Current Topics in Rocket Propulsion An Open Source Conference

APRIL 14, 2018

Westcott Sports and Social Club Ashendon Rd Westcott Buckinghamshire HP18 0NZ

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CURRENT TOPICS IN ROCKET PROPULSION

WHY: When research into rocketry recommenced in the UK in the mid 1930’s it was primarily military funded and hence classified. Little information was made available to the general public about UK rocket research and the conferences, symposia etc were classified and this remained the case right up to the end of the 20th century.

However, the “Times, they are a changing”

Unclassified Rocket Propulsion activity at Westcott (The former Rocket Propulsion Establishment and in its day one of the most secretive sites in the UK) is expanding and the government is pushing the Space sector as a major economic growth area of the UK economy. To celebrate the increase in activity at Westcott it has been decided to run an Open Source conference covering some current topics in near term Rocket propulsion.

The West Midlands Branch of the British Interplanetary Society is organising the daylong conference with the aim of showcasing current UK rocket research, in particular those companies actively engaged in Rocket Propulsion Research at Westcott, to BIS members, academia and interested members of the public.

The main objective is to give those who are not actively engaged in the subject of Rocket Propulsion an update as to the current technology level in some areas of the subject and where this might lead us, in respect of near-term future activities in space. In addition, there are many associated areas of technology that bear directly on the ability of current propulsion systems to provide better and more effective use of existing and planned propulsive capabilities (such as the properties and use of graphene, additive manufacturing, new polymers etc.)

ROCKET PROPULSION ESTABLISHMENT WESTCOTT: Around 1935 with the likelihood of another war in Europe and the increasing sophistication and capability of bomber aircraft it was decided that the UK should investigate anti -aircraft defence using rockets as an addition to anti -aircraft artillery. This effort led to the development of the Cordite (Solvent-less Extruded Double Base Propellant) powered unguided Anti-aircraft rockets, and to the adoption of these Cordite rocket motors for numerous other uses by the allies during World War II.

As World War II progressed it became apparent that Germany had made great strides in liquid propellant rocket propulsion and so by wars end there was a great deal of effort expended to capture material and personnel who had been involved with missile and rocket development. Early in the war such rocket work as was undertaken in the UK had been dispersed around the United Kingdom for strategic reasons. Some site examples being The Flame Warfare Establishment at Langhurst, Woolwich Arsenal, Fort Halstead, Waltham Abbey, Aberporth and ROF Bishopton. It was decided to concentrate research into the new weapon systems at one site (in the terminology of the day GAT’s Guided Aerial Torpedoes quickly superseded by GAP’s Guided Aerial Projectiles) Initial management for weapons development for all three-armed forces was provided by the Royal Navy. Thus, on the 1st

April 1946 a former Bomber Operational Training Unit airfield at Westcott became the Guided Projectile Establishment.

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Initial plans were that Westcott would be responsible for all aspects of missile Research and Development. However, post war rationalisation and a turf war between the various military services and the existing research establishments led to the RAE at Farnborough assuming overall control of Research and Development in missiles and their propulsion systems. Rocket propulsion research and development for both civil and military applications was to be carried out at Westcott along with closely related work on propellants at the Explosives (and Propellants) Research and Development Establishment (ERDE) at Waltham Abbey. On the 1st of August 1947 Westcott thus became the Rocket Propulsion Department of RAE (RAE/RPD)

The first group of German Rocket scientists and technicians had arrived on site in November 1946 (a further 7 arrived a little later) and as well as working on assigned projects another task was to work with the British staff to analyse and report on the vast quantity of captured German material.

Early work included firing of Walter engines and Rocket Assisted Take Off units RATO’s (a Walter 109-510 exploded at D site resulting in fatalities in November 1947) Although not a Westcott design, further development and firings of LOP/GAP (British Liquid Oxygen Petrol/Guided Air Projectile occurred LOP/GAP was a successor to Lizzie the first British Liquid propellant rocket engine developed by Lubbock and Gollin at Langhurst 1943) and would evolve into the propulsion unit for the Research Test Vehicle 1 (RTV1).

