials
for state investigators, state inspectors and
repairmen.
7. Conduct pilot training programs for selected
state investigators, state inspectors and
repairmen.
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8. Review results of these pilot training
programs.
9. Revise instructional program as needed in
terms of findings from pilot programs.
10. Select twenty-five (25) automotive teachers
for pilot training program to focus on im-
plementation of delivery system throughout
the State for the state inspectors and re-
pairmen on motor vehicle emissions control.
11. Review results from pilot training program for
twenty-five (25) automotive teachers.
12. Revise instructional program for teachers
as needed in terms of findings from pilot
program.
13. Conduct training program for remaining one-
hundred (100) to one-hundred and twenty-
five (125) automotive teachers throughout
the State.
As noted in the flow chart (Appendix A), the one-
hundred and twenty-five (125) to one-hundred and fifty
(150) automotive teachers would become the key implemen-
tators for dissimination of the motor vehicle emissions
control program for the inspectors and repairmen through-
out the statewide system.
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PROGRESS REPORT ON CONTRACT #C-290-760
1. An investigation has been conducted concerning:
1. The training requirements of the state investiga-
tors , state inspectors and repairmen on the orien-
tation and basic maintenance of the motor vehicle
emissions control systems (see outlines reflect-
ing content in Appendix D).
2. The "State of the Art" in Colorado on service sta-
tions, inspectors and repairmen (Appendix B).
3. Summary and conclusions of data compiled and analyz-
ed by Automotive Testing Laboratories, Inc. on field
tests of selected automobiles on emissions control
(Appendix C).
4. Instructional materials available from other sources
on motor vehicle emissions control.
11. Instructional materials have been developed for a six-
hour pilot training program for state investigators and
state inspectors (Appendix D).
III. Fifteen state inspectors have been selected from the
Denver metropolitan area to attend the six-hour pilot
training program (Appendix E).
IV. Pilot training program for the fifteen inspectors will
be conducted at Automotive Testing Laboratories, Inc.
on December 11-13, 1973 (Pre-test and Post-test are be-
ing used with these fifteen inspectors for evaluation
of program).
V. Fifteen state investigators will attend a six-hour pilot
training program at Automotive Testing Laboratories,
Inc. the first part of January, 1974 (Pre-test and Post-
test will be used with these fifteen state investiga-
tors for evaluation of program).
Note:
Operating simultaneously with the pilot training
programs for state investigators and state inspec-
tors is a pilot training program for sixty select-
ed repairmen under a contract with Region VIII of
the Environmental Protection Agency. All results
of this pilot training program for repairmen will be
reported as available.
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SEQUENCING AND PROJECTED TIME SCHEDULE
Contract #C-290-760
Interim report on progress of project.
Six hour (6) pilot training program
for fifteen state inspectors.
Six hour (6) pilot training program
for fifteen state investigators.
Preliminary report on the pilot train-
ing programs for the state inspectors
and state investigators.
Final report on the fifteen (15)
state investigators and fifteen (15)
state inspectors pilot training pro-
grams with recommendations for
effectiveness and cost estimates.
Note: By June 30, 1974, a complete report will
be available concerning the pilot training
program on emissions control for the sixty
(60) motor vehicle repairmen from Region
VIII Office, EPA.
PROPOSED SCHEDULE FOR TRAINING PROGRAM
FOR AUTOMOTIVE TEACHERS
June 24, 1974: Forty hour (40) pilot training pro-
gram for twenty-five (25) automotive
teachers.
July-August, 1974: Conduct four (4) forty hour (40)
training programs for one-hundred
(100) automotive teachers (25
teachers in each 40 hour session).
September, 1974: Automotive teachers start training
sessions for inspectors and repair-
men in their homebase location
throughout the State.
December 1, 1973:
December 11-13, 1973:
January, 1974:
February 1, 1974:
March 1, 1974:
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PROJECTED COST FOR PILOT PROGRAM FOR TWENTY-FIVE (25)
AUTOMOTIVE TEACHERS FOR FORTY HOURS (40) OF INSTRUCTION
AT COLORADO STATE UNIVERSITY CAMPUS.
Instructional Cost:
Lead teacher - one man month including
preparation of materials, teach-
ing and evaluation
Assistant teacher - Same as above
Office Supplies, Brochures, Telephones,
Mailing, etc.
Instructional Materials, Collecting, Com-
piling, Duplicating, Transparancies,
Tapes, Slides, etc.
