Kestrel Process Group

Asset Integrity, equipment safety assessment

LY/SB-103

Utilities distribution board 103

Report A-1025

Methodology v4.2

2026-02-28

Assessed risk

Critical

Highest score

Findings

Immediate

Coverage

15/15

Next due

2027-02-28

Stop use, isolate, escalate to the responsible engineer

Asset class

LV switchboard / distribution board

Facility

Lyndale Packing, Cranfield Way

Area

Utilities yard

Criticality

Manufacturer

Vaughan Switchgear

Model / serial

Z152 / 59281-49

Installed

2006-06-01

Inspector

M. Osei

Findings (7)

R-SB-01Energised parts reachableImmediate dangerphotographic evidenceS5 × L3 = 15Critical

Live parts can be contacted without removing a cover or using a tool.

Action Restrict access to the board immediately and have an electrical worker restore the dead front before it is handed back.

Arc flash / electric shock · due 2026-02-28 · AS/NZS 3000 §1.5.4 · evidence VC-EXPOSED-CONDUCTOR

R-SB-02Blanking or gland plate missingNon-conformingphotographic evidenceS4 × L3 = 12High

An unused way or cutout is open, so the enclosure no longer provides its rated protection.

Action Fit correct blanks and gland plates. Do not use tape or sheet offcuts.

Arc flash / electric shock · due 2026-03-07 · IEC 61439-1 §8.4.2 · evidence VC-MISSING-BLANK

R-SB-03No arc-flash or shock-hazard labellingNon-conformingphotographic evidenceS3 × L4 = 12High

The board carries no hazard label, so a worker cannot select PPE from information at the equipment.

Action Calculate incident energy for the board and fit a label showing the boundary and PPE category.

Arc flash / electric shock · due 2026-03-30 · NFPA 70E §130.5(H) · evidence VC-NO-ARCFLASH-LABEL

R-SB-08Working space obstructed by stored materialNon-conformingphotographic evidenceS3 × L4 = 12High

Material is stored in the space a worker must occupy to operate or escape from the board.

Action Clear the zone, mark it on the floor, and give the displaced material a defined home.

Access, egress and emergency response impaired · due 2026-03-07 · AS/NZS 3000 §2.9.3 · evidence VC-OBSTRUCTED-ACCESS

R-SB-06Thermographic survey overdueRecords / traceabilityS2 × L4 = 8Moderate

No thermographic survey has been recorded within the interval.

Action Book the survey while the board is under representative load, and file the report against the board identifier.

Loss of design or inspection traceability · due 2026-04-29 · NETA MTS §9.15

R-SB-15Main switch not identifiedRecords / traceabilityS2 × L4 = 8Moderate

The main switch is not labelled, delaying isolation in an emergency.

Action Label the main switch with what it isolates, in durable marking.

Access, egress and emergency response impaired · due 2026-03-30 · AS/NZS 3000 §2.3.2

R-SB-11No single-line diagram at the boardRecords / traceabilityS2 × L3 = 6Moderate

No single-line diagram is available at the equipment.

Action Produce and laminate a current single-line diagram and fix it at the board.

Loss of design or inspection traceability · due 2026-04-29 · IEC 61439-1 §6.2

Photographic record

Site photograph taken at assessment

An illustrated wall-mounted distribution board with left-hand door open, a MAIN 400A rotary isolator, an uncovered busbar chamber at upper right, three rows of miniature circuit breakers behind an escutcheon, and cables entering from below. It is not clearly a motor control centre, as no starters or bucket units are shown.

Energised parts reachable, Bare copper-coloured horizontal and vertical busbars with bolted joints are visible with no cover fitted. A red-insulated conductor lands on the right-hand end of the bars.
Blanking plate or gland plate missing, Dark empty openings sit where breakers should be, with no blanks fitted. A dark rectangular opening is also visible at the bottom right of the enclosure, where a cable enters.
No arc-flash or shock-hazard label, Only the 'MAIN 400A' text, the 'CIRCUIT SCHEDULE' heading and a schedule sheet are visible. No warning triangle, shock-hazard label or incident-energy sticker is seen on the visible face.
Working space obstructed, Three cardboard boxes are placed on the floor immediately in front of and below the board, in the standing space.
Housekeeping around the asset, Cardboard boxes are left on the floor around the asset. No spillage, water or dust is visible.

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

Assessment record

Identification and records · Board identifierLY-SB-103

Identification and records · Is a current single-line diagram available at the board?No

Identification and records · Is the circuit schedule present and matching the installed ways?Yes

Identification and records · Is an arc-flash / shock-hazard label fitted?Yes

Enclosure integrity · Do the doors close and lock as designed?Yes

Enclosure integrity · Are all unused ways blanked and gland plates complete?Yes

Enclosure integrity · Are any energised parts reachable without a tool?No

Enclosure integrity · Enclosure damageNone

Terminations and thermal condition · Months since last thermographic survey35 months

Terminations and thermal condition · Was a hotspot recorded above the alarm threshold?No

Terminations and thermal condition · Are cable terminations supported and strain-relieved?Yes

Protection and access · Months since residual current devices were tested4 months

Protection and access · Is the main switch identified and its function labelled?No

Protection and access · Clear working space in front of the board1371 mm

Protection and access · Is the working space free of stored material?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.