In Feburary 1950 the construction of the Solid Propellant Laboratories (SPL) development scale rocket motor filling factory commenced and by July 1950 the first Solid motor filled (a

7 inch diameter motor filled with SU/K a type of Extruded Double Base) was later fired at 6 Site. It was quickly realised that given the understanding of propulsion technology and its

Figure 1 - Final Design of RTV1 Combustion Chamber

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state of development at the time that for efficient and effective use solid propellant powered vehicles needed to be treated as rounds of ammunition i.e. instant readiness. This of course did not stop Liquid propellant research.

Over the years many “contractor” companies ran their own rocket propulsion development programmes on site and in April 1947 one of the first was Napiers at 35 Site working on monopropellants. Westcott also collaborated extensively with industry, a good example being the Hydrogen Peroxide/Kerosene Gamma engine designed at Westcott and further developed by the then Armstrong Siddeley Motors. These engines went on to be successfully used in Black Knight and Black Arrow.

Westcott finally became an independent Establishment again as the Rocket Propulsion Establishment (RPE) Westcott in June 1958.

Many research departments and facilities existed on site amongst them Heat Transfer, Combustion Chamber Design, Propellant Manufacture and Supply, Materials, Instrumentation, Valve Spray and Flow Lab, Environmental Chambers, Centrifuge, Vibration Shock and Drop, Radio Attenuation, Liquid Hydrogen production. Other work undertaken includes expulsion charges, turbo-pumps, propellant feed systems, gas generators, propellant tank design, Liquid propellant Guns and of course design testing and manufacture of both Monopropellant and Bi-Propellant Rocket Engines for use on space vehicles and satellites.

For further information see the following A History of No 11 OTU by Jim Hampton - Covers the site as an RAF Airfield Westcott a Chronology by John Harlow - Covers 1942 construction of Airfield to

1999 Westcott edited by Mark Perman - Contains The official history by Maureen Fowler a

complete listing of Firing sites, there uses and many photo’s plus some promotional leaflets.

Figure 2 - Beta 1 Combustion Chamber

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THE BRITISH INTERPLANETARY SOCIETY – WEST

MIDLANDS BRANCH Formed in 2011 this branch has been at the forefront of UK branch activity since its creation. One of the objectives of regional branches is to increase coverage of BIS activities across the country ensuring a wider audience that can’t always make London-based meetings. Since start-up, the programme of events has increased with 4 planned for 2018.

The officers of BIS WM are: President John Harlow MBE (Fellow) Secretary Mark Perman (Fellow) Assistant Secretary & Treasurer Bob Stanton (Member)

With Bob Stanton also supporting Mark Perman in arranging events.

Lectures & Films Normally held twice yearly at the Gardeners Arms public house in Droitwich on a wide range of topics in space projects, astronautics and astronomy

Cosford 2017 This ad hoc weekend event is held at the RAF Museum at Cosford has a heavy emphasis on space history.

Salt Fest An annual event held in Droitwich where BIS WM have organized a ‘space corner’ for space and astronomy-related organizations to exhibit and interest the general public.

Space Day BIS WM has been organizing this annual event since 2012. The first few were held at the library in Droitwich and more recently at the Hive in Worcester (part of the University of Worcester campus) Events are aimed at inspiring young people and schools bring students to enjoy a wide range of space-related activities, talks and events. Now the biggest free Space event in the Midlands.

Westcott In conjunction with the twice-yearly Westcott pensioners social event, BIS WM have organized films, lectures and site tours on special occasions

Rocket History These two events were held at the Culham Science Park to bring together past ‘rocketeers’ to flesh out the lesser known facts and history of rocket projects

All the events for 2018 can be seen on the main BIS web-site and Facebook group (bis - wm)

british interplanetary society - west midlands branch

If you are in the area please call in at any of our events, you would be most welcome.