Travel for Field Work
Secretarial and Clerical Assistance
Twenty-five Teachers (participants)
Tuition (two credits)($75) x 25 =
Reference manual ($30) x 25 =
State Handbook ($4) x 25 =
Text book ($3.75) x 25 =
Travel (300 @12$) ($36) x 25 =
Per Diem (5 days @$25)($125) x 25 =
$2950.00
$1750.00
1200.00
1875.00
750.00
100.00
93.75
900.00
3125.00
350.00
500.00
200.00
300.00
6843.75
Equipment to Supplement Existing Laboratory
Equipment on Campus
Lease:
Four (4) HC-C0 Analyzers for
two (2) weeks @ $75 525.00
Purchase:
One (1) HC-C0 Analyzer 2200.00
Four (4) Timing lights @$60.50ea. 242.00
Four (4) OHM Meters @$86.OOea. 344.00
Four (4) Tachometer-Dwell meters
@$124.OOea. 496.00
Four (4) Vacuum guages @$61.OOea. 244.00
Four (4) Compression testers
@$15.OOea. 60.00
Four (4) Crank case vent guages
@$3.50ea. 14.00
One (1) Oscilloscope @$1000 1000.00
Sub-Total
PERA(Wages & Salaries)
$3250 x 9.5%
8% Indirect Cost
TOTAL
5125.00
$16,268.75
308.75
1,326.20
$17,903.70
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This projected cost would be approximately $717.00
for each of the twenty-five (25) teachers in the original
pilot training program. The cost of offering the program
to the remaining one hundred (100) to one hundred and
twenty-five (125) automotive teachers could be approxi-
mately $185.00 less per teacher because of some reduced
instructional and equipment cost.
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EQUIPMENT AND INSTRUCTIONAL MATERIALS PROJECTED
FOR EACH TRAINING SITE IN STATE.
If the various automotive teaching facilities(in edu-
cational institutions) statewide were used as the training
sites, there could be approximately seventy-seven (Appendix
F). The minimum projected equipment an,d instructional mater-
ials needed in each with the estimated cost is listed below.
Three (3) manuals (Mitchell or
equivalent) ($30 ea.) $90.00
Five (5) State Handbooks ($4.00 ea.) 20.00
Five (5) Textbooks ($3.75 ea.) 18.75
One (1) complete instructional packet
of developed training materials
on motor vehicle emissions control
($250.00 ea) 250.00
One (1) HC-C0 Analyzer ($2200. ea.) 2200.00
Two (2) Timing lights ($60.50 ea.) 121.00
Two (2) OHM meters ($86. ea.) 172.00
Two (2) Tachometers-Dwell meters
($124 ea.) 248.00
Two (2) Vacuum guages ($61. ea.) 122.00
Two (2) Compression guages SL5. ea.) 30.00
Two (2) Crank case vent guages ($3.50 ea.) 7.00
One (1) Oscilloscope ($1000. ea.) 1000.00
$4,278.75
If all seventy-seven (77) sites were established, and if
all minimum equipment had to be purchased, then the total
figure would be approximately:
$329,463.00
It is estimated each teacher who successfully completes
the training program and is certified by the State, could
teach approximately ten (10) classes of eleven (11) state
inspectors and/or repairmen in one of these seventy-seven
facilities. Based on one hundred and twenty-five teachers,
teaching ten (10) classes each, they could provide instruction
for 13,750 state inspectors and/or repairmen.
Note: No allowance has been considered concerning
costs for use of facilities or cost to state
inspectors or repairmen and pay to the auto-
motive teachers for conducting the program.
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FACTORS TO BE CONSIDERED IN ESTABLISHING STATEWIDE
MOTOR VEHICLE EMISSIONS CONTROL PROGRAM.
1. Should the safety inspection and the emission inspection
be carried on at the same facility and time or should
they be two separate entities?
2. Who should bear the cost of up-grading the inspection
station with the required equipment, training and certi-
fication of the motor vehicle emissions control repairman?
3. Consideration of cost to the state and the individual
garage and automobile owner.
4. Should the inspection rate be increased a proportional
amount to the investment in equipment between safety and
emission inspection or should a time factor for inspec-
tion be considered as the determining factor?
5. Length of time required for the garage owner to retrieve
his initial investment for equipment via the inspection
charge.
6. Should mechanics be certified only after completion of
an approved training program or should there only be a
test for certification with no class requirement?
7. Consideration of the public and the mechanic in the trade
of the acceptance of this type of a program.
8. Criteria used to select teachers where approved vocational
instructors are not available to present the program.
9. What criteria should be used to determine the location of
the area training centers, times and dates of classes?
10. Should programs and specifications vary in different
areas of the state, depending on population, elevation,
etc?
11. Consideration of a form of communication to keep the re-
pairmen up-to-date on new and modified pollution control
devices.
12. Consideration of a spot check system to evaluate the
effectiveness of the inspection system on vehicles and
on the individual repairmen's performance.
13. Development of a State Handbook which could be used as a
guide for the state inspectors, state investigators, and
the motor vehicle emissions repairmen in performing the
duties as related to the pollution control program. This
Handbook could also include the information needed for a
§uide in licensing an inspection station.
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APPENDIX A
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PROPOSED DELIVERY SYSTEM FOR
MOTOR VEHICLE EMISSION CONTROL
INSTRUCTIONAL PROGRAM BY THE
COLORADO DEPT. OF HEALTH
COLORADO STATE UNIVERSITY
/
CERTIFIED AUTOMOTIVE
TEACHERS
STATE INVESTIGATORS
/
HIGH SCHOOL STUDENTS
JR. & COMfl. COLLEGE STUDENTS
ADULT EDUCATION
STATE INSPECTORS
APPROVED INSPECTION
STATIONS
MECHANICS
WHO PERFORM
MAINTENANCE
AND SERVICE
\
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APPENDIX B
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STATE OF THE ART
Investigation and experience were used in generating this
review of facilities, equipment and repairmen in on-going busi-
nesses of inspection, service and maintenance in the State of
Colorado.
