Kestrel Process Group

Asset Integrity — equipment safety assessment

NG/GM-104

Case erector 104

Report A-1060

Methodology v3.9

2024-10-28

Assessed risk

High

Highest score

Findings

Immediate

Coverage

16/16

Next due

2025-10-28

Act before the equipment is next relied upon

Asset class

Guarded machinery / conveyor

Facility

Northgate Works, Ardmore Industrial Estate

Area

Boiler house

Criticality

Manufacturer

Vertek

Model / serial

F952 / 34885-84

Installed

2010-09-01

Inspector

J. Barros

Findings (3)

R-GM-05Guard aperture exceeds safe gapNon-conformingS4 × L3 = 12High

A gap in the guarding allows a hand to reach the hazard at the measured distance.

Action Close the aperture or move the guard back until the safe-distance table is satisfied.

Entanglement or crushing at moving parts · due 2024-11-11 · ISO 13857 §4.2

R-GM-06Emergency stop out of reachNon-conformingS4 × L3 = 12High

An operator cannot reach an emergency stop from every working position.

Action Add stops or a pull-cord run so no working position is more than the methodology's distance from one.

Entanglement or crushing at moving parts · due 2024-11-11 · AS 4024.1601 §5.5

R-GM-15Spillage or accumulation around the machineObservationS2 × L4 = 8Moderate

Accumulated product or spillage is a slip hazard and hides developing faults.

Action Clean down and add the area to the shift housekeeping round.

Access, egress and emergency response impaired · due 2024-11-11 · ISO 12100 §6.2.7

Assessment record

Identification and records · Is a current risk assessment on file for this machine?Yes

Identification and records · Is the manufacturer's manual available on site?Yes

Identification and records · Has the machine been modified since commissioning?No

Guarding · Are all fixed guards present and secured with tools-required fixings?Yes

Guarding · Are movable guards interlocked?Yes

Guarding · Is any interlock bypassed, taped or defeated?No

Guarding · Are in-running nips and drives guarded?Yes

Guarding · Largest gap in guarding35 mm

Emergency stop and isolation · Furthest distance from any operating position to an emergency stop6 m

Emergency stop and isolation · Does the pull-cord stop the machine from every point along its run?Yes

Emergency stop and isolation · Does restart require a deliberate reset at the machine?Yes

Emergency stop and isolation · Is the isolation / lockout point identified and lockable?Yes

Emergency stop and isolation · Are all stored energy sources documented for isolation?Yes

Workplace · Is hazard and isolation signage in place?Yes

Workplace · Clear walkway width alongside the machine1356 mm

Workplace · Housekeeping around the machineSpillage or accumulation

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.