Kestrel Process Group

Asset Integrity — equipment safety assessment

NG/GM-113

Screw conveyor 113

Report A-1074

Methodology v4.0

2025-11-28

Assessed risk

Critical

Highest score

Findings

Immediate

Coverage

16/16

Next due

2026-11-28

Stop use, isolate, escalate to the responsible engineer

Asset class

Guarded machinery / conveyor

Facility

Northgate Works, Ardmore Industrial Estate

Area

Utilities yard

Criticality

Manufacturer

Vertek

Model / serial

I452 / 20063-82

Installed

2004-12-01

Inspector

T. Fenwick

Findings (6)

R-GM-01Fixed guard missingImmediate dangerphotographic evidenceS5 × L4 = 20Critical

A fixed guard is absent and the hazard it covered is reachable during normal operation.

Action Stop the machine and lock it out until the guard is refitted with tools-required fixings.

Entanglement or crushing at moving parts · due 2025-11-28 · AS 4024.1601 §5.2 · evidence VC-MISSING-GUARD

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 2025-12-12 · ISO 13857 §4.2

R-GM-15Spillage or accumulation around the machineObservationphotographic evidenceS2 × 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 2025-12-12 · ISO 12100 §6.2.7 · evidence VC-HOUSEKEEPING

R-GM-14Walkway alongside the machine too narrowImprovement opportunityS2 × L3 = 6Moderate

The walkway beside the machine is narrower than the methodology allows.

Action Widen or re-route the walkway, or barrier it off if the width cannot be achieved.

Access, egress and emergency response impaired · due 2026-01-27 · ISO 14122-2 §4.2

R-GM-17Leak or product loss at the machineObservationphotographic evidenceS2 × L3 = 6Moderate

Fluid loss is visible at a gland, gearbox or hydraulic joint.

Action Repair the leak and clean the area so the next assessment can distinguish new loss from old.

Loss of containment to environment · due 2025-12-28 · ISO 12100 §6.2.7 · evidence VC-LEAK

R-GM-13Hazard or isolation signage missingImprovement opportunityS1 × L4 = 4Low

The machine carries no hazard or isolation signage.

Action Fit signage at each access point covering the hazard and the isolation requirement.

Loss of design or inspection traceability · due 2026-02-26 · ISO 7010

Photographic record

Site photograph taken at assessment

Illustration of a conveyor drive end with an open gearbox/belt-and-pulley drive on a green frame at left, a yellow mesh guard panel mid-span, an E-stop pull-cord with red button along the top, and a brown fluid pool on the floor beneath the drive.

Leak, drip or product staining — A brown/amber pool with scattered droplets sits under the drive, with a dark line running down from the underside of the blue gearbox/motor into the pool.
Guard removed or rotating part exposed — Drive pulleys, belt and gear wheel are fully visible in the open within a black-backed frame with bolt holes/fixings at each corner and along the edges, no cover panel fitted.
Housekeeping around the asset — Spilled liquid pool roughly 1 m across with scattered droplet spatter spreading across the floor slab.

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

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 guarding32 mm

Emergency stop and isolation · Furthest distance from any operating position to an emergency stop1.3 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?No

Workplace · Clear walkway width alongside the machine669 mm

Workplace · Housekeeping around the machineMinor debris

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.