FACILITIES
The automotive inspection and maintenance facilities in
Colorado vary from one-man operations to those of forty (40) or
more employees. These facilities also vary in the types of
services offered, from general repair type service to extremely
specialized services on a specific make of automobile. The
equipment in these on-going businesses will vary greatly, de-
pending on the type of repair the facility is oriented to per-
form. With this diversification, the nature and the quality of
the equipment found in the facilities will vary considerably
throughout the state.
The pricing structure for services rendered is also a re-
flection of the variation among facilities. Statewide, an oper-
ation such as adjusting the timing on the automobile varies from
$1.50 to $6.00. This difference in pricing for a seemingly com-
parable operation is a result of each facility adjusting to its
particular clientel.
In most cases, owners and operators of automotive inspec-
tion service and maintenance facilities do not find it profi-
table to perform the required "Automobile Safety Inspection" as
outlined by the State; however, most of the owners and operators
believe this is a function of their operation and they have par-
ticipated. The present charge which they are allowed to assess
for the "Safety Inspection" does not provide the necessary time,
and in turn the money, to cover the individual performing the
inspection nor the equipment used during the inspection.
Several of the owners and operators have indicated that if the
"Motor Vehicle Emissions Inspection" is to become a part of the
semi-annual "Safety Inspection", then sufficient amount of train-
ing, time and money will have to be provided for the individual
and the facility involved in the inspection and/or maintenance.
EQUIPMENT
The equipment presently used for the semi-annual "Automo-
bile Safety Inspection" is quite minimal and in most cases is
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sufficient. The equipment needed for the "Motor Vehicle
Emissions Control" is of a different nature and will require
a greater outlay of money for the owner and operator of the
facility. A projection of $2500 to $3000 outlay for each facil-
ity is in line with the present cost of the basic equipment
needed to perform a good "Emissions" inspection. This would
include the necessary equipment to help diagnose the problem
source concerning excessive "Emissions".
INSPECTORS AND REPAIRMEN
Unfortunately these two terms have broad implications
throughout the state and are used quite loosely in many
circles. They apply equally to well-trained and experienced
personnel as well as to personnel with little or no background
in the automotive service industry.
It is in this area that the most time, effort and money
must be provided in the education and training for personnel
to perform the necessary inspection and maintenance on "Motor
Vehicle Emissions Control". The education and training nec-
essary in this area will build on previous knowledge and skill
in such sections as tune-up, carburation, etc. However, per-
sonnel will have to be developed to have a thorough understand-
ing of the various systems and component parts pertaining to
the total operation. These personnel should be distinctly
identified as having appropriate credentials and be well-
qualified to perform the necessary services as needed by the
customer.
As a system is developed to provide the necessary educa-
tion and training for up-grading present personnel in the field,
as well as a certification and recertification program, it will
be necessary to adjust the "charge" for the services rendered
whereby the individual owner and operator can provide the need-
ed service and still expect sufficient return on the time and
investment involved.
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STRATEGIES INVESTIGATED
BY AUTOMOTIVE TESTING LABORATORIES,
I. Idle emission inspection and
maintenance.
II. Exhaust Control retrofit.
III. Modified engine tuning adjust
ments.
IV. Mandatory engine maintenance.
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CONCLUSIONS AND RECOMMENDATIONS FROM AUTOMOTIVE TESTING
LABORATORIES, INC. ON IDLE TEST DATA
(RESULTS OF COMPLETE STUDY IN OFFICE OF MOTOR VEHICLE DIVISION,
COLORADO STATE DEPARTMENT OF HEALTH)
CONCLUSIONS
Each of the strategies investigated was found to be effective in
reducing HC and CO emissions.
1.1 The range of reduction for HC is from a low of about 1% for the
high altitude kits to a high of about 75% for catalytic retrofit.
1.2 The range of CO reduction is from a low of about 3% for idle
emissions inspection at 20% rejection to a high of about 85% for
catalytic retrofit.
1.3 The range of NO^ reduction is from a low of about -30% for the
high altitude kits to a high of about 45% for VSAD/Air Bleed
retrofit.
The range of cost effectiveness (CE) is wide.
2.1 CE for HC ranges from a low of 5 milligrams/mile/dollar (mmd) for
the high altitude kits and LPG conversion to a high of about 100
mmd for idle emissions inspection at 30 to 60% rejection and
certain combinations of modified engine tuning adjustments.
2.2 CE for CO ranges from a low of about 75 mmd for LPG conversion
to a high of about 4000 mmd for certain combinations of modified
engine tuning adjustments.
2.3 CE for NOx ranges from a low of -75 mmd for the high altitude
kits to a high of about 50 mmd for VSAD/Air Bleed retrofits.
With respect to idle emissions inspection and maintenance:
3.1 The effectiveness curve for HC rose sharply from 0 to 30% rejection
and continued to rise at a reduced rate to 60% rejection. HC
reduction at 30% rejection is about 10%. At 60% rejection HC
reduction is about 13%. CE for HC rose sharply from 0 to 30%
rejection. The CE curve is relatively flat from 30 to 60%
rejection at a level of about 100 mmd.
