Annual inspection - pressure vessels per AS 3788 and AS 1210
Estimated duration: 2 - 4 hours • Frequency: annual (or as per risk assessment)
Vessel Details
| # | Inspection Action | Type | Done | Notes |
|---|---|---|---|---|
| External Visual Inspection | ||||
| 1 | External visual inspection (corrosion, bulging, dents, cracks, paint condition) | INSPECT | ☐ | |
| 2 | Inspect all nozzles and connections (corrosion, leaks) | INSPECT | ☐ | |
| 3 | Check insulation/lagging condition (damage, moisture, missing sections) | CHECK | ☐ | |
| 4 | Check foundation and supports (corrosion, settlement, cracks) | CHECK | ☐ | |
| 5 | Inspect welds (visual for cracking, dye penetrant if concern) | INSPECT | ☐ | |
| 6 | Inspect bolted connections and flanges (leaks, gasket condition) | INSPECT | ☐ | |
| Fittings / Instruments | ||||
| 7 | Inspect pressure gauge (calibration current, readable, correct range) | INSPECT | ☐ | |
| 8 | Test safety relief valve (pop test to rated pressure, or bench test if removed) | TEST | ☐ | |
| 9 | Inspect drain valve (operable, not blocked) | INSPECT | ☐ | |
| 10 | Inspect sight glass / level gauge (if fitted - clean, readable) | INSPECT | ☐ | |
| Nameplate / Records | ||||
| 11 | Verify nameplate data (legible, matches records - design pressure, temperature, contents, manufacturer) | VERIFY | ☐ | |
| 12 | Review operating log (pressure and temperature history, any excursions) | REVIEW | ☐ | |
| 13 | Verify compliance labels and inspection stickers (current) | VERIFY | ☐ | |
| NDT / Thickness Testing | ||||
| 14 | Ultrasonic thickness test (if due per inspection schedule or risk assessment) | MEASURE | ☐ | |
| Risk Assessment / Compliance | ||||
| 15 | Review risk assessment (update if changes to conditions/contents) | REVIEW | ☐ | |
| 16 | Compliance documentation per AS 3788 (Pressure Equipment - In-service Inspection) | VERIFY | ☐ | |
| 17 | Update vessel inspection register | UPDATE | ☐ | |
Consumables / Materials (if NDT required)
| Material | Notes |
|---|---|
| Dye penetrant | For surface crack detection (if NDT required) |
| Developer | For dye penetrant inspection |
| Cleaner / solvent | Surface preparation before NDT |
| UT couplant gel | For ultrasonic thickness testing |
NDT consumables only required if non-destructive testing is part of the inspection scope for this vessel. Inspector must be a competent person per AS 3788.
Notes / Defects Identified
Next Inspection Due
Inspector (Competent Person)
Site Manager / Plant Owner