Kestrel Process Group

Asset Integrity — equipment safety assessment

NG/CR-107

Press shop crane 107

Report A-1053

Methodology v4.0

2025-06-28

Assessed risk

Critical

Highest score

Findings

Immediate

Coverage

17/17

Next due

2025-12-28

Stop use, isolate, escalate to the responsible engineer

Asset class

Overhead travelling crane / hoist

Facility

Northgate Works, Ardmore Industrial Estate

Area

Line 2

Criticality

Manufacturer

Konektis

Model / serial

N288 / 46863-69

Installed

2020-03-01

Inspector

J. Barros

Findings (4)

R-CR-05Broken wires at or beyond discard criteriaImmediate dangerphotographic evidenceS5 × L3 = 15Critical

Rope condition meets the discard criteria in the methodology.

Action Take the crane out of service and replace the rope as an assembly, with a certificate for the new rope.

Dropped or swinging load · due 2025-06-28 · ISO 4309 §5.2 · evidence VC-ROPE-DAMAGE

R-CR-01Hook safety latch missing or defeatedNon-conformingS4 × L4 = 16Critical

The hook can no longer retain a sling under slack-rope conditions.

Action Fit a correct latch for the hook size before the next lift. Tag the crane out until it is fitted.

Dropped or swinging load · due 2025-06-29 · AS 2550.1 §7.3

R-CR-07Rope corroded or unlubricatedNon-conformingphotographic evidenceS3 × L3 = 9Moderate

Corrosion or lack of lubrication is degrading the rope faster than the inspection interval assumes.

Action Clean and dress the rope with the manufacturer's lubricant and shorten the inspection interval until the trend stops.

Dropped or swinging load · due 2025-07-12 · ISO 4309 §5.5 · evidence VC-CORR-HEAVY

R-CR-14Major inspection overdueNon-conformingS3 × L3 = 9Moderate

The crane is outside its major inspection interval.

Action Book the major inspection with a competent person and plan the outage it needs.

Loss of design or inspection traceability · due 2025-08-27 · AS 2550.1 §5.5

Photographic record

Site photograph taken at assessment

An illustration of an overhead crane hook block hanging on two wire ropes, with a single hook and safety latch, showing rust-coloured patches on the block, ropes and hook.

Heavy corrosion or section loss — Large irregular orange-brown flaking patches spread across the block casing edge and across the hook bowl, covering a substantial area of those surfaces; texture appears as scale rather than light staining. Section loss cannot be measured from the image.
Light surface corrosion or coating breakdown — Smaller rust-brown bloom on the left rope leg and light staining around the SWL marking on the block face.
Rope or chain damage — Two or three short curved wire strands stand proud of the rope surface, consistent with broken wires.

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

Assessment record

Identification and records · Is the safe working load marked and legible?Yes

Identification and records · Marked safe working load9212 kg

Identification and records · Is the crane log book current?Yes

Identification and records · Months since last major inspection40 months

Hook and block · Is the hook safety latch fitted and effective?No

Hook and block · Throat opening increase over as-new3 %

Hook and block · Is the hook free of twist, cracking or gouging?Yes

Hook and block · Does the block rotate and seat freely?Yes

Rope, chain and reeving · Broken wires in any one rope lay0 wires

Rope, chain and reeving · Rope deformationMinor

Rope, chain and reeving · Is the rope adequately lubricated and free of corrosion?No

Rope, chain and reeving · Are the rope terminations correct and secure?Yes

Controls, limits and structure · Does the upper hoist limit operate on test?Yes

Controls, limits and structure · Does the emergency stop isolate all motions?Yes

Controls, limits and structure · Does the hoist brake hold the test load without creep?Yes

Controls, limits and structure · Are travel end stops and buffers in place and undamaged?Yes

Controls, limits and structure · Pendant / control conditionWorn but legible

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.