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T E C H N I C A L M AT T E R S
I

JUNE 2009 Issue 4

Welcome to the fourth issue of Technical Matters, a Lloyd’s Register publication


containing case studies covering technical issues and their solutions.

IN THIS ISSUE

2 Hull flow simulations

3 Lubricating pump
failures

4 Propeller induced
noise

5 Intermediate bearing

6 Stabiliser fins
Fluorescent magnetic particle crack detection -
7 Furnace collapse the most sensitive means of detecting cracks

8 Gear Scuffing

9 Air start manifold


explosions

10 Cylinder head

11 Thrust block
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2 T E C H N I C A L M AT T E R S June 2009

CASE STUDY 1

Hull flow simulations


Lloyd’s Register Technical
Investigations (TI) has, for the
SUBJECT VESSEL past fifteen years, been actively
TYPE engaged in studying wake fields
Container Ship with the use of Computational
Fluid Dynamics (CFD). This
research has resulted in some
ISSUE interesting insights to the
CFD assessment of developments of flows over the
vortex generator submerged afterbody, in support
of more efficient and more
reliable ships.

A common application of
CFD methods is to improve
the prediction of propeller
inflows, i.e. ship wakes. These
methodologies have been applied The result was a reduction in hull CFD analysis allows detailed
to a medium sized containership pressures radiated from the examination of flow features
which suffered from high collapsing sheet and tip vortex that would not be possible using
vibration and noise levels in the cavitation on the propeller. model tests. The flow can be
all-aft accommodation. To remedy visualised in various ways such
the high vibration and noise Two CFD models were analysed: as viewing of the vorticity in
levels, this ship was fitted with one with, and one without the wake and examination of
vortex generators to alter the vortex generators added. It was streamlines around the dynamic
inflow into the propeller. found that with addition of the ship form.
vortex generators a reduction in
propeller inflow velocities near
top dead centre was achieved, as
desired. The vortex generator
was also found to reduce the
axial velocity elsewhere in the
propeller disc.

The traditional way of analysing


propeller inflow wakes consists
of measuring the wake in a
LESSON
conventional towing tank on
a Froude scaled model, without Computational Fluid
an operating propeller. Although Dynamics provides an
such methods have, in the past, unrivalled level of
been used to provide hull
detail of the local flow
pressure and propeller inflow
predictions, they have some behaviour enhancing
shortcomings; including understanding and
problems associated with post helping find optimal
experiment corrections which
solutions. CFD methods
must be applied to counteract
scaling effects, and the absence can and should be
of the interactions between the used to address
propeller and hull. shortcomings in the
traditional methods of
predicting aft-end
flows.
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June 2009 T E C H N I C A L M AT T E R S 3

CASE STUDY 2

Lubricating pump failures


A small container ship had
problems with its main engine
SUBJECT VESSEL driven lubricating oil system since
TYPE construction. There were three
Container Ship separate failures of the two
lubricating oil pumps. In each
incident, one of the lubricating oil
ISSUE pumps failed catastrophically. The
Repeated failure of principal damage caused was the
lubricating oil pumps failure of a number of the
connecting rod bottom end
bearings. After each failure a large
amount of both fine and coarse
metal debris was found in the oil A trouble-shooting programme A one-hundred hour sea trial
filtration system. Lloyd’s Register was undertaken when the was conducted on completion
Technical Investigations (TI) was ship was in port for repair of the pipework modifications.
asked to attend the vessel to after the third pump failure. Technical Investigations (TI)
investigate and advise. The programme involved attended during the sea trial
running the engine under a and provided real time condition
Prior to each failure the lubrication number of steady conditions monitoring of the engine
oil pressure was reported to using the auxiliary electrically driven pumps.
have fluctuated rapidly. Such driven lubricating oil pump.
a characteristic is often indicative On completion of the sea trial,
of air pockets travelling through A number of problems were both of the lubricating oil pumps
the oil suction system. identified, including: were removed and dismantled
for inspection. The pumps
• aerated oil being delivered were found to be in as-new
to the pump suction pipes conditions. It was concluded that
due to the pump suction and the circumstances that caused
engine discharge pipes being the previous failures had
in close proximity; been rectified and no further
problems have been reported
• the accumulation of air in the by the owner.
suction system due to pipe
geometry;