3.2 The effectiveness curve for CO rose sharply from 0% rejection and
continued to rise at a reduced rate through 60% rejection. CO
reduction at 30% rejection is about 5%. At 60% rejection CO
reduction is about 9%. CE for CO rose sharply from 0% rejection
and continued to rise at a reduced rate through 60% rejection.
CE at 30% rejection is about 750 mmd. At 60% rejection CE is
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3.3 The effectiveness curve for NO rises gradually from 0 to 60%
rejection. At 60% rejection NO reduction is about 2%. The CE
curve rises sharply from 0 to 2u% rejection and continues to rise
at a reduced rate through 60% rejection. CE at 30% rejection is
about 3 mmd. At 60% rejection CE is about 5 mmd.
3.4 The garages (licensed safety inspection stations) selected to
perform idle emissions inspection represent a cross-section of
the automobile repair industry.
3.5 Training provided to station personnel was adequate with respect
to task objectives. However, more extensive training is required
with respect to an overall emissions control program.
3.6 The idle emissions inspection, adjustment and repair procedures
provided to garages was adequate. Application of these procedures
resulted in substantial emissions reductions and reasonable cost
effectiveness ratios. However, several problems were experienced
with station personnel with respect to data transmittal and atten-
tion to inspection pass/fail limits.
3.7 Actual inspection failure rates were higher than design failure
rates. The difference is attributed primarily to the performance
of one station which failed all vehicles tested. One other
station appears to be borderline in this respect.
3.8 Inspection charges range from an average low of $1.50 per inspec-
tion at one station to an average high of $6.00 per inspection
at another station. The overall average inspection charge is
$4.05 which is consistent with laboratory estimated inspection
costs.
3.9 The average station cost per failed vehicle ranges from a low of
$2.53 to a high of $14.25. The overall average cost per failed
vehicle is $10.57.
3.10 The average station repair cost per vehicle for all vehicles
ranges from a low of $0.76 to $12.26. The overall average cost
per vehicle for all vehicles is $6.14.
3.11 The average combined station cost (inspection and repair) per
failed vehicle ranges from a low of $4.76 to a high of $14.76
with an average cost per vehicle of $10.18.
3.12 Average overcharge per failed vehicle is estimated to range from
8 to 22% as determined from direct charges. Average overcharge
per failed vehicle is estimated to be as high as 38% if direct
repair charges and estimated repair charges to repair problem
vehicles are combined. In terms of costs average overcharge per
station is from $0.85 to $2.31 per failed vehicle or as high as
$4.66 per failed vehicle.
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3.13 Correlation coefficients developed between laboratory instru-
mentation and garage instrumentation are wide in range. Average
station correlation coefficients range from a low of 0.4 3 to a
high of 0.83 for HC emissions at curb idle. At 2500 engine rpm
the correlation coefficients range from 0.26 to 0.84. For CO
at curb idle the range of correlation coefficients is from 0.4 8
to 0.89. At 2500 engine rpm the range is from 0.26 to 0.89.
In this respect the performance of two of the stations (20% of
the sample) is unacceptable.
With respect to exhaust control retrofit:
4.1 For HC and CO reduction the catalytic system was the most
effective with reductions of 75% and 85% respectively. The
catalytic system was followed by LPG conversion with 40% and
55% reduction for HC and CO respectively. Catalytic system CE
was about 25 mmd for HC and 4 50 mmd for CO. The CE ratio for
LPG conversion was about 5 mmd for HC and 75 mmd for CO.
4.2 Of the remaining retrofits, EGR/Air Bleed combined, Air Bleed
alone and Float Bowl Pressure Regulation (FBPR)systems are the
most effective HC and CO reducing retrofits with a range from
about 17% to 20% HC reduction and 20% to nearly 50% CO reduction.
4.3 For NOx reduction the VSAD/Air Bleed, VSAD/EGR, EGR/Air Bleed
and EGR retrofit are the more effective systems with a range
from about 25% to 45% NO„ reduction.
4.4 The change in fuel economy for the various retrofits ranges from
an improvement of about 21% for LPG conversion to a deterioration
of about 8% for EGR only and VSAD/Air Bleed systems. Of the less
costly and elaborate systems fuel economy improved about 2.5%
for EGR/Air Bleed and FBPR systems.
4.5 CE for HC ranges from a low of about 5 mmd for EGR and high
altitude kit retrofit to a high of about 50 to 60 mmd for EGR/Air
Bleed and VSAD/Air Bleed respectively.
4.6 CE for CO ranges from a low of about 75 mmd for LPG conversion
to a high of about 1150 mmd for Air Bleed and FBPR systems.
4.7 CE for NOx ranges from a low of -75 mmd for the high altitude
kits to a high of about 50 mmd for VSAD/Air Bleed retrofit.
4.8 Retrofit kits are relatively easy to install except LPG systems
and catalytic systems where air pumps are not currently installed.
Intrinsic problems are associated with high altitude kit instal-
lation performed under typical garage-type conditions.
