Specialised gear is employed to take away deposits and scale from the inside of boiler tubes, guaranteeing optimum warmth switch and operational effectivity. This gear could vary from easy mechanical brushes to classy automated methods using high-pressure water jets or different cleansing media. An instance can be a system utilizing rotating brushes pushed by an electrical motor, propelled by the tube to dislodge amassed particles.
Clear boiler tubes are important for protected and environment friendly operation. Scale buildup reduces warmth switch, resulting in elevated gas consumption, decreased steam manufacturing, and potential overheating, which may injury the boiler and create security hazards. Traditionally, guide cleansing strategies have been time-consuming and arduous, requiring vital downtime. The event of automated cleansing options has considerably decreased downtime and improved employee security.
This dialogue will additional discover the varied forms of cleansing gear, their purposes, and the advantages they provide when it comes to improved effectivity, decreased upkeep prices, and prolonged boiler lifespan. It would additionally look at finest practices for tube cleansing and the significance of normal upkeep applications.
1. Sorts
Boiler tube cleansing machine varieties are categorized primarily based on cleansing technique and tube configuration. Principal varieties embrace mechanical, water-jet, and chemical cleansing machines. Mechanical cleaners make the most of brushes or scrapers, efficient for eradicating arduous deposits however probably abrasive to tube surfaces. Water-jet cleaners make use of high-pressure water streams, supreme for softer deposits and fewer prone to trigger tube injury. Chemical cleansing includes circulating cleansing options by the tubes, fitted to particular forms of scale or corrosion. Choosing the proper machine kind is determined by components equivalent to boiler design, gas kind, and the character of the deposits.
Understanding the strengths and limitations of every kind is essential for optimum cleansing and minimal tube put on. As an example, a coal-fired boiler with vital soot buildup could profit from a mechanical cleaner with sturdy scraping capabilities, whereas a gas-fired boiler with lighter deposits would possibly profit from a water-jet system. Chemical cleansing might be focused in direction of particular scale compositions, like calcium or iron oxide, typically employed as a supplemental strategy to mechanical or water-jet strategies. Improper machine choice may end up in ineffective cleansing and even tube injury, highlighting the significance of cautious consideration primarily based on particular operational parameters.
The selection of boiler tube cleansing machine kind immediately impacts cleansing efficacy, operational effectivity, and tube lifespan. Matching the machine to the precise software minimizes downtime, extends boiler life, and reduces general upkeep prices. A complete understanding of accessible cleansing applied sciences, coupled with an intensive evaluation of the boiler working surroundings, is crucial for knowledgeable decision-making and optimum boiler efficiency.
2. Purposes
Boiler tube cleansing machine purposes span numerous industries reliant on steam technology. Energy crops, chemical processing services, refineries, and pulp and paper mills characterize key areas the place these machines are important. The precise software dictates the kind of cleansing machine employed and the frequency of cleansing. For instance, energy crops using coal-fired boilers typically require extra frequent and sturdy cleansing as a result of increased ash and soot accumulation in comparison with pure gas-fired boilers in different industries. Understanding the operational context, together with gas kind, boiler design, and steam demand, is essential for choosing the suitable cleansing know-how and establishing efficient upkeep schedules.
Matching the cleansing machine to the precise software optimizes efficiency and minimizes downtime. In energy technology, sustaining clear boiler tubes is paramount for environment friendly power conversion and dependable electrical energy provide. In chemical processing, tube cleanliness ensures constant warmth switch for essential reactions. In refineries, environment friendly steam technology is crucial for numerous processes, and clear tubes contribute to optimum gas effectivity. Pulp and paper mills rely closely on steam for drying and different processes, making boiler tube cleanliness essential for manufacturing continuity. Selecting the proper cleansing machine and implementing a daily upkeep program tailor-made to the precise industrial software immediately impacts operational effectivity, output high quality, and profitability.
Efficient boiler tube cleansing contributes considerably to operational security and cost-effectiveness throughout numerous industries. By eradicating deposits that impede warmth switch, these machines stop overheating, scale back gas consumption, and reduce downtime related to upkeep and repairs. The selection of cleansing technique and frequency have to be tailor-made to the precise software to maximise these advantages. A well-maintained boiler system, supported by acceptable cleansing applied sciences, interprets to improved security, decreased operational prices, and elevated gear lifespan, whatever the industrial setting.