• contamination of the
LESSON
lubricating oil with fine metal Quality control and
particles possibly extending cleanliness procedures
back to original construction.
must be followed
An extensive range of
during shipyard
modifications were made to the construction and
sump tank and the off-engine maintenance. While
lubricating oil pipework system.
it is preferable to
A thorough cleaning of the
entire system was also carried
eliminate problems
out to remove all metal debris. such as aeration
during the design
stage it is possible to
subsequently conduct
remedial work to
minimise occurrences
and impact.
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4 T E C H N I C A L M AT T E R S June 2009

CASE STUDY 3

Accommodation block noise


Sister ships can often experience
similar in-service problems which
SUBJECT VESSEL arise due to common design or
TYPE manufacturing faults. When a ship
General Cargo Carrier builder reported that disturbing
bursts of noise, close to the shaft
rate, were reported in the aft
ISSUE areas of the accommodation
Aft-end noise from tip blocks of the first four sister ships • propeller observations using energy in the frequency range
vortex cavitation in a series of small general cargo a borescope and low light 90-120 Hz.
carriers, Lloyd’s Register Technical video system.
Investigations (TI) was consulted. • accommodation noise This was the first known case of
measurements. a once per revolution broadband
The vessels were fitted with a four • vibration measurements. noise source which was not from
bladed, controllable pitch propeller • hull pressure measurements. a “singing propeller”. It was
installed in a high efficiency duct concluded that dimensional
with a relatively bluff headbox Borescope observations of flow variations on the propeller and
connection to the hull. Prior to TI’s at the duct exit plane showed duct may have led to the
involvement, fairing pieces had variable length sections of formation of the strong cavitating
been applied to the duct headbox a strong cavitating tip vortex vortex. Recommendations were
with little success and the blades of emerging from the duct at made to survey the other ships
one vessel had been replaced with shaft rate. Tip vortex cavitation and to pay close attention to the
spares. Some deviations in the structures were also observed blade inspection process, assembly
allowable tolerances had been within the duct, some and installation inside the ducts.
identified by the builder. disintegrating. Audio and
video recordings showed a Palliative solutions included
The reported nature of the noise correspondence between the injecting air into the upper duct
strongly suggested a type of dominant collapse of the tip region, applying acoustic
propeller cavitation as the vortex emerging from the duct. damping materials and insulating
primary source and hence sea the stairwell adjacent to the
trials were organised in order to Pressure and vibration pulses cabins experiencing high noise
define the noise and cavitation contained low-frequency levels. Ultimately the problem
characteristics in both the load and broadband activity; was tackled at source and a
and ballast conditions. the latter from bursts of redesigned propeller was fitted.

LESSON
Conventional vibration
and noise
measurements are
often insufficient to
identify the types of
the cavitation and
such problems may be
solved by viewing the
blades and the tip
vortex structures with
a borescope and a
video capture system
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June 2009 T E C H N I C A L M AT T E R S 5

CASE STUDY 4

Intermediate bearing
During a partially laden voyage
a direct drive diesel powered
SUBJECT VESSEL Chemical Tanker suffered a severe
TYPE failure of the intermediate shaft
Chemical Tanker pedestal bearing. Significant
wiping damage occurred to the
bearing white metal surface
ISSUE requiring the ship to be towed
Failure of the to port for repair.
intermediate shaft
bearing The vessel had recently completed
a five yearly dry-dock survey
during which the propulsion
shafting had been dismantled for
inspection. The inspection had
load along the shafting system It was found by calculation
revealed no problems and the
length. In particular it was found that the satisfactory operation
shafting was refitted.
that the forward sternbush and of the shafting system could
the second aft engine bearing be achieved even though the
Following the failure bearing
had insufficient downwards load. forward sternbush was only
loads and shaft deflections were
The second aft engine main lightly loaded. This was
measured using the jack-up
bearing was considered to be supported by recent operating
technique. The results revealed
at risk of fatigue damage. experience.
an unsatisfactory distribution of

Calculations revealed that the Following the completion of


scope for improvement of the the refitting a sea trial was
alignment conditions by carried out where the helm
adjustment of the intermediate was held over for prolonged
bearing was limited. Loading periods of time putting
of the engine second aft main strain on the shafting system.
bearing by fitting an upwards During these turns, the aft
offset bearing shell was sternbush and intermediate
therefore recommended. Such bearing temperatures remained
adjustment would improve the stable. Also there was no
loading on the engine bearing abnormal vibration found
but would have negligible effect during increases and decreases
at the forward sternbush. in shaft speed.

