1 Textbook
1 Textbook
1 Textbook
TEXTBOOK
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Kiln System Maintenance
Module 0: Maintenance Procedures for Preheater and Calciner
TABLE OF CONTENTS
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Kiln System Maintenance
Module 0: Maintenance Procedures for Preheater and Calciner
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Kiln System Maintenance
Module 0: Maintenance Procedures for Preheater and Calciner
TABLE OF FIGURES
Fig. 0 1 Kiln design development ................................................................................ 6
Fig. 0 2 ILC – In-Line Calciner. .................................................................................. 8
Fig. 0 3 Suspension preheater ...................................................................................... 7
Fig. 0 4 Different preheater designs ............................................................................ 8
Fig. 0 5 Heat transfer ................................................................................................... 9
Fig. 0 6 Function .......................................................................................................... 9
Fig. 0 7 Typical preheater tower design .................................................................... 10
Fig. 0 8 Tangential duct + 1st stage cyclon ............................................................... 11
Fig. 0 9 Tangential duct + 1st stage cyclone ............................................................. 11
Fig. 0 10 SLC-D Calciner .......................................................................................... 12
Fig. 0 11 Typical riser ducts ...................................................................................... 13
Fig. 0 12 The smoke chamber ................................................................................... 14
Fig. 0 13 High temperature double sluice flap (A version) ....................................... 15
Fig. 0 14 High temperature single sluice flap (B version)......................................... 15
Fig. 0 15 Expansion joint. .......................................................................................... 16
Fig. 0 16 Splitter and dividing Gate .......................................................................... 17
Fig. 0 17 Lamella seal for splitter gate ...................................................................... 17
Fig. 0 18 Material Distribution Box .......................................................................... 18
Fig. 0 19 Clean-out ports ........................................................................................... 18
Fig. 0 20 Cyclone Door with Auxiliary Port ............................................................. 19
Fig. 0 21 Air blasters ................................................................................................. 19
Fig. 0 22 Air lances.................................................................................................... 20
Fig. 0 23 By-pass ....................................................................................................... 20
Fig. 0 24 Platforms .................................................................................................... 21
Fig. 0 25 Instrumentation........................................................................................... 21
Fig. 0 26 1 st. stage central pipe ................................................................................. 22
Fig. 0 27 2.nd. stage pendulum supported central pipe ............................................. 23
Fig. 0 28 2.nd. stage pendulum supported central pipe ............................................. 23
Fig. 0 29 Lowermost central pipes. Cast steel elements ............................................ 24
Fig. 0 30 Corrosion rate as a function of condensation, acid content and temperature
........................................................................................................................... 32
Fig. 0 31 Cyclone plug .............................................................................................. 39
Fig. 0 32 Cyclone blow-out ....................................................................................... 39
Fig. 0 33 Air blasters ................................................................................................. 40
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Module 0: Maintenance Procedures for Preheater and Calciner
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1.1 INTRODUCTION
The kiln system group of machines are a central group of machines in a cement
manufacturing plant. A high availability/high run-factor is essential for the overall
economy of the plant. This implies a stable mechanical function of the equipment
over a period as long as possible.
Spontaneous stop of the system will cause expenses for spare parts and repair. It will
also be the cause for loss of production, which can be difficult to retrieve.
The competent management will, of course, take precautions against such situations
and for this purpose introduce preventive maintenance to the preheater system in-
cluding the calciner.
The preheater and calciner are comparatively new introductions to the kiln system.
The fig bellow illustrates the development of the equipment through time.
-1950
1950
to
1960
1970
1990
2000 -
The latest addition to the equipment being the calciner, with its own individual de-
velopment:
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Low-Nox and
Dawn draft.
1.2 DESIGN
The preheater consists in a series of cyclones with the mission to provide for the heat
transmission from the kiln gases to the raw mill feed before it enters the calciner or
kiln inlet. The process is illustrated in the figures shown bellow.
SP - Suspension preheater
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The counter current flow between the raw meal and the kiln gases provides for the
heat transmission as shown in the figures above and in detail in the figure bellow.
Material Heat
Separation Transfer
Fig. 0 6 Function
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The central pipe of the first (uppermost) stage consists of rolled steel plates
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Low Pressure-cyclones
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The function of the cyclone is to separate the raw material for the ce-
ment-making process from the process gases. In geometric
terms, the cyclone is designed for optimization of the processing ca-
pacity.