3. Performance
Performance in a boiler tube cleansing machine dictates its effectiveness and suitability for particular purposes. A number of components contribute to the general performance: the cleansing technique employed (mechanical, water-jet, chemical), the machine’s maneuverability inside the tubes, the ability supply, and the management system’s sophistication. Trigger and impact relationships are direct: a machine’s design and working ideas immediately affect its cleansing efficacy, pace, and influence on the tubes themselves. As an example, a mechanically pushed brush system successfully removes arduous deposits however requires cautious operation to keep away from tube erosion, whereas a high-pressure water jet system affords gentler cleansing however could also be much less efficient towards cussed scale. The machine’s potential to navigate tube bends and entry difficult-to-reach areas is one other essential side of performance, impacting general cleansing protection and effectivity.
As a essential element of any boiler upkeep technique, the cleansing machine’s performance impacts operational effectivity, prices, and security. A machine able to speedy and efficient cleansing minimizes downtime and reduces labor prices. Moreover, correct tube cleansing enhances warmth switch, resulting in gas financial savings and decreased emissions. From a security perspective, efficient scale removing mitigates the chance of tube overheating and potential boiler failures. Contemplate an influence plant using a classy automated cleansing system: the flexibility to program cleansing cycles, monitor progress, and modify parameters remotely optimizes cleansing efficacy whereas minimizing human intervention and related dangers. Conversely, a smaller industrial boiler could require a extra transportable, operated by hand machine, prioritizing ease of use and maneuverability inside a confined area. Sensible software concerns dictate the required performance for optimum efficiency in every particular context.
Understanding the performance of a boiler tube cleansing machine is paramount for choosing the suitable know-how and maximizing its advantages. Matching the machine’s capabilities to the precise boiler design, gas kind, and operational necessities ensures efficient cleansing, minimizes downtime, and optimizes useful resource utilization. Challenges stay in growing much more environment friendly and versatile cleansing applied sciences able to addressing complicated deposit compositions and minimizing tube put on. Finally, developments in boiler tube cleansing machine performance contribute to safer, extra environment friendly, and sustainable steam technology throughout numerous industries.
4. Effectivity Enhancements
Effectivity enhancements are intrinsically linked to using boiler tube cleansing machines. Scale and deposit accumulation inside boiler tubes impede warmth switch, forcing the boiler to devour extra gas to take care of steam manufacturing. This discount in thermal effectivity interprets immediately into elevated operational prices and a bigger environmental footprint. Using a boiler tube cleansing machine successfully removes these impediments, restoring optimum warmth switch and maximizing gas effectivity. The cause-and-effect relationship is evident: common cleansing results in measurable enhancements in boiler efficiency, decreasing gas consumption and minimizing wasted power. For instance, an influence plant implementing a strong tube cleansing program can expertise a major lower in gas consumption, immediately impacting electrical energy technology prices and decreasing greenhouse fuel emissions.
As a essential element of boiler upkeep, tube cleansing contributes considerably to general plant effectivity. In industrial settings the place steam is crucial for processes like heating, drying, or sterilization, sustaining clear boiler tubes ensures a constant and dependable steam provide, maximizing manufacturing output and minimizing disruptions. Contemplate a meals processing facility the place steam is used for sterilization: environment friendly boiler operation, facilitated by clear tubes, ensures constant product high quality and minimizes the chance of manufacturing delays as a result of boiler inefficiencies. The sensible significance of understanding this connection is obvious within the tangible advantages: decreased operational prices, improved productiveness, and enhanced environmental sustainability.
Optimized boiler effectivity, facilitated by common tube cleansing, is essential for financial and environmental sustainability. Challenges stay in growing extra environment friendly cleansing applied sciences and optimizing cleansing schedules to reduce downtime and maximize advantages. The continuing improvement of automated cleansing methods and superior diagnostic instruments guarantees additional enhancements in boiler effectivity and operational reliability. Finally, the connection between effectivity enhancements and boiler tube cleansing machines highlights the essential position of proactive upkeep in attaining sustainable and cost-effective steam technology throughout numerous industries.