4.9 The application of retrofit is broad with respect to the add-on
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of the light-duty vehicle population can be retrofitted with
one or more systems. High altitude kits supplied by Chrysler
Corporation are limited to certain of the carburetor models.
Other models are recommended for retrofit as a complete
carburetor replacement only.
4.10 Labor and parts costs as applied to the high altitude kits is
reasonable with a range from about $3.90 to $13.64 per vehicle.
With respect to the add-on systems the range is from about
$20 for Air Bleed systems to about $650 for LPG systems installed.
Labor and parts costs for high altitude kit installations are
expected to be higher if installed under more exacting conditions.
5. -With respect to modified tuning specifications:
5.1 The greatest HC reductions are obtained from modified adjustment
combinations of A/F ratio-idle rpm and A/F ratio-choke, both of
which are on the order of 15%. Individually, the greatest HC
reduction is obtained from the experimental A/F ratio setting
where HC reduction is about 10%.
5.2 The greatest CO reductions are derived from modified adjustment
combinations of A/F ratio-ignition timing, A/F ratio-idle rpm
and A/F ratio-choke which are on the order of 25 to 30%. Indi-
vidually, the greatest CO reduction is obtained from the experi-
mental A/F ratio setting, where reduction is about 25%.
5.3 Each of the adjustments individually and in combination result
in NOx increases on the order of 20 to 3 5%.
5.4 Modified tuning adjustments are relatively easy to perform.
However, idle rpm adjustments to the experimental value pose
problems relating to safety.
5.5 Adjustments can be applied to virtually all light-duty vehicles.
5.6 Adjustment cost for any two of the parameters investigated is
estimated to be about $5.00 per vehicle.
5.7 Low costs and high effectiveness combine to make certain com-
binations of modified tuning specifications by far the most CO
cost effective of the strategies investigated. The most HC
cost effective strategy is shared equally by certain of the com-
bined modified tuning specifications and idle inspection and
maintenance at the higher rejection rates.
6. With respect to mandatory engine maintenance:
6.1 Mandatory engine maintenance is effective in reducing HC, CO and
N0X emissions. HC reduction is in the order of 20%, CO reduction
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is about 10% and NOx reduction is about 8%. An overall fuel
economy improvement of about 1% was obtained.
6.2 Cost effectiveness ranking is low primarily because of associated
high costs for maintenance. CE for HC was about 30 rmtid as op-
posed to CE for HC of about 100 mmd for idle inspection at 30%
and higher rejection rates and modified tuning specifications.
CE for CO was about 200 mmd as opposed to a CE for CO of about
4000 mmd for modified tuning specifications.
6.3 Costs are estimated to average from a low of about $33.00 per
vehicle to a high of about $60.00 per vehicle.
6.4 Problems relating to parts installation and engine adjustments
are not expected to be unusual.
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RECOMMENDATIONS
1. Since idle emissions inspection and maintenance were found to be an
effective and cost effective strategy to reduce exhaust hydrocarbon
and carbon monoxide emissions without an accompanying increase in
oxides of nitrogen emissions, it is recommended that idle emissions
inspection of light-duty vehicles be implemented in the State of
Colorado.
1.1 Because of the various problems which developed through utili-
zation of licensed safety inspection stations to perform idle
emissions inspections, it is not recommended that idle emissions
inspection be performed in the existing network of licensed
safety inspection stations.
1.2 A state owned, state operated inspection network or a privately
operated, state enfranchised inspection network exist as alter-
natives to idle emissions inspection in the existing safety
inspection network. It is recommended that these alternatives
be considered.
2. Since certain of the California approved exhaust control retrofit
devices were found to be both effective and cost effective in reducing
exhaust hydrocarbon, carbon monoxide and oxides of nitrogen emissions,
it is recommended that a program of mandatory retrofit device installa-
tion be implemented.
2.1 For economic and other reasons it is recommended that light-
duty vehicles be defined as comprising three categories of
vehicles; fleet vehicles (10 or more vehicles under common
ownership), precontrolled vehicles (1967 and older model-year
vehicles) and controlled vehicles (1968 through 1972 model-year
vehicles).
2.1.1 It is recommended that emissions standards of retrofit
performance be established for application to fleet
vehicles. It is further recommended that emissions
standards established for fleet vehicles be related to
emissions reductions shown to be feasible by catalytic
converter and LP gas conversion tests.
2.1.2 It is recommended that standards of retrofit performance
be established for application to pre-controlled vehicles.
It is further recommended that emissions standards estab-
lished for pre-controlled vehicles be related to emissions
reductions shown to be feasible by EGR/Air Bleed retrofit
system tests.
2.1.3 It is recommended that standards of retrofit performance
be established for application to controlled vehicles.
It is further recommended that emissions standards estab-
lished for controlled vehicles be related to emissions
reductions shown to be feasible by EGR/Air Bleed retrofit
system tests.
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Because of intrinsic vehicle operational problems resulting from
installation of the altitude kits under typical garage-type condi-
tions, mandatory application of the strategy is not recommended.
3.1 Since the high altitude kits were shown to have good potential
for reducing carbon monoxide emissions and fuel economy bene-
fits and further, since it is assumed that high altitude kits
can be successfully installed under certain controlled condi-
tions, it is recommended that voluntary installation of the
kits under the controlled conditions be encouraged. Prior to
an implementation program of voluntary installation, however,
the impact on the atmosphere of higher oxides of nitrogen
emissions resulting from kit installation should be assessed.