The riser duct is the process connecting duct between, for example, two cy-
clones. The heat exchange process takes place in the riser duct in which the
separated raw material from a superjacent (colder) cyclone is admitted via a
distribution box in the riser duct, and this material is subsequently directed to
the next cyclone in which the material is once again separated from the proc-
ess gases. The riser duct is made of steel plates which are lined on the inner
side with insulation and refractory material.
The smoke chamber constitutes the interface between the cyclone preheater
and the rotary kiln, its primary function being to divert the exhaust gases from
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the kiln up into the cyclone preheater and to feed the preheated raw material
into the kiln. The smoke chamber is a sectionalized structure made up of steel
plates which are lined on the inner side with insulation and refractory material
To transfer the raw material separated in the cyclone to the next stage in
the process, down pipes are incorporated from the bottom of the
cyclone to the exact point where the raw material is to be re-
introduced to the process. The feed point is normally provided with a
distribution box, the purpose of which is to disperse the material in the
process gases. The down pipes contain a number of integrated com-
ponents, a brief description of which is given below:
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Sluice flaps
The sl ui ce fl ap i s a vai l abl e i n t wo versi ons. The A version is
mounted vertically and features two flaps; version B is mounted at
inclined angle and features one flap. The function of the sluice flap
is to prevent the process gas from being drawn through the down-pipe
up into the cyclone, instead leading it through the riser duct. The sluice
flaps are manufactured from steel plates on the outer side and of
special, heat-resisting steel on the inner side.
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Expansion joints
Expansion joints are manufactured from steel bellows and are in-
tegrated in the system to absorb the thermal expansions in the
downpipes. For pipes of substantial length, the same pipe may
quite often be provided with several expansion joints.
Splitter gate:
The splitter gate is manufactured from steel plates with a rotat-
ing central section which, via its physical position, will divide
the flow of material to two downpipes in the desired ratio.
Changeover gate
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Distribution box
The distribution boxes are manufactured from steel plating on the outer side
and from special, heat-resistant steel on the inner side. Its purpose is de-
scribed in the introductory notes of this section
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Clean-out port
To be able to clean or unblock a cyclone with air lances they are supplied
with clean-out ports (Pocking holes)
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The side skirts of the cyclones are procided with hinged dors as shown in the
Fig bellow.
Air blasters
For clean-up operations, air lances and air blasters are nor-
mally included in the supply in quantities deemed necessary by
FLS to start up the process.
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Fig. 0 23 By-pass
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1.2.1.7 Platforms
Fig. 0 24 Platforms
1.2.1.8 Instrumentation
Various instruments which are used for controlling the process are fit-
ted at vital locations. The signals from these points of measurements are
normally assembled in a central control system from which the process
is controlled.
Fig. 0 25 Instrumentation
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1.2.1.9 lining
The primary function of the central pipe is to enhance the efficiency of the cyclone,
thereby ensuring effective separation of the raw meal from the gas stream.
1. Stage:
Welded directly to the 1.stage cyclone and with a bottom plate cone to provide
for extra stiffness
This pipes are made with a hinged suspension as shown in the fig bellow.
The pipe are made of heat resistant plate material and usually provided with a
reinforcement ring in the bottom.
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The central pipe consists of cast steel elements. See fig 0.29.
The single elements are mounted by staggered bonding and that means that
each element is involved in the process in maintaining the structural stability
of the pipe.
A locking element is fitted at the termination end of the pipe, and this ele-
ment is also mounted trough bonding.
2.1 INTRODUCTION
The main objective of the preventive maintenance is to perform actions in order to
prevent breakdowns or faults to occur. This means that the preventive maintenance
does not necessarily comprise actions due to an observed fault, which might evolve
to a breakdown. Instead, the preventive maintenance is generally based on actions
taken before faults start to happen.
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The performance of preventive maintenance work will necessarily also include a cer-
tain attitude towards and understanding of the production process as a whole. This
can easily be illustrated just by putting the simple question:
"Why bother about that particular machine - it works just fine for the moment?"
The ultimate goal of the preventive maintenance is to secure a sustained and reliable
function of the equipment according to its specifications. However, this will to some
degree cause a dilemma since most preventive maintenance actions inevitably will
require a shutdown of the machinery, at least for some period. The solution to that
will then be to find the correct balance between:
and
the production loss during the shutdown period required to perform this
maintenance.
For a preheater installation this can at least partly be solved by utilizing the normal
shutdown periods during re-bricking of the kiln, where the preheater in any case is at
a standstill.