Flywheel
&
engine
coupling LESSON
Shafting systems require
Intermediate shaft careful alignment,
Propeller Main
shaft Sterntube fwd bearing Intermediate bearing
engine especially when the
shaftlines are short and
stiff. Appropriate
combinations of
Sterntube measurements and
aft bearing
analysis can enable
correct alignment
of the shafting
components.
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6 T E C H N I C A L M AT T E R S June 2009

CASE STUDY 5

Stabiliser fins
Two retractable stabilising fins
were attached to the sides of
SUBJECT VESSEL a Ro-Ro cargo and car carrier
TYPE where, by adjusting the angle
Passenger/Ro-Ro ship of attack, they could provide
a variable lifting force to reduce
vessel roll.
ISSUE
Stabiliser fin failure After three years in service one
of the stabilisers was found to
be missing, having failed due
to fatigue some time before.

By examining the remaining part


of the fatigued stabiliser stock at
the Lloyd’s Register Materials and
NDE Laboratory it was found that
a fatigue crack had grown from
a single initiation point, 5 mm
below the shaft surface, in the
fusion zone between a weld and
the base material. Welded
regions often show characteristic
non-uniformities and inclusions
at the base material interface.
It was also found that no heat
treatment had been undertaken
to eliminate residual stresses.
These residual stresses can often
encourage crack growth.

It was calculated that the shaft shaft due to roll of the ship in Recommendations were made
had a low factor of safety against service. The low factor of safety that the stabiliser stocks on sister
the bending loads imposed on the was apparent from the fatigue vessels should be examined
pattern as the fatigue crack had visually and by non-destructive
propagated for only 15% of the testing for the presence of cracks.
shaft diameter before rapid brittle Recommendations were also
fracture finally occurred. given to fitting shafts with an
increased operating margin
During the initial stages of crack against imposed bending loads.
growth there were three distinct
bands of relatively slow
propagation interspersed with two
narrow bands of more rapid LESSON
propagation. These changes in Poor manufacturing
crack growth rate indicated practises and
significant changes in service
component selection
loading, such as loading induced
by especially rough sea conditions. can often lead to early
failure during service
life. Understanding the
mechanisms of failure
can lead to more
robust solutions.
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June 2009 T E C H N I C A L M AT T E R S 7

CASE STUDY 6

Furnace collapse
Following the collapse of an
Inert Gas Generator (IGG)
SUBJECT VESSEL furnace onboard a LNG carrier
TYPE an investigation was carried out
LNG Carrier into how the controls and
instrumentation could have
allowed the failure to occur.
ISSUE
Inert gas generator The IGG was cooled using
furnace collapse seawater taken from the ballast
system, and the hot discharge
water was returned to the sea
through a position controlled
effluent regulating valve.

Fwd

Top

1250mm
The inert gas and effluent It was therefore possible for
pressures were compared using the IGG burner to continue
1720mm

Port Stbd
a Proportional Integral (PI) to operate with no apparent
controller which controlled the external indication that failure
position of the effluent valve. had occurred.
It was found that the two
pressure transducers of the PI A number of recommendations
Aft controller were both blocked were made to modify the method
Fwd IGG
combustion chamber with debris, giving false and manner by which the system
damage readings, therefore causing the shut off the burner if the cooling
effluent valve to be incorrectly water were to be reduced or
positioned. At the time of the blocked. It was also recommended
730mm furnace collapse the valve was to include a mechanical fail safe
1 metre
found to be fully closed. device which would allow the
Port Stbd
continued flow of cooling water
1270mm