Certain modified engine adjustments have been shown to be both
effective and cost effective in reducing exhaust hydrocarbon and
carbon monoxide emissions although the modified adjustments caused
an increase in emissions of nitrogen oxides. It is therefore recom-
mended that a program of mandatory adjustment to certain of the
experimental values be implemented if it can be demonstrated that
adverse affects such as increased photochemical reaction, reduced
visibility and adverse health affects will not result from the
higher levels of nitrogen oxides discharged to the atmosphere.
Although engine maintenance was shown to be an effective exhaust
hydrocarbon, carbon monoxide and nitrogen oxides reducing strategy,
a program of mandatory engine maintenance is not recommended because
of its relatively poor cost effectiveness. It is recommended,
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APPENDIX D
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INSTRUCTIONAL OUTLINE FOR MOTOR
VEHICLE EMISSION CONTROL
STATE INVESTIGATORS
SIX HOURS OF INSTRUCTION
I. Introduction
A. Aims of program statewide.
B. Role of investigator as applied to automotive emission controls
C. Evaluation test for proficiency.
II. General problem of air pollution
A. Types of pollutants
B. Sources of pollutants
1. Stationary
2. Mobile
C. Impact of air pollution
1. Persons
2. Property
3. Plant and animal life
4. Photochemical effect
ill. Auotomobile emissions
A. Regulations, laws, and ordinances
1. Federal standards and specifications
2. State standards and specifications
3. Air quality control regions
4. Official handbook
B. Programs present and future
1. Vehicle maintenance
2. Vehicle inspection
3. Public indoctrination
IV. Current control methods for emissions
A. Crank case emissions
1. Road draft tubes
2. Open PCV
3. Closed PCV
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B. Engine modifications
1. Lean carburation
2. Heated air intake system
3. Vacuum advance delay ignition systems
4. Internal engine changes
5. Air injection systems
C. Evaporative losses
1. Vapor storage systems
2. Tank overfill protection
V. Emission testing equipment and techniques
A.
Tach-dwell meter
B.
Timing light
C.
Vacuum gauge
D.
HC-CO analyzer
E.
PCV valve tester
VI. Safety precautions
A. Exhaust disposal
B. Personal safety
C. Calibrating gasses
II. Inspection procedures
A. Use of handbook
B. Pass-fail techniques
C. State forms
D. Owner recourse procedures
II. Laboratory session
A. Calibration and use of equipment
B. Live inspections using handbook
1. Demonstrate safety
2. Visual inspection
3. HC-CO analyzer inspection on vehicle
4. Complete necessary forms (either pass or fail)
5. Simulate disputed HC-CO readings
6. Inspect premises for possible station license
7. Inspect premises for appropriate equipment
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Review and testing
A. Safety precautions
B. Duties of investigator
C. Calibration checks
D. Questions and answers
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INSTRUCTIONAL OUTLINE FOR MOTOR
VEHICLE EMISSION CONTROL
STATE INSPECTORS
SIX HOURS OF INSTRUCTION
I. Introduction
A. Aims of statewide program
B. Role of inspector as applied to automotive emission control
C. Evaluation test for proficiency
II. The general problem of air pollution
A. Types of pollutants
B. Sources of pollutants
1. Stationary
2. Mobile
C. Impact of air pollution
1. Persons
2. Property
3. Plant and animal life
4. Photochemical effects
II- Automobile emissions
A. Regulations, laws and ordinances
1. Federal standards and specifications
2. State standards and specifications
3. Air quality regions
4.~ Official handbook
B. Inspection
1. Safety procedures
2. Visual areas of inspection
a. Crank case emission systems
b. Evaporative emission systems
c. Engine modifications
d. Air injection
e. Exhaust gas recirculation
f. Visable contaminents
3. Analatical inspection
a. Infrared analyzer
b. Meter reading
c. Various types of instruments
d. Calibration and care of test equipment
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C. Data recording and procedure
1. Pass vehicle procedure
2. Fail vehicle procedure
IV. Laboratory session
A. Live inspections
1. Demonstrate safety procedures
2. Visual inspection of all emission related hardware
3. Visual contaminent inspection
4. Analyzer and meter reading
5. Data recording
6. Passing or failing vehicle procedure
V. Role of inspection in public relations
A. inspector's role as official arm of state program
B. Ways and means available to inspector to assist public with
possible corrective action, preventative maintenance, additional
knowledge.
C. Owner procedures providing for cases of unjust inspections and
consumer protection.
VI. Review and testing
A. Review use, care, and calibaration of equipment
B. Review use of handbook
C. Review Inspector's image as an important factor affecting public
opinion of the inspection program.