To cover the preventive maintenance required for all possible preheater types that
one might encounter in the a cement plants, will be beyond the scope of this module.
Therefore a more general approach has been taken and some actions common for
several preheater types have been described and covered in this module as follows:
In the following a short description of the two different principles will be given.
The war imposed a great change in technology and the attitude towards maintenance.
Equipment had to be more reliable so both materials and design had to be improved
considerably. At the same time, equipment started to become more complex e.g. the
introduction of fluid couplings - and also more expensive to produce. From that time
until the late 70's and the early 80's, equipment design and reliability changed dra-
matically and with that the maintenance needs. Hydraulics and electronics were in-
troduced and soon regarded as compulsory components in any type of equipment.
The power: weight ratios increased, power economy improved and superior lubri-
cants were developed. Larger, more reliable and also more expensive units were
built as the industry demanded an increase in both production and productivity.
In the course of this development, the old "fix when fail" strategy soon became to-
tally inadequate and as a result "scheduled (or planned) maintenance" was intro-
duced. This was a conscious effort to:
reduce costs
lower downtime
increase productivity.
The "Repair before failure" strategy was born, with too much rather than too little
maintenance being the standard. It is interesting to note that a side effect of this
strategy was that the relations between the production and maintenance department
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became very hostile. The maintenance people tended to look upon the production
staff as some brutes doing their best in trying to destroy the machinery. The produc-
tion people, on the other hand, saw the maintenance as a "pain in the neck" forcing
them to long production stops just because the run hour meter said that a particular
part was due for change, even though the machinery was running perfectly well.
Many types of today's machinery have on-board diagnostics and sophisticated elec-
tronics to aid maintenance. Due to that, equipment produced now is highly complex
and very expensive, representing a considerable investment. The maintenance re-
quires the specialists’ knowledge/skills and a much more professional and disci-
plined approach compared to previous needs.
"Condition Monitoring"
and
"Condition-based Maintenance"
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Reliable diagnostic tools and skills are essential if the "Condition-based preventive
Maintenance" concept is to become a success.
The main aim of inspection is to locate potential faults before they develop
and thereby way prevent an unplanned production stop due to a breakdown
- following need for repair. Unless carried out thoroughly and by a well-
qualified staff an inspection is of only little value and may be misleading.
It is important to keep in mind that the parts most difficult to access are
most likely to repay careful inspection.
Modern cement plants in a competitive market are extremely attentive to the devel-
opment in turnover and costs. Generally a clear tendency can be observed:
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Cement plants wish to reduce the number of permanent staff and are also
highly interested in reducing the amount of capital tied up in spare parts
etc.
As precisely such views are catered for by the maintenance philosophy based on the
condition of the equipment, i.e. condition based preventive maintenance, many pro-
gressive plants base their maintenance policy on this philosophy.
However, a prerequisite of the success of such a maintenance policy is that the plant
is able to pinpoint the maintenance tasks which is necessary to perform at a given
moment. Another prerequisite is that the plant is capable of carrying out the activi-
ties in question at that particular moment, meaning that a sufficient number of quali-
fied personnel and all spare parts required for the operation are available.
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the one responsible for the daily maintenance, by alerting the preventive mainte-
nance staff to locate the cause of the observation.
This clearly shows that instead of a contradiction, the relation between the daily and
the preventive maintenance is rather a highly co-operative one where they rely upon
each other to reach the same target.
1Lubrication
2Cleaning
3 Inspection and adjustment
4 Checking of condition
5 Replacement (incl. lubricants)
6 Performance test
Pos. Text .1 .2 .3 .4 .5 .6
Al Steel plates . . . A T .
A2 Doors/holes/hatches . . 2A A T .
A3 Expansions . 2A . A T .
A4 Sluice flaps • • 2A A . .
A5 Distribution boxes . . . A • •
A6 Air lances . . . A T .
A7 Central pipe, stage I . . . A T .
By-pass . • • A T .
A9 Measuring points . 2A . A T .
A10 Air Blasters .T T T T
T
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2.5.2 Clean-up
The most important part of the preventive maintenance, which unfortunately though of-
ten is more or less neglected or looked upon as a necessary evil, is cleaning. A clean and
proper workspace is a prerequisite for a well functioning maintenance, both the daily
and the preventive, as well as it is highly contributively to the safety.
Expansions (A3)
All expansions must be cleaned so that bellows or cloth are clean in order to ensure op-
timum functionality.
Doors/holes/hatches (A2)
All doors, clean-out holes and hatches must be inspected and adjusted to ensure full
functionality.