John Harlow 2018

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CURRENT TOPICS IN ROCKET PROPULSION HELD IN THE HALL OF THE FORMER V100 CLUB

Provisional Programme: Time Event /Topic Lead Present

09.00 Registration Coffee/Tea BIS Staff

09.45 Opening Welcome John Harlow/Mark Perman

BIS WM Bob Stanton

Morning Session Chair: John Harlow10.00 Talk 1 Chemical Rocket Developments – Current and Future

Nammo Adam Watts

10.40 Talk 2 Integrated Liquid Engine Design Cranfield University Bob Parkinson

11.20 Break Coffee/Tea11.40 Talk 3 Low Cost Propulsion for Future Small Launch Vehicles

Kingston University Malcolm Claus

12.20 Talk 4 Hybrid Rocket Engines Aspirespace Rocket Engineering Society Rick Newlands

13.00 Lunch (Booked as part of Conference Price)

Afternoon Session Chair: Mark Perman 14.00 Talk 5 A new UK satellite launch vehicle and its propulsion requirements

British Interplanetary Society Robin H Brand

14.40 Talk 6 Ionic Propellants A Suitable Replacement for Hydrazine? Aerojet Rocketdyne John Harlow

15.20 Break Coffee/Tea 15.40 Talk 7 Low cost turbopump investigations for small satellite launcher application

Cranfield University Jordan Murray

16.20 Talk 8 SABRE TF1 – Development of the SABRE Demonstrator Test Facility

Reaction Engines Mike HoodReaction Engines Russ Payne

17.00 Wash up General Discussion and Questions John Harlow Mark Perman

17.15 ish Close

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ABSTRACTS

Adam Watts – Nammo Westcott – Chemical Rocket Developments –

Current and Future A top-level overview of the varied and forward-thinking rocket and alternative propellant activities that are being undertaken by Nammo Space in order to meet the projected requirements of the global satellite propulsion customers. The presentation will attempt to introduce the audience to the issues facing the in-space rocket business and the excitement of sending new thrusters and engines into space.

John Harlow - Aerojet Rocketdyne - Ionic Propellants a Suitable

Replacement for Hydrazine?

Since replacing Hydrogen Peroxide, anhydrous Hydrazine has been the monopropellant of choice for space use since 1967. It continues to be used extensively in both spacecraft and launch vehicle upper stage attitude/orbit control and as the fuel component of spacecraft Dual Mode propulsion systems. However, due to increasing concern over toxic effects the threat exists that it may be placed on the ‘At-Risk’ register leading to a ban under REACH.

Ionic propellants have long been suggested as a viable alternative to Hydrazine, especially given their ‘green’ credentials. However, these propellants have their own set of issues that have delayed introduction and may yet limit their applicability in replacing Hydrazine in current propulsion applications.

This presentation outlines some historical facts concerning the origins of Ionic Propellants and charts the progress made to date. Current status is shown along with examples of the potential shortcomings of both current and proposed propulsion systems using these propellants.

Bob Parkinson - Cranfield University - Integrated (Liquid) Engine Design Since the early 1990’s the author has been involved in developing Integrated (spreadsheet) System Models for spacecraft design. Such models are useful in designing systems in which the various sub-systems interact strongly together and allow for the concurrent design and optimization of the whole system in the confident knowledge that all the parts fit together. More recently, in his role as Visiting Professor at Cranfield, lecturing on Space Propulsion, the author has been developing an integrated system design capability for pump-fed liquid engines drawing on his early work on heat transfer and mixing. Supporting computer programs are now available for liquid- and gas-side heat transfer and combustion. The paper will illustrate the structure of the Integrated System Model and the availability of the supporting analysis programs.

Jordan Murray – Cranfield University – Low Cost Turbopump

Investigations for Small Satellite Launcher Application The rapid expansion of the small satellite market has triggered increasing interest and activity within the private sector surrounding dedicated small satellite launchers. To provide a cost effective, frequent and tailored launch service, the conventional first stage liquid rocket engine is being redesigned to strip out unwanted cost and weight. In a pump fed system, the turbopump typically represents 20-30% of the total engine cost and has a design and fabrication time in the region of 3.5 years. Redesign of the conventional turbopump therefore

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represents a significant opportunity to contribute towards the development of a low-cost launch vehicle for small satellite application. Typically, full emission centrifugal pumps are used as the basis for a rocket turbopump design. This imparts complex design and manufacturing methods to achieve minimum weight, maximum efficiency and performance. Partial emission centrifugal pumps, although often overlooked due to their expected reduced efficiency and unstable head-flow curve, can provide under the correct parameters, minimum weight, satisfactory and in some cases superior performance and a simple, easily manufactured pump. This presentation explores the potential of a low cost partial emission centrifugal pump design for small satellite launcher application.