D. Certification test
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INSTRUCTIONAL OUTLINE FOR MOTOR VEHICLE
EMISSION CONTROL
REPAIRMEN
FIFTEEN HOURS OF INSTRUCTION
I. Introduction
A. Aims of statewide program
B. Role of repairmen as applied to automotive emission control
C. Evaluation test for proficiency
II. General problem of air pollution
A. Types of pollutants
B. Sources of pollutants
1. Stationary
2. Mobile
C. Impact of air pollution
1. Persons
2. Property
3. Plant and animal life
4. Photochemical effects
II. Automotive emissions
A. Regulations, laws and ordinances
1. Federal standards and specifications
2. State standards and specifications
3. Air quality control regions
4. Official handbook
B. Inspections
1. Safety procedures
2. Visual areas of inspections
a. Crank case emission systems
b. Evaporative emission systems
c. Engine modifications
d. Air injection
e. Exhaust gas recirculation
f. Visable contaminents
3. Analatical inspection
a. Infrared analyzer
b. Meter readings
c. Various types of instrumentation
d. Calibration and care of testing instruments
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C. Data recording and procedure
1. Pass Vehicle Procedure
2. Fail Vehicle Procedure
IV. Emission reduction and control methods
A. Pre-Combustion Controls
1. Evaporative
a. Tank over-fill protection
b. Fuel vapor trapping methods
1. Charcoal cannister
2. Vapor separator
3. Crank case storage
2. Intake air temperature control
3. Intake manifold temperature controls
a. Exhaust heat riser valve
b. Coolant temperature controls
c. Exhaust cross-over temperature control
B. Direct combustion controls
1. Internal engine modifications and fuel distribution
a. Compression ratio
b. Combustion
c. Improved intake manifold flow
d. Valve timing overlap
e. Redesigned pistons
2. Carburation modification
3. Ignition controls
4. Exhaust gas recirculation system
C. Post-combustion controls
1. Crank case ventilation controls
2. Air injection system
3. Converters and catalytic exhaust conditioning devices
D. Engine protection controls
1. Overheating controls
2. Overspeeding controls
V. Service of emission controls (in laboratory)
A. Safety precautions to be observed (in laboratory)
1. Fuels and fumes
2. Equipment
3. Running engine
B. Pre-combustion controls
1. Evaporative controls
a. Diagnosis & service of fuel vapor trapping system
b. Diagnosis and service of crank case storage system
2. Intake air temperature controls
3. Intake manifold temperature controls
a. Diagnosis of temperature controlled intake manifold
malfunctioning
b. Diagnosis and service of heat riser valve
c. Diagnosis and service of coolant temperature control
(1) Thermostat
(2) Temperature controlled fans
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Co Servicing combustion controls
1. Diagnosis of carburetor circuits
a. Starting
be Low speed
c. Cruising
d. Wide open
e. Deceleration
2. Diagnosis and service of ignition controls
a. Service during starting
b. Service during idle cold and hot
c. Service during acceleration
d. Service during deceleration
e. Service during cruising
3. Service and diagnosis of EGR system
D. Service of post combustion controls
1. Diagnosis and service of crank case ventilating system
2. Diagnosis and service of air injection system
3. Diagnosis and service of converters and catalytic exhaust
conditioners
E. Engine protection controls servicing
1. Diagnosis and service of overheat control device
2. Diagnosis and service of engine overspeed control device
F. Miscellaneous
G. Demonstration of practical application
Review and testing
A. Review safety procedures
B. Review question and answer period
C. Practice use of reference book
D. Certification test
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APPENDIX E
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FIFTEEN SELECTED PARTICIPANTS FOR
PILOT TRAINING PROGRAM FOR STATE INSPECTORS
Emicks Auto Service
1475 Jasmine
Denver, Colorado
Russell E. Emick
855 Newport St. Denver
Dennis D. Quella
1793 S. Oswego, Aurora
Raymond J. Fernandez
2321 W. 58th Ave., Denver
Hutter Auto Service
15 35 Chester
Denver, Colorado
Jess Gieger
1750 S. Yuma, Denver
Don Hutter
935 S. Joliet, Aurora
Jack Wright L.
10782 E. Exposition #349, Aurora
Steve Stolhand
3100 W. Colorado Ave. , Denver
Lambert Auto Electric
4619 Brighton Blvd.
Denver, Colorado
Bill Hartridge
1522 Bowman PI., Northglenn
Mike Pauls
5477 Grovest, Denver
Timothy Lanigan
3151 Eliot, Denver
James Thompson
927 E. 6th, Broomfield
Ardell A. Sherry
11907 Keowgl Dr., Northglenn
Franklin-"E. Hoover
8470 W. Oregon PI., Denver
Donald A. Greer
6500 E. 88th Ave. #200, Henderson
Courtney Lambert
560 Lansing, Aurora
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SECONDARY AND POST-SECONDARY SCHOOLS