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ness meter for metal. (DO NOT FORGET to calibrate the instrument for the expected
thickness!).
In case the parts are affected by corrosion to an extent which exceeds 20 per cent of the
original thickness, some special action must be taken without undue delay to determine
what remedial action should be taken.
The corrosion attacks of the preheater and calciner can be generally divided in to to
types:
Prevention:
It is difficult to give blanket advice on lessening dew-point corrosion because
much depends on the precise plant configuration and service environment. How-
ever, general comments are:
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1) Plant operation: careful plant operation and maintenance represent a major and
more general way to prevent dew point corrosion. The inherent variability of ex-
cess oxygen, furnace temperature, combustion method and fuel ashing characteris-
tics can affect this type of corrosion more than changes in fuel sulphur content.
Adequate temperature monitoring of stacks should be ensure at top and bottom.
Stack operating temperature should be maintained within design limits at all times.
For low-carbon steel stacks, adequate insulation and lining condition must be en-
sured. Stacks should not be run wet or cold unless specifically designed to do so.
2) Design: all air in-leakage in ductwork, expansion joints, sampling ports and ac-
cess doors must be prevented. Door seals should be replaced routinely, and a gas-
tight fit ensured. Thermal insulation should be maintained in good condition, leak-
ing expansion joints replaced and sampling port covers properly refitted after use.
Prevention: If temperature can not be lowered, the only solution is to change the
steel quality for another with a higher oxidation resistance. Fig. 2 shows the corro-
sion rate expressed as weight loss of carbon steels at 430, 540, 650 and 760 °C
(800, 1000, 1200 and 1400 °F). These results suggest that carbon steel is not suit-
able for temperatures above 650 °C (1200 °F). However regarding creep strength
the limit is 400º C.
Chromium is the most important alloying element for improving oxidation resis-
tance. This is due to the formation of the more protective chromium oxide layer. A
minimum of 18 wt % Cr is needed to develop a continuous chromia (chromium ox-
ide) scale that protects against further oxidation attack.
Chromium-Molybdenum (Cr-Mo) steels are used at higher temperatures than car-
bon steel because of higher tensile and creep-rupture strengths. Mo and Cr provide
not only solid solution strengthening but also carbide strengthening.
When service temperatures are above 640 °C (1200 °F), ferritic steels drastically
loose their strengths. Another problem of the ferritic qualities is the so-called 475
°C (885 °F) embrittlement: a phase transformation in the ferritic structures due to
which the steel becomes brittle. Then for use at 475 °C or at temperatures above
640 °C, austenitic qualities are required. The stabilisation of austenite, obtained by
addition of Nickel (Ni), provides the steel with higher strength and more creep re-
sistance. Nevertheless, some austenitic stainless steels can suffer significant ductil-
ity loss or embrittlement upon exposure to temperatures in the range 540 to 800 °C
(1000 to 1500 °F) due to sigma phase formation
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Carburization
Description: Metals or alloys are generally susceptible to carburization when ex-
posed to an environment containing carbon source (e.g. carbon monoxide, methane
or other hydrogen containing gases at elevated temperatures, or pet-coke). Carburi-
zation attack generally results in the formation of chromium (Cr), Molybdenum
(Mo) or even iron (Fe) carbides within the grains and at the grain boundaries, which
often cause the alloy to suffer embrittlement as well as degradation in the mechani-
cal properties due to sensitisation
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Sulphidation
Description: Sulphur is one of the most common corrosive contaminants in high-
temperature industrial environments. Sulphur is generally present as an impurity in
fuels or feed stocks. When combustion takes place with excess air to ensure com-
plete combustion of fuel for generating heat in many industrial processes, such as
coal- and oil-fired power generation, sulphur in the fuel reacts with oxygen to form
SO2 and SO3. An atmosphere of this type is oxidising. Oxidising environments are
usually much less corrosive than reducing environments, where sulphur is in the
form of H2S. However, sulphidation in oxidising environments (as well as in re-
ducing environments) is frequently accelerated by other fuel impurities such as so-
dium, potassium and chlorine, which might react among themselves and / or with
sulphur during combustion to form sat vapours. These salt vapours may then de-
posit at lower temperatures on metal surfaces, resulting in accelerated sulphidation
attack
Prevention: If the environment can not be changed to a more oxidising one or tem-
perature can be changed, a proper alloy shall be chosen
Energy saving is attained through improvement of cyclone efficiency in the hot cy-
clone leading to a decrease in power consumption. Among other advantages of the
use of central pipes, the following can be mentioned: Production increase, less
clogging tendency, reduction of the required capacity of the smoke gas fans and
possibility of adjustment of the final composition of the material leaving the pre-
heater
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Prevention: As this form for corrosion is due to the presence of a carburizing at-
mosphere at high temperatures, two solutions can be suggested:
1. Change of the environment: Either use another fuel than pet-coke or try to
burn the pet-coke before the small particles reach the surface of the central
pipe. This can some times be achieved by milling the pet-coke to a very fine
level.