The combustion chamber flooded if the effluent valve were to close


causing the Level Shut Down at an inappropriate moment.
Alarm to operate. The alarm
appeared to have tripped the
Aft Split ballast pump but not the burner
flame. The resulting shortage
LESSON
Fwd
of water to the lit furnace Safety critical systems
Outlet caused overheating of the should always be
Bottom
combustion chamber wall which
designed with a
300mm yielded and collapsed.
certain degree of
Port Stbd The Temperature Shut Down redundancy. By
1250mm

Alarm did not detect the rise in anticipating and


temperature of the combustion
planning for all
chamber wall due to its remote
location from the point of failure.
possible risks at the
Aft design stage hazards
can usually be avoided
and/or mitigated.
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8 T E C H N I C A L M AT T E R S June 2009

CASE STUDY 7

Gear scuffing
Severe scuffing damage occurred
on the teeth of the two input
SUBJECT VESSEL pinions and main wheel of the
TYPE main propulsion gearing during
LNG Carrier trials of a newly built diesel
electric LNG carrier. The
propulsion system consists of
ISSUE twin electric motors driving a
Scuffing of the main single output main propulsion
reduction gearing shaft and fixed pitch propeller
through single reduction, single-
helix gears. Lloyd’s Register
Technical Investigations (TI) was
asked to attend onboard at the
newbuilding yard to inspect the
tooth flank damage and assist
with the failure investigation.
The scuffing damage was machining including design
Failure of the gears was traced due to a breakdown of the modifications to the gear tooth
from trial records to occurring elasto-hydrodynamic oil film flank. The main wheel tooth
during a rapid acceleration test. which should normally be flanks were polished in-situ.
In this test, the propulsion plant present between mating gear
was accelerated from stationary teeth. The breakdown resulted Following repair, the reduction
to full away in a little over from a combination of the gearing successfully completed
eleven minutes. selection of the pinion gear sea trials. This was achieved by
tooth-end design and the rapid modifying the pinions helix
rate of torque input to the correction and end relief. The
pinion gears from the electric propulsion electric motor speed-
propulsion motors. It was torque characteristics had also
considered likely that the been modified to reduce the
damage was initiated at the initial rate of torque delivery
starboard mesh and then to the pinion gears.
transferred to the port mesh
in way of the main wheel.

The damaged pinion gears were


returned to the gearing
manufacturer for remedial
LESSON
Gear meshing design
can be complex.
Precision must be
employed when
cutting gear teeth and
aligning the gear
wheels to ensure good
contact between the
mesh. Correct
lubrication is also
essential in preventing
premature gear
failure.
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June 2009 T E C H N I C A L M AT T E R S 9

CASE STUDY 8

Air start manifold explosions


During testing of the stop-start
function of an oil tanker main
SUBJECT VESSEL diesel engine an explosion in the
TYPE main starting air manifold was
Oil Tanker experienced. Damage was
sustained to the manifold itself,
the automatic valve and the inlet
ISSUE pipe to a cylinder unit. The
Main engine air start explosion occurred on two
manifold explosions separate occasions before Lloyd’s
Register Technical Investigations
(TI) was called in to determine
the cause.

Examination of the main engine


air start system revealed the
following:

• the air start valves fitted to • during engine operation the manifold, igniting the mist and
the engine had air leaks in all air start manifold contained oil deposits and hence causing
valves in way of the valve seat: a large amount of mist the explosions.
and smoke.
• the starting air manifold The system was repaired
and the air inlet pipes had It was found that the air by replacement of the air
an internal coating of distributor, which provides the distribution system along with
a black oily/sooty substance timing for opening the air start machining and lapping of the air
(consistent with the physical valves, was worn excessively start valve seat. The air start
characteristics often found by the ingress of hard foreign manifold, piping and associated
after an explosion). Oil sludge objects. The wear allowed air to machinery were also thoroughly
deposits were removed from enter unintended air start pilot cleaned. Recommendations were
the air start manifold and lines, opening both correct and also made to overhaul the main
sent for analysis, proving incorrect air start valves. Firing air compressor lubrication system,
that the source of the oil from the main engine cylinder to prevent the air start manifold
contamination was the main had then allowed an ignition becoming contaminated with
air compressor lubricating oil: source into the air start lubricating oil.