Malcolm Claus and Adam Baker - Kingston University - Low Cost

Propulsion for Future Small Launch Vehicles Rocket propulsion is widely acknowledged as the main cost driver for any launch vehicle, stemming from complexity, extensive testing, use of exotic materials and use of turbomachinery. Tackling these challenges with a low-cost solution has been a goal of the KU rocketlab since its formation in 2010. This presentation will describe recent three research results in low cost propulsion aimed at future small launch vehicles. The first is a vortex combustion approach which has been used successfully to cool the wall of a small (200N thrust) chamber built of low cost materials, in place of more costly fuel film or regenerative cooling. The second innovation is the development and successful cryogenic testing of a small-scale piston-based oxidiser pump able to deliver 1 kg/s of propellant for the booster stage of a launcher. The third is innovation is the construction and testing of a small water-cooled bipropellant engine, fabricated by ALM (Additive Layer Manufacturing) in partnership with Canon UK. These innovations were developed through PhD and MRes research projects. The long term aim of Kingston University's Access to Space strategy is to fly all of these in an experimental sounding rocket to the edge of space.

Robin Brand - Project Leader BIS NLV feasibility study - A New UK

Satellite Launch Vehicle and its Propulsion Requirements This paper describes an application for UK based rocket propulsion. It examines how the propulsion requirements for the BIS Nanosat “Reference Launch Vehicle” have been arrived at and explains the solution that has been derived.

As the study is a technology neutral open-sourced investigation, the paper will offer unprecedented information on the economic and technical factors involved. These have been determined by developing a sophisticated economic model for analysing small satellite launch vehicle development and operation, that includes both technical “parts-count” and marketing inputs.

The overall conclusion is that a three-stage liquid fuelled rocket, launched vertically from the northern coast of Scotland, is the most short-term economically efficient solution. The launch corridor that results imposes particular constraints on the design of the vehicle and its engines, these the study believes are essential to consider at the design stage.

By the time of the Westcott conference the study will have completed Phase 1 and issued its report and moved on to Phase2. It is hoped that feedback from the conference will help inform this next Phase.

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Mike Hood – Test Facility, Lead Engineer & Russ Payne – Chief Design

Engineer - Reaction Engines - SABRE TF1 – Development of the SABRE

Demonstrator Test Facility

The Synergetic Air Breathing Rocket Engine (SABRE) is a class of combined cycle engines that have the potential to revolutionise aerospace propulsion. SABRE burns hydrogen fuel in air-breathing mode up to speeds in excess of Mach 5, then switches to a high-performance rocket mode that utilises on-board liquid oxygen. Novel light-weight compact heat exchangers allow efficient thermodynamic energy exchange between engine components via a helium loop, which results in an attractive combination of high thrust to weight and specific impulse in air-breathing mode.

One of the unique features of SABRE is that much of its air-breathing operation can be tested on the ground. Testing an engine as unique as SABRE however, requires a custom-made facility. Conventional air propulsion facilities require large air feeds and conventional fuel systems; such a test facility can be fully enclosed if noise controls require it. This enclosed approach is not, however, compatible with hydrogen-fuelled systems. Conventional rocket test stands are designed to handle hydrogen fuels safely but lack the air inflow systems of a conventional air-breathing test facility and must be located remotely to accommodate the noise levels they generate during test.

This presentation will look at the current development of the SABRE engine and the construction of its unique test facility SABRE TF1, at Westcott Venture Park.