5. Price Financial savings
Price financial savings characterize a major driver for using boiler tube cleansing machines. Sustaining clear boiler tubes immediately impacts operational expenditures, influencing gas consumption, upkeep necessities, and gear lifespan. Understanding the multifaceted nature of those price financial savings is essential for justifying investments in cleansing gear and establishing efficient upkeep methods.
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Diminished Gas Consumption
Scale and deposits act as insulation, decreasing warmth switch and necessitating elevated gas consumption to take care of desired steam output. Common cleansing restores optimum warmth switch, immediately decreasing gas utilization and related prices. For instance, a producing facility experiencing a ten% enchancment in boiler effectivity as a result of cleaner tubes can notice substantial financial savings on annual gas expenditures. This direct correlation between tube cleanliness and gas consumption underscores the financial advantages of efficient cleansing applications.
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Decrease Upkeep Prices
Uncared for boiler tubes can result in expensive repairs and untimely gear failure. Overheating as a result of scale buildup may cause tube warping, leaks, and even catastrophic boiler injury. Proactive cleansing minimizes these dangers, decreasing the frequency and expense of main repairs. As an example, avoiding a single boiler tube failure by common cleansing can save 1000’s of {dollars} in alternative elements and labor, to not point out the price of manufacturing downtime. Preventive upkeep by tube cleansing represents a cheap strategy to preserving boiler integrity and increasing its operational lifespan.
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Prolonged Tools Lifespan
Common cleansing contributes on to prolonged boiler lifespan. By mitigating the damaging results of scale and corrosion, cleansing preserves tube integrity and reduces the pressure on different boiler elements. This prolonged lifespan interprets to delayed capital expenditures related to boiler alternative. For instance, extending the lifetime of a boiler by 5 years by a diligent cleansing program can defer vital capital funding, permitting these funds to be allotted to different essential areas of the operation. This long-term price profit highlights the strategic significance of incorporating tube cleansing right into a complete asset administration plan.
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Minimized Downtime
Environment friendly boiler tube cleansing minimizes downtime related to upkeep and repairs. Deliberate cleansing actions are usually much less disruptive than emergency repairs ensuing from uncared for upkeep. Diminished downtime interprets immediately into elevated manufacturing output and income technology. In steady course of industries, equivalent to chemical manufacturing or energy technology, minimizing downtime is paramount for sustaining profitability and assembly buyer calls for. Investing in efficient cleansing gear and implementing a well-structured upkeep program minimizes unscheduled outages and maximizes operational continuity, contributing on to the underside line.
The cumulative influence of those price financial savings makes a compelling case for investing in and using boiler tube cleansing machines. Whereas the preliminary price of the gear and implementation of a cleansing program represents an upfront funding, the long-term advantages when it comes to decreased operational prices, prolonged gear lifespan, and improved productiveness far outweigh the preliminary expenditure. A complete cost-benefit evaluation, contemplating the precise operational context and the potential financial savings outlined above, offers a transparent justification for integrating boiler tube cleansing into a strong upkeep technique.
6. Security Enhancements
Security enhancements are paramount in boiler operation, and boiler tube cleansing machines play a vital position in mitigating dangers related to scale buildup and corrosion. These machines contribute considerably to a safer working surroundings and stop probably catastrophic incidents. Understanding this connection is crucial for implementing efficient boiler upkeep applications and prioritizing employee security.
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Overheating Prevention
Scale and deposits act as insulation, decreasing warmth switch and resulting in localized overheating. This overheating can weaken tube partitions, rising the chance of ruptures and explosions. Common cleansing with acceptable gear removes these deposits, guaranteeing environment friendly warmth switch and stopping harmful temperature spikes. For instance, in an influence plant, stopping tube overheating is essential for sustaining steady steam manufacturing and avoiding disruptions to electrical energy technology. The direct hyperlink between tube cleanliness and overheating prevention underscores the significance of normal upkeep in guaranteeing a protected working surroundings.