LESSON
Good maintenance
and cleanliness
procedures should
always be followed.
Prevention can often
avoid not only an
expensive breakdown
but a dangerous
situation from arising.
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10 T E C H N I C A L M AT T E R S June 2009

CASE STUDY 9

Cylinder head
A diesel electric propelled cruise
ship sustained extensive damage
SUBJECT VESSEL to a cylinder head, valve and
TYPE running gear in one of its
Cruise Ship auxiliary engines. A subsequent
engine inspection revealed
cracks in the cylinder head of
ISSUE an adjacent engine cylinder.
Cylinder head damage Lloyd’s Register Technical
Investigations were asked to
investigate the damage and
establish whether the two
incidences had a common cause.

The primary cause of damage The cylinder head cooling


to the first cylinder head, water spaces were contaminated
valve and running gear was a with a black oily substance.
detached inlet valve head (tulip), The substance was identified
which had become separated as using gas chromatography
a result of the development of analysis to be heavy fuel oil.
a fatigue crack from multiple The coating of oil covering the
origins associated with a bend water spaces impaired the heat
in the valve spindle. transfer to the water, increasing
both the temperature gradient
Fibrous debris was found in and stresses in the thin hottest
the valve bridge oil-way which sections of the flame deck.
restricted the oil flow to the
sliding surfaces of the valve It is improbable that the two
bridge piece and valve guide damages were linked.
post. Galling and seizure
damage were identified on the
components. This damage had
impaired the valve motion and
allowed contact with the head
of the piston.
LESSON
In the second incident, cracking Often successive
was found on the cylinder head failures can be linked
between the exhaust valve seat to a common cause,
and injector sleeve bore. The
but at times they will
cracking was characteristic of an
increase in the thermal stresses be due to different
between these sections. circumstances. Failure
investigation,
therefore, requires
that all factors and
circumstances are
taken into
consideration and
judged with relevant
experience, to
determine the correct
causes.
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June 2009 T E C H N I C A L M AT T E R S 11

CASE STUDY 10

Thrust block
A twin screw diesel electric oil
tanker experienced repeated
SUBJECT VESSEL failures of the starboard shaftline
TYPE axial thrust bearing. The two sets
Oil Tanker of propulsion shafting consisted of
an electric motor directly coupled
to a thrust shaft, intermediate
ISSUE shaft, propeller shaft, and fixed
Repeated failure of pitch propeller. Each thrust shaft
thrust block bearings was supported by oil lubricated
white metal bearings each side
of the thrust collar with the
ahead and astern thrusts taken
by eleven tilting pads each side
of the collar. Overheating and
wiping of the white metal of
the tilting pads occurred on three
separate occasions early in the
life of the vessel.

Extensive work was undertaken


by Technical Investigations (TI)
before attending onboard the
vessel. A review of the complete At the same time, the design and Recommendations were made
shafting design was undertaken operation of the tilting pad to replace the existing thrust
and third-party reports from elements was investigated using block holding-down bolts with
previous trials and measurements Computational Fluid Dynamics hydraulically tightened,
were re-assessed. The propulsion (CFD). Modelling was carried out expanding sleeve type bolts.
shaftline torsional, lateral and to investigate the effect of
axial dynamic characteristics varying the oil viscosity, the
were modelled using Lloyd’s operating temperature and
Register shafting software suite. different designs of leading edge
The shaft alignment was studied geometry on the bearing oil film
to investigate possible effects on thickness. The minimum thickness
LESSON
the dynamic characteristics. at service speed was estimated to
be 32 microns (0.032 mm). Complex hypotheses,
A comprehensive onboard measurements and
investigation was undertaken. The cause of the failure was analysis are often
Simultaneous dynamic eventually identified using a
deployed in
measurements were made of the simple mechanical dial-gauge
significant parameters on both indicator. Relative movement determining and
shaftlines in order to compare between the upper and lower effectively rectifying
their behaviour over the full thrust block casing halves was the cause of failure. It
operational manoeuvring and occurring as a result of loosening
is a sobering thought,
speed ranges ahead and astern. of the holding-down bolts. The
The theoretical modelling carried unequal reactions in the upper however, that the
out beforehand allowed and lower casings overloaded cause of the failure
immediate evaluation of the thrust pads which reduced the can occasionally be
results within the short time oil film thickness and resulted
identified with basic
available onboard. in overheating and failure.
instrumentation and
can be due to
something much
simpler.
TechMatters4_200509.qxd:TechMatters210708v5.qxd 20/5/09 15:43 Page 12