Automotive
Teachers
in School
IN THE STATE OF COLORADO
WITH POTENTIAL FACILITIES FOR
CONDUCTING AUTOMOTIVE EMISSION CONTROL PROGRAM
Mapleton High
601 E. 64th Ave.
Denver, CO 80229
Ranum High
2401 W. 80th Ave.
Westminster, CO 80030
Westminster High
7300 Lowell Blvd.
Westminster, CO 80030
Brighton High
270 S. 8th Ave.
Brighton, CO 80601
Meritt Hutton High
810 Eppinger Blvd.
Thornton, CO 80229
North Glen High
601 W. 100th Place
North Glen, CO 80221
Alamosa High
401 Victoria
Alamosa, CO 81101
Sheridan High
Box 1198
Englewood, CO 80110
Aurora Technical Center
500 Buckley Rd.
Aurora, CO 80010
East High
1525 Detroit
Denver, CO 80206
North High
3960 N. Speer Blvd.
Denver, CO 80211
West High
931 Elati St.
Denver, CO 80204
Secondary Schools
2
Cherry Creek High
9300 E. Union Ave.
Englewood, CO 80110
SEMBCS Career Center
3897 Jason
Englewood, CO 80110
Pagosa Springs High
Box 487
Pagosa Springs, CO 81147
Boulder Valley Voc-Tec. Center
6600 Arapahoe
Boulder, CO 80303
Career Development Center
1200 S. Sunset
Longmont, CO 80501
Salida High
Box 7 0
Salida, CO 81201
Kit Carson High
Box 185
Kit Carson, CO 80825
Centauri High
Box 72
La Jara, CO 81141
Centennial Senior High
Box 347
San Luis, CO 81152
Harrison High
2755 Janitell Rd.
Colorado Springs, CO 80906
Widefield High
615 Widefield
Security, CO 80911
Canon City High
1313 College Ave.
Canon City, CO 81212
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Emily Griffith Opportunity Sch.
1250 Walton St.
Denver, CO 80204
Douglas Co. Sr. High
Box Q
Castle Rock, CO 80104
Colorado High
1590 W. Fillmore
Colorado Springs, CO 80904
William Mitchell High
1205 Potter Dr.
Colorado Springs, CO 80909
Palmer High
301 N. Nevada
Colorado Springs, CO 80902
Wasson High
2115 Afton Way
Colorado Springs, CO 80909
Bear Creek High
3490 S. Kipling
Morrison, CO 80465
Evergreen Sr. High
Evergreen, CO 8 0439
Golden Sr. High
701 W. 24th
Golden, CO 80401
Jefferson Sr. High
2305 Pierce St.
Lakewood, CO 8 0215
Lakewood Sr. High
9700 W. 8th
Lakewood, CO 80215
Wheatridge Sr. High
9505 W. 32nd Ave.
Wheatridge, CO 80002
Warren Occupational Tech. Ctr.
13300 W. Ellsworth
Golden, CO 80401
Florence High
400 Washington Ave.
Florence, CO 81226
Glenwood Springs High
Box 820
Glenwood Springs, CO 81601
Walsenburg High
Walsenburg, CO 81089
Alameda High
1255 S. Wadsworth
Denver, CO 80226
Arvada Sr. High
7951 W. 65th Ave.
Arvada, CO 80002
Arvada West Sr. High
11325 Allendale Dr.
Arvada, CO 80002
Durango High
201 12th St.
Durango, CO 81301
Trinidad High
816 West St.
Trinidad, CO 81082
Aquilar High
Box 567
Aquilar, CO 81020
Vocational School
2115 Grand Ave.
Grand Junction, CO 81501
Montrose High
700 S. Townsend
Montrose, CO 81401
Brush High
206 Colorado Ave.
Brush, CO 8 0723
Aspen High
Box 300
Aspen, CO 81611
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Lake County High
Leadville, CO 8 0461
Revera High
Sedgewick, CO 80749
Rangely High
Box 928
Rangely, CO 81648
Larimer County Voc-Tec Center
Box 2397
Ft. Collins, CO 80521
Woodlin High
V7oodrow, CO 8 0757
Greeley Central High
1515 14th Ave.
Greeley, CO 80631
1 Wray High
Wray, CO 80758
1 Adams City High
6855 Cherry St.
Commerce City, CO 80022
Post Secondary Schools
1 Arapahoe Community College
5900 S. Santa Fe Drive
Littleton, CO 80120
2 Community College of Denver (Auraria)
12 50 Bannock
Denver, CO 80204
3 Community College of Denver (North)
1001 E. 62nd Ave.
Denver, CO 80216
3 Community College of Denver (Red Rocks)
2600 W. 6th Ave.
Golden, CO 80401
7 El Paso Community College
2200 Bott Avenue
Colorado Springs, CO 80904
1 Colorado State Reformatory
Box R
Buena Vista, CO 81211
1 Golden Key Vocational School
Box 99
Canon City, CO 81212
1 Colorado Mountain College
Glenwood Springs, CO 81601
2 Colorado Mountain College
Leadville, CO 80461
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3 Trinidad State Junior College
Trinidad, CO 81082
2 Northeastern Junior College
Sterling, CO 80751
3 Mesa Junior College
Grand Junction, CO 81501
2 San Juan Basin AVTS
Box 970
Cortez, CO 81321
2 Morgan County Community College
300 Main St.
Ft. Morgan, CO 80701
2 Otero Junior College
La Junta, CO 81050
2 Lamar Community College
24 00 S. Main
Lamar, CO 81052
9 Southern Colorado State College
Area Vocational Center
900 W. Orman Ave.
Pueblo, CO 81004
2 S.L.A.V.S.
RR 2
Monte Vista, CO 81144
2 Aims College
Box 69
Greeley, CO 80631
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