2. Change of the alloy used for the steel casting: Materials recommended in lit-
erature to withstand carburization are: W.St.Nr. 2.4879 or the ASTM quali-
ties A297 - HT, HP, HW and HX.
The air blasters constitute a risk factor because of the working pressure of 5 - 7 bar.
Proper maintenance of these units is of critical importance to prevent pipe and hose
connections, screwed connections, miscellaneous valves and the pressure tank from
posing any danger to the operators etc.. It is essential to ensure that the operators are
trained in how to maintain and handle these units, in accordance with the instructions
given by the manufacturer.
2.5.5 Replacement
Steel parts and various components must be replaced, at the latest, when 50 per cent of
the original material thickness is gone as a result of corrosion.
Otherwise, replacements must be made as and when deemed to be necessary.
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Hot raw meal may accumulate in cyclones, riser pipes and feed pipes and must be re-
moved.
Inspection or cleaning cyclones, riser pipes or feed pipes involves a certain risk which,
however, is reduced on the condition that the below rules are adhered to.
Before carrying out the job, check that the voltage to the control cabinet for air blasters
is interrupted and that all blasters have been vented.
There must be a slight negative pressure in the system during all cleaning jobs.
The negative pressure reduces the risk that hot air and dust blows on the persons doing
the cleaning job.
All personnel doing cleaning jobs on cyclones in operation must know the escape
routes.
Persons who are to inspect a cyclone, a riser pipe or feed pipes must wear a face mask, a
helmet, long heat-insulating, fireproof gloves and wooden-soled boots or other suitable
footwear.
During work in places involving a risk of dust rushes or other dropping material, the
person doing the job must wear a safety belt with life-line which is held by an assistant.
Before opening clean-out doors or hatches, check through the small inspection hole that
there are no dust accumulations behind the door/hatch which will flow out when the
door/hatch is opened.
On account of the risk of hot dust or raw meal flowing out when opening doors/hatches,
never stand directly on the ordinary floor or platform, but on a scaffold elevated above
the floor.
When opening clean-out holes in a cyclone preheater, there will always be hot dust be-
hind the opening, and therefore the scaffold, platform or other means used for standing
on must be made of non-inflammable material.
In case of a platform, same must be a grate so that any hot material will drop through
the grate. Be aware of where the material may drop and which damage it may cause,
e.g. to electric cables, etc. Provide the necessary shielding/roping-off.
In case of dust accumulations, remove these by cleaning through the small inspection
hole.
Dust accumulations or cakings are most efficiently removed with air spears.
When cleaning cyclones, riser pipes or feed pipes, start at the bottom so that the mate-
rial loosened can proceed through the system.
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Be aware that there may be rushes of hot material from higher-level cyclones.
Following any inspection of cyclones, riser pipes or feed pipes, make sure that all clean-
out doors and hatches are closed carefully again.
In connection with any major kiln stop during which the plant is cooled down, cyclones,
riser pipes and feed pipes must be checked.
This check can be made from both outside and inside.
Inside inspection of the cyclone preheater must not be done before the cyclone preheater
has cooled off sufficiently.
Be aware that large dust accumulations may feel cold on the surface, but can still be
very hot inside.
The power supply for control cabinet of air-blasters must be interrupted and all blasters
must have been vented.
If the installation is equipped with gamma ray level indicators, they must be set on OFF
and be locked before making an inside inspection.
All work lamps must be connected to low voltage.
Check that no foreign objects have been left in the cyclone preheater.
All hatches and doors must be closed and heating be started immediately after this
check.
If hot material is to be discharged from cyclone preheater or tertiary air duct during op-
eration, this must be done properly so that the hot material under no circumstances can
injure persons or damage equipment.
The hot material must cool off by itself without using any auxiliary means.
Using water or similar may cause serious steam explosions!
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Hot Dust
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Air Blasters
Protective Clothing
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Dust Hazard
Dust Hazard
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Fall Protection
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