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Corrosion Mitigation
Corrosion weakens boiler tubes, making them inclined to failure beneath stress. Sure forms of deposits can speed up corrosion, additional compromising tube integrity. Boiler tube cleansing machines, notably these using chemical cleansing strategies, can take away corrosive deposits and assist keep the protecting oxide layer on tube surfaces, mitigating corrosion dangers and increasing tube lifespan. In chemical processing crops, the place corrosive supplies are sometimes current, efficient tube cleansing is crucial for stopping leaks and guaranteeing the integrity of the boiler system.
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Diminished Threat of Explosions
Overheating and corrosion considerably enhance the chance of boiler tube ruptures, which may result in explosions. The speedy launch of high-pressure steam and scorching water may cause extreme accidents and property injury. By stopping overheating and corrosion, boiler tube cleansing machines contribute on to a safer working surroundings and reduce the chance of catastrophic incidents. In industrial settings the place boilers function at excessive pressures, common cleansing is paramount for mitigating explosion dangers and guaranteeing employee security.
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Improved Working Circumstances
Guide cleansing of boiler tubes generally is a hazardous process, exposing employees to confined areas, excessive temperatures, and probably dangerous cleansing chemical substances. Automated cleansing machines scale back the necessity for guide intervention, minimizing these dangers and enhancing general working circumstances. As an example, remotely operated cleansing methods permit technicians to carry out cleansing operations from a protected distance, decreasing publicity to hazardous environments. Prioritizing employee security by using automated cleansing gear fosters a extra optimistic and safe work surroundings.
The connection between security enhancements and boiler tube cleansing machines is plain. By stopping overheating, mitigating corrosion, decreasing explosion dangers, and enhancing working circumstances, these machines contribute considerably to a safer and extra productive operational surroundings. Investing in acceptable cleansing gear and implementing a strong upkeep program demonstrates a dedication to employee security and minimizes the potential for expensive and harmful incidents. Moreover, prioritizing security by proactive upkeep fosters a tradition of accountability and reinforces the significance of sustaining a safe and environment friendly operational surroundings throughout numerous industries reliant on steam technology.
7. Upkeep Necessities
Upkeep necessities for boiler tube cleansing machines are important for guaranteeing their continued effectiveness and longevity. Common maintenance immediately impacts the machine’s efficiency, reliability, and general cost-effectiveness. A well-maintained cleansing machine interprets to optimized cleansing cycles, minimized downtime, and a safer working surroundings. Neglecting upkeep can result in decreased cleansing efficacy, elevated threat of kit failure, and probably hazardous working circumstances.
A number of key elements of upkeep are essential for optimum machine efficiency. These embrace common inspections, lubrication of transferring elements, alternative of worn elements (equivalent to brushes, seals, and nozzles), and calibration of management methods. The frequency and scope of upkeep rely on the kind of cleansing machine, its utilization frequency, and the working surroundings. For instance, a mechanically pushed cleansing machine utilized in a coal-fired energy plant could require extra frequent upkeep because of the harsh working circumstances in comparison with a water-jet system utilized in a pure gas-fired boiler. Understanding the precise upkeep necessities for every kind of machine is crucial for maximizing its lifespan and guaranteeing constant efficiency.
Correct upkeep of boiler tube cleansing machines affords a number of sensible advantages. Firstly, it ensures constant cleansing efficacy, maximizing warmth switch and minimizing gas consumption. Secondly, common upkeep reduces the chance of sudden gear failures, minimizing downtime and related manufacturing losses. Thirdly, a well-maintained machine contributes to a safer working surroundings by decreasing the chance of malfunctions and potential hazards. Lastly, proactive upkeep extends the lifespan of the cleansing machine, maximizing the return on funding and minimizing the necessity for untimely alternative. By understanding and addressing the precise upkeep necessities of every cleansing machine, operators can guarantee optimum efficiency, security, and cost-effectiveness all through the gear’s operational life.
8. Return on Funding
Return on funding (ROI) is a essential think about evaluating the financial viability of boiler tube cleansing machines. Buying and working these machines represents a major capital funding, and understanding the potential returns is crucial for justifying the expenditure. The ROI of a boiler tube cleansing machine is multifaceted, encompassing each direct and oblique price financial savings, in addition to enhancements in operational effectivity and security. A number of components affect the ROI, together with the kind of cleansing machine, the frequency of use, the precise boiler software, and the general upkeep technique. An intensive cost-benefit evaluation, contemplating each the preliminary funding and the long-term operational financial savings, offers a complete evaluation of the potential ROI.