Richard Newlands - Aspirespace Rocket Engineering Society – Hybrid

Rocket Engines Hybrid research has received little funding over the years as hybrids have no obvious military application. However, when done properly hybrid development programmes are generally cheaper than alternative engine concepts, and hybrids are much more tolerant of low quality control, abuse, and off design “whoopsies” which has made them especially popular with Amateur rocketry organisations and commercial manned spaceflight. The early promise of cheap simplicity has given way to the realisation that a hybrid is fundamentally a rocket engine, with all the traditional rocketry engineering issues that implies.

In my talk, the following issues will be discussed: General introduction to hybrid rocket engines: comparison with solids and liquids Fuel regression rate and multi-ports Fuel choice: HTPB a poor choice! - plastics, cryofuels and wax Oxidiser choice: Lox, nitrous oxide, HTP O:F ratio wander during the burn Actual performance data vs theoretical Why implementing large hybrids is harder than expected: drivers and barriers Hybrid safety - hazards analysis, terminal flatulence, nitrous oxide decomposition and

materials compatibility Price comparison Hybrid use in amateur rocketry today Hybrid use at large scale today: SpaceShipTwo, Bloodhound, and Gilmour Space

Technologies.

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BIOGRAPHIES

Adam Watts

Adam Watts has been 7 years with the company that is now Nammo Westcott. Like all of the team, he has had active involvement in many aspects of the business from programme management of development programmes through rocket testing and now business and strategic development of the Nammo Space group of companies. Although not a rocket engineer, he has enormous interest and enthusiasm for the subject of chemical propulsion and has direct interaction with key customers

John Harlow

John has had a very interesting career being fortunate enough to have spent a lot of time involved with the technical aspects of rocketry. Having cut his teeth on Polaris, John went on to work on both launchers and other re-entry systems. He has worked for and/or with the MoD, Foreign Office, United Nations to name but a few and this has taken him to most satellite Prime Contractors and launch facilities around the planet.

He is a Past President of the BIS, a member of the IAA History Committee and currently has a consultancy contract with Aerojet Rocketdyne.

Bob Parkinson

Dr Bob Parkinson was at RPE Westcott from 1965 to 1980, initially working on the use of liquid hydrogen for the future European launch vehicle, later spending 10 years as Head of Solid Motor Design. In 1982 he joined British Aerospace Space Systems at Stevenage where he was one of the originators of the HoToL project (a predecessor to Skylon), and was also responsible for the original design of the Envisat satellite. Throughout the 1990s he was involved in numerous studies of future space and interplanetary exploration programmes and helped to introduce the Integrated System Modelling methodology to the ESA while working on the EuroMoon project in 1998. He retired from – what was then - Astrium in

2002, following which he was a consultant to the ESA Aurora studies on Mars missions and acted as a consultant on lunar and Mars missions and small launch vehicles. He is a Visiting Professor at Queen Mary, University of London and for the Astronautics and Space Engineering Course at the University of Cranfield where he teaches Space Propulsion and System Engineering. He has been a member of the International Academy of Astronautics since 1988 and was President of the British Interplanetary Society 2009 - 2012. He was awarded an MBE for “services to the Space industry” in 2002.

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Jordan Murray CEng, MEng, PMQ

Studied Mechanical Engineering at Manchester University (2007-2011). Background in nuclear engineering; uranium enrichment (2011-2017). Currently working for Airbus Defence & Space, Stevenage as a Propulsion Engineer (2017 - present). Studying a part-time Masters in Astronautics and Space Engineering at Cranfield University (2015-2018).

Malcolm Claus

Dr Malcolm Claus MRAeS, Senior Lecturer in Space Engineering and Computational Fluid Dynamics, Kingston University. Malcolm Claus has been at Kingston University for six years. However, prior to this he has worked within the aerospace and defence industry for a number of companies (Hunting Engineering, Insys, Lockheed Martin, MBDA as well as at the USAFA). His work focused on guided weapons mainly their aerodynamics propulsion and system analysis

Richard Newlands

Rick Newlands is a graduate of Southampton’s Aero/Astro course, and one day he’ll get around to a PHD. He’s been firing amateur rockets since age 14, and has experience of solids, liquids, hybrids, and water rockets – both hot and cold!

He’s one of the ‘rocketeers in residence’ of the Aspirespace rocket engineering society - of which he is chairman - and is a council member of the United Kingdom Rocketry Association specifically dealing with safety and technical issues.