12 T E C H N I C A L M AT T E R S June 2009 Lloyd’s Register ODS


Three years ago Dr Myllerup was
appointed a Senior Vice President
of Lloyd's Register and Head of
Lloyd's Register Technical
Investigation & Analysis with
the responsibility to integrate

Technical investigations expertise


Ødegaard & Danneskiold-Samsøe
(ØDS), the Technical Investigation
Department and Structural Analysis
Services (SAS).

From the 1 July 2008 these services


have been integrated into a single
entity known as Lloyd’s Register
Dr Claus Peter John ODS and the growth strategy is
Myllerup Filcek Maguire illustrated by the acquisition of
Martec in February 2008 and the
opening of the Shanghai office in
July 2008.

Lloyd's Register ODS services are


Dr Claus Myllerup joined Peter Filcek joined the John Maguire Joined offered across all business streams,
Ødegaard & Danneskiold- Technical Investigations (TI) Lloyd’s Register in 1989 but it is a division of the Marine
Samsøe (ØDS) in 1996 following of Lloyd's Register in 1979 within the HQ-Industrial Consultancy Services.
a two year period with Castrol and has worked on a wide Division. He transferred to
as Technical Consultant. variety of marine and land HQ-Engineering Services
failure investigations and Group in 1994, into the
When he joined as manager of measurements. He became Technical Investigations
the Machinery Dynamics Principal Surveyor in charge (TI). He was appointed
Group Dr Myllerup supervised of Failure Investigations in Engineering Projects TECHNICAL
and carried out numerous 2000, and Technical Manager Principal in TI in 1999, and M AT T E R S
experimental, computational, in 2004 responsible for Development Manager in
For further information
and theoretical consulting technical matters within TI. 2004. For the last four years relating to our technical
projects within the field of he has been responsible for investigation services,
machinery dynamics. The He graduated in Marine developing the products please contact Peter Filcek,
range of clients was wide, but Engineering at Newcastle- and services offered by TI, Technical Manager of
they were mainly within the upon-Tyne and obtained including all related material, Technical Investigations:
oil and gas industry. experience of engine and also responsible for T +44 (0)20 7423 1765
manufacture, ship repairing, carrying out special technical F +44 (0)20 7423 1804
During 2005 ØDS was acquired E peter.filcek@lr.org
marine engineering, and investigations.
by Lloyd’s Register, he was by
the power station industries Managing Editor:
then the Deputy Managing
before joining Lloyd’s Prior to Lloyd’s Register, he Nick Savvides
Director at ØDS. Under his
Register in 1977. He trained was a civil engineer with WS Marine Business Development
leadership the company has
as an Engineering Surveyor Atkins from 1976, leading to T +44 (0)20 7423 2105
grown from 15 to 55 staff and F +44 (0)20 7423 2213
in plan approval and in the chartered engineer status in
the client base has grown to E nick.savvides@lr.org
port of Rotterdam. 1980. Between 1976 and
encompass most of the major
1989 he spent periods in the
players in the industries the Tehnical Matters is produced by
UK, Algeria, Morocco and Marine Business Development and
company serves.
Saudi Arabia on a variety designed by Pipeline Design. Care
of assignments. is taken to ensure that the
Dr Myllerup is a member
information in Technical Matters is
of the Society of Engineers of accurate and up to date. However,
Denmark and the American Lloyd’s Register accepts no
.
Society of Mechanical responsibility for inaccuracies in,
Engineers. or changes to such information.

Lloyd’s Register EMEA Lloyd’s Register Asia Lloyd’s Register Americas, Inc.
T + 44 (0)20 7709 9166 T + 852 2287 9333 T +1 (1)281 675 3100
F + 44 (0)20 7423 2057 F + 852 2526 2921 F +1 (1)281 675 3139
E emea@lr.org E asia@lr.org E americas@lr.org

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June 2009
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