A number of key components contribute to a optimistic ROI for boiler tube cleansing machines. Diminished gas consumption as a result of improved warmth switch represents a direct and sometimes substantial price saving. Minimized upkeep bills ensuing from fewer tube failures and prolonged gear lifespan additional improve the ROI. Elevated operational effectivity, stemming from decreased downtime and improved steam manufacturing, contributes to increased productiveness and profitability. Enhanced security, by the prevention of overheating and corrosion-related incidents, mitigates the chance of expensive accidents and downtime. For instance, a chemical processing plant investing in an automatic cleansing system could expertise a major ROI by decreased downtime, decrease upkeep prices, and elevated manufacturing output. Equally, an influence plant implementing a daily cleansing program can obtain a optimistic ROI by decreased gas consumption and improved boiler effectivity.
Maximizing ROI requires a strategic strategy to boiler tube cleansing. Choosing the suitable cleansing know-how for the precise software is essential. Implementing a well-defined upkeep program, together with common inspections and preventative upkeep of the cleansing gear itself, ensures optimum efficiency and longevity. Monitoring key efficiency indicators, equivalent to gas consumption, cleansing cycle instances, and upkeep prices, offers invaluable information for evaluating the effectiveness of the cleansing program and figuring out areas for enchancment. Challenges stay in precisely quantifying the long-term advantages of tube cleansing, notably when it comes to decreased threat and improved security. Nonetheless, a complete evaluation of each the tangible and intangible advantages, coupled with a proactive upkeep technique, demonstrates the numerous potential for a optimistic ROI from investing in and using boiler tube cleansing machines. This understanding underscores the significance of incorporating tube cleansing right into a complete asset administration plan for attaining sustainable and cost-effective steam technology throughout numerous industries.
Regularly Requested Questions
This part addresses frequent inquiries relating to boiler tube cleansing machines, offering concise and informative responses to facilitate knowledgeable decision-making and promote finest practices.
Query 1: How continuously ought to boiler tubes be cleaned?
Cleansing frequency is determined by components equivalent to gas kind, boiler working hours, and the character of deposits. A professional technician can assess particular operational parameters and advocate an acceptable cleansing schedule. Common inspections are essential for figuring out the necessity for cleansing and stopping extreme scale buildup.
Query 2: What are the first dangers related to neglecting boiler tube cleansing?
Neglecting cleansing can result in decreased warmth switch, elevated gas consumption, and potential overheating. Overheating may cause tube warping, leaks, and even catastrophic boiler failures, posing vital security hazards and incurring expensive repairs.
Query 3: What are the several types of boiler tube cleansing machines out there?
Principal varieties embrace mechanical cleaners (utilizing brushes or scrapers), water-jet cleaners (using high-pressure water), and chemical cleaners (circulating specialised options). The optimum alternative is determined by components equivalent to the kind of boiler, the character of deposits, and the specified degree of cleansing aggressiveness.
Query 4: How does one choose the suitable boiler tube cleansing machine?
Choice includes contemplating components equivalent to boiler design, gas kind, deposit composition, and operational constraints. Consulting with skilled professionals is advisable to make sure the chosen machine aligns with particular wants and maximizes cleansing effectiveness.
Query 5: What are the important thing upkeep necessities for these machines?
Common inspections, lubrication, alternative of worn elements (brushes, seals, nozzles), and calibration of management methods are important for sustaining optimum efficiency and increasing gear lifespan. Particular upkeep necessities range relying on the machine kind and working surroundings.
Query 6: How can one justify the funding in a boiler tube cleansing machine?
A complete cost-benefit evaluation, contemplating gas financial savings, decreased upkeep prices, prolonged gear lifespan, and enhanced security, demonstrates the long-term financial benefits of investing in and using these machines. Improved operational effectivity and minimized downtime additional contribute to a optimistic return on funding.