Though retired through ill health, Rick consults for amateur/student rocketry groups around the world and provides technical advice for small British launch vehicle companies such as Newton Launch Systems. He also performed early consultation for Virgin Galactic’s Launcher One. He’s a member of the British Interplanetary Society’s Education committee, and a member of their Nanosat Launch Vehicle study group advising on propulsion and trajectories.

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Robin Brand

Robin Brand (BSc CEng MIET FBIS) is chair of the BIS Technical Committee, and Project Leader of the BIS Nanosat Launch Vehicle Feasibility Study, which he started in March 2016. He joined the BIS in 2009, and became a Fellow in January 2017.

Although an electronics engineer by profession, he has always had a great interest in space matters. He gives frequent talks around the country, and presented a paper on the BIS NLV feasibility study at RISpace 2017 in Glasgow last October. He has written the definitive book on the ‘Skylark’ sounding rocket, see www.skylark.space.

Mike Hood – Test Facility, Lead Engineer

Mike Hood has 40 years’ experience in a diverse array of R&D environments from 2 years at the British Antarctic Research Station ‘Halley Bay’ on the Brunt Ice Shelf, to working on zero energy fission reactors (DIMPLE and ZEBRA) and the SGHWR reactor at Winfrith Dorset. Followed by work on fusion reactors COMPASS, and MAST at Culham in the UK and on RFX at Padova in Italy.

In 2005 Mike became involved with Reaction Engines supporting the building of their B9 test facility. In 2011 Mike joined Reaction Engines full time, where he ran the B9 test facility, being part of the team that developed and demonstrated the world’s first light weight precooler with frost control (the Precooler is a key enabling technology for the SABRE engine).

Currently Mike is the lead engineer for a new test facility at Westcott Venture Park called SABRE TF1, where he is leading a team responsible for designing and constructing this unique test facility for the development of the air breathing cycle of the SABRE engine.

Russ Payne – Chief Design Engineer

Russ started his career with the UK Atomic Energy Authority, initially at Harwell, and continued that relationship during his Batchelor’s degree in Physics and Electronics. Russ completed a PhD in Digital Signal Processing before joining Rolls-Royce Defence Aero Engines in Bristol, UK. Since the late 1990’s Russ has held Chief Design Engineer [CDE] positions across many different aero engine programmes, both in-service [‘fleet’] types and development/early service types. In 2012 Russ moved to the civil Aero Engine business in RR Derby as CDE for the new Trent XWB engine family (Airbus A350) before finishing his 27 career with Rolls-Royce, again as CDE for the Global Aero Engine Controls business in Birmingham.

Russ joined Reaction Engines in March 2017, finally won over by the opportunities offered by the SABRE Demonstrator programme.

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GETTING TO THE WESTCOTT SPORT AND SOCIAL CLUB

Image courtesy of Google

Distances! (Source: RAC Route Planner. All distances have been rounded down)

Aylesbury Vale Parkway 5 miles Aylesbury 7 miles Bicester 9 miles Bicester North 10 miles J9 M40 11 miles J20 M25 28 miles Oxford 20 miles Milton Keynes 21 miles Central London 49 miles Birmingham 78 miles

TO WADDESDON

& AYLESBURY

TO BICESTER

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By Road From the M40 take Exit 9 A41 for Bicester At Bicester stay on the A41 signposted for Aylesbury for 9 miles. You will see signs for Westcott Venture Park Turn Right onto Westcott High Street continue straight on onto Ashendon Rd. After 800 metres turn Right into Westcott Sports and Social Club Continue down the road with the wood on your left until you come to the Club buildings.

From Aylesbury Take the A41 signposted Waddesdon/Bicester and the M40. Continue on the A41 through Waddesdon in total for 7 miles You will see signs for Westcott Venture Park Turn Lef onto Westcott High Street continue straight on onto Ashendon Rd. After 800 metres turn Right into Westcott Sports and Social Club Continue down the road with the wood on your left until you come to the Club buildings.

Sat Nav Users Please use HP18 0NZ.

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