Kestrel Process Group

Asset Integrity — equipment safety assessment

HP/PV-108

Steam separator 108

Report A-1015

Methodology v4.0

2025-10-28

Assessed risk

High

Highest score

Findings

Immediate

Coverage

18/18

Next due

2026-10-28

Act before the equipment is next relied upon

Asset class

Pressure vessel / air receiver

Facility

Havenport Terminal, Dock Road

Area

Compressor house

Criticality

Manufacturer

Wessex Vessels

Model / serial

Z905 / 96628-55

Installed

2007-05-01

Inspector

P. Nakamura

Findings (4)

R-PV-03Relief discharge path obstructedNon-conformingS4 × L3 = 12High

The relief device cannot discharge freely to a safe location.

Action Clear the discharge path and re-route it away from any walkway or work position.

Uncontrolled release of stored pressure · due 2025-11-04 · AS/NZS 3788 §5.6

R-PV-06Heavy external corrosion or section lossNon-conformingphotographic evidenceS4 × L3 = 12High

External corrosion has progressed to the point where remaining wall thickness cannot be assumed.

Action Arrange ultrasonic thickness testing at the affected areas and compare against the minimum design thickness before the next fill.

Structural failure under load · due 2025-11-11 · API 510 §6.3 · evidence VC-CORR-HEAVY

R-PV-10Data plate missing or unreadableRecords / traceabilityphotographic evidenceS2 × L4 = 8Moderate

The vessel cannot be traced to its registered design data from markings on the equipment.

Action Recover the design registration from the plant register and fit a durable replacement plate carrying the registration number and MAWP.

Loss of design or inspection traceability · due 2025-12-27 · AS/NZS 3788 §4.4 · evidence VC-NAMEPLATE

R-PV-15Working space around the vessel restrictedImprovement opportunityphotographic evidenceS2 × L3 = 6Moderate

There is not enough clear space to inspect, isolate or escape from the vessel position.

Action Clear and mark the working space around the vessel.

Access, egress and emergency response impaired · due 2025-12-27 · ISO 12100 §6.2.7 · evidence VC-OBSTRUCTED-ACCESS

Photographic record

Site photograph taken at assessment

A vertical blue air receiver on a low frame support, with a top-mounted small gauge and PSV, a side-mounted pressure gauge, and extensive orange rust over the lower shell and base — consistent with air receiver 104.

Heavy corrosion or section loss — Large continuous orange-brown flaking rust mass covering the bottom of the shell, spreading onto the support frame and floor; a second rust patch sits on the upper shell at the nameplate area.
Nameplate missing or unreadable — A plate-shaped panel is visible but is largely covered by an orange rust bloom; no stamped text can be read.
Working space obstructed — A cardboard box on a pallet and a green container are stored in the floor space beside the vessel.
Housekeeping around the asset — Rust scale and debris have accumulated on and around the base frame, spilling onto the floor slab.

Assisted by claude-opus-5; every observation adjudicated by the inspector before use.

Assessment record

Identification and records · Is the manufacturer's data plate present and legible?Yes

Identification and records · Design registration / plant numberPVR-96628

Identification and records · Maximum allowable working pressure846 kPa

Identification and records · Months since last internal inspection27 months

Identification and records · Is the pressure test within its interval?Yes

Pressure relief · Is a pressure relief device fitted?Yes

Pressure relief · Is the set pressure at or below MAWP?Yes

Pressure relief · Months since relief device certification42 months

Pressure relief · Discharge pathObstructed or capped

Pressure relief · Is an isolation valve fitted between the vessel and the relief device?No

External condition · External corrosionLight

External condition · Are the visible weld seams free of cracking or undercut?Yes

External condition · Saddle and support conditionSound

External condition · Is the drain operable and the vessel free of standing condensate?Yes

Instrumentation and surrounds · Is a pressure gauge fitted and readable?Yes

Instrumentation and surrounds · Is the isolation point identified and accessible?Yes

Instrumentation and surrounds · Clear working space around the vessel1134 mm

Instrumentation and surrounds · Is required signage in place?Yes

The PDF is generated server-side from this same data — same findings, same wording, same methodology version, plus the photo plate and a sign-off block.