Proactive upkeep by common boiler tube cleansing is crucial for guaranteeing protected, environment friendly, and cost-effective operation. Addressing these continuously requested questions helps make clear the significance of investing in and correctly using these machines. Diligent consideration to cleansing and upkeep contributes considerably to optimized boiler efficiency, decreased operational prices, and a safer working surroundings.
The next part will delve into particular case research, illustrating the sensible advantages of implementing sturdy boiler tube cleansing applications throughout numerous industrial purposes.
Ideas for Efficient Boiler Tube Cleansing
Implementing a strong cleansing routine is essential for sustaining boiler effectivity, reliability, and security. The following tips provide sensible steering for optimizing cleansing practices and maximizing the advantages of specialised gear.
Tip 1: Perceive Deposit Composition
Analyzing the composition of deposits inside boiler tubes is essential for choosing the suitable cleansing technique. Completely different deposits (e.g., scale, soot, corrosion merchandise) require particular cleansing approaches. Laboratory evaluation can present invaluable insights into deposit composition, enabling knowledgeable choices relating to cleansing know-how and chemical choice.
Tip 2: Set up a Common Cleansing Schedule
Common cleansing prevents extreme buildup and minimizes the chance of efficiency degradation. Cleansing frequency needs to be decided primarily based on components equivalent to gas kind, working hours, and water high quality. A well-defined schedule ensures constant cleansing and prevents sudden downtime.
Tip 3: Select the Proper Cleansing Expertise
Mechanical, water-jet, and chemical cleansing strategies every provide distinct benefits and limitations. Matching the cleansing know-how to the precise deposit kind and boiler design is essential for maximizing cleansing efficacy and minimizing potential injury to tube surfaces.
Tip 4: Prioritize Operator Coaching
Correct coaching ensures operators perceive the protected and efficient operation of cleansing gear. Skilled personnel can optimize cleansing parameters, reduce tube put on, and cling to security protocols, maximizing the advantages of the cleansing program.
Tip 5: Examine Tubes Usually
Common inspections, together with visible examinations and thickness measurements, present invaluable information on tube situation and deposit accumulation. These inspections allow proactive upkeep, determine potential issues early, and optimize cleansing schedules.
Tip 6: Preserve Cleansing Tools
Correct upkeep of cleansing gear, together with lubrication, element alternative, and calibration, ensures constant efficiency and extends gear lifespan. Common upkeep minimizes the chance of kit failure and optimizes cleansing efficacy.
Tip 7: Doc Cleansing Actions
Sustaining detailed information of cleansing actions, together with dates, strategies, and observations, offers invaluable information for monitoring efficiency and figuring out tendencies. This documentation helps knowledgeable decision-making relating to future cleansing methods and facilitates steady enchancment.
Adhering to those ideas optimizes boiler tube cleansing practices, maximizing effectivity features, minimizing operational prices, and guaranteeing a protected working surroundings. A proactive strategy to cleansing, coupled with an intensive understanding of deposit composition and acceptable cleansing applied sciences, contributes considerably to long-term boiler reliability and efficiency.
The next conclusion will summarize the important thing takeaways and emphasize the significance of incorporating sturdy boiler tube cleansing practices right into a complete upkeep technique.
Conclusion
Boiler tube cleansing machines are important for sustaining operational effectivity, minimizing prices, and guaranteeing security in steam technology methods. This exploration has detailed the varied forms of cleansing machines, their purposes throughout numerous industries, and their influence on boiler efficiency. Key takeaways embrace the significance of understanding deposit composition, choosing acceptable cleansing applied sciences, adhering to common upkeep schedules, and prioritizing operator coaching. The direct correlation between clear boiler tubes and optimized gas consumption, decreased upkeep bills, and enhanced security underscores the essential position of those machines in attaining sustainable and cost-effective steam technology.
Continued developments in cleansing applied sciences, coupled with a higher emphasis on proactive upkeep methods, promise additional enhancements in boiler effectivity, reliability, and security. Integrating boiler tube cleansing machines right into a complete asset administration plan represents a vital funding for any group reliant on steam technology. Prioritizing common and efficient tube cleansing contributes considerably to a extra sustainable, cost-effective, and safe operational surroundings throughout numerous industries, guaranteeing the long-term reliability and efficiency of essential steam technology property.
