Who can inspect pressure vessels under AS 3788?

AS 3788 requires inspections to be carried out by a competent person with appropriate qualifications and experience in pressure equipment inspection. This typically means a qualified pressure equipment inspector holding relevant certifications such as API 510 (Pressure Vessel Inspector), AINDT Level II in the applicable NDT methods, or equivalent qualifications recognised by the state or territory regulator. Some jurisdictions require inspectors to be registered or authorised by the regulatory authority.

What is the maximum inspection interval for pressure vessels?

AS 3788:2006 Table 8.1 sets maximum intervals that vary by equipment type and inspection type. For most pressure vessels, the maximum external inspection interval is 3 years and the maximum internal inspection interval is 6 years. These intervals can be reduced based on corrosion rates, service conditions, previous defect history or regulatory requirements. Risk-based inspection programmes may allow interval adjustments where supported by a documented assessment.

What is the difference between external and internal inspections?

An external inspection covers the outside surfaces of the vessel, its supports, foundations, insulation, piping connections and cathodic protection without requiring entry into the vessel. An internal inspection involves examining the inside surfaces, welds, nozzles and internal components, which usually requires the vessel to be taken out of service, drained, cleaned and made safe for entry. Internal inspections provide a more thorough assessment but require more preparation and downtime.

Can I manage AS 3788 inspections digitally?

Yes. Digital inspection platforms allow inspectors to record findings on a tablet, capture photos of defects, log thickness readings against monitoring point maps, attach NDT reports and automatically calculate corrosion rates. MapTrack supports pressure equipment inspection workflows with digital checklists, automated scheduling, defect tracking and compliance dashboards. Book a demo to see how it works for your pressure equipment fleet.

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Free AS 3788:2006 pressure vessel inspection checklist. Section 8 in-service inspection requirements for boilers and pressure vessels. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a as 3788 pressure vessel inspection checklist?

An AS 3788 pressure vessel inspection checklist is a structured document used to verify that pressure vessels and boilers comply with the in-service inspection requirements of Australian Standard AS 3788:2006, Pressure equipment - In-service inspection. Section 8 of this standard defines the inspection procedures, acceptance criteria and reporting requirements for pressure equipment that is already in operation. The checklist guides the inspector through external and internal visual examinations, thickness measurements, non-destructive testing, safety fitting checks, documentation reviews and condition assessments.

Pressure vessels operate under conditions that can cause progressive degradation through corrosion, erosion, fatigue cracking, creep and hydrogen damage. Undetected deterioration can lead to catastrophic failure, resulting in serious injury, fatalities and major property damage. In Australia, the Work Health and Safety Regulations require that pressure equipment is inspected by a competent person at intervals specified in the relevant Australian Standard. AS 3788 is the primary standard for in-service inspection of pressure vessels, boilers, heat exchangers, air receivers, process columns and similar equipment. Maintaining completed inspection checklists provides documented evidence of compliance with WHS Regulations, supports insurance requirements, and creates a permanent record of each vessel condition throughout its operational life.

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Benefits of using this as 3788 pressure vessel inspection checklist

Regulatory compliance: documented evidence of inspections required under WHS Regulations and referenced by state and territory regulators for registered pressure equipment.
Early defect detection: systematic examination of internal and external surfaces, welds, nozzles and fittings identifies corrosion, cracking or thinning before they reach critical levels.
Insurance support: insurers of pressure equipment typically require inspection records conforming to AS 3788 as a condition of cover.
Fitness for service: inspection findings feed directly into fitness-for-service assessments (AS/NZS 3788 Appendix J), allowing informed decisions about continued operation, repair or retirement.
Maintenance planning: thickness measurement trends and condition data support risk-based inspection scheduling and capital planning for repairs or replacements.
Safety assurance: pressure vessel failures can be catastrophic. Thorough inspections of shells, heads, nozzles, safety valves and support structures directly protect workers and surrounding assets.

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When you digitise pressure vessel checklists in MapTrack, you get:

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Build conditional logic (show or hide questions based on answers).
Take pictures or attach photos. Not possible with a paper-based form.
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Set recurring audit schedules with automatic reminders and escalation.
Produce regulator-ready PDF compliance packs in one click.
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What to include in a as 3788 pressure vessel inspection checklist

This as 3788 pressure vessel inspection checklist covers 11 key areas:

Vessel identification: asset ID, serial number, registration number, make and manufacturer, design standard (e.g. AS 1210, AS/NZS 1200), design pressure and temperature, maximum allowable working pressure (MAWP), contents or service and location.
Inspection details: inspection date, inspector name and qualifications (e.g. API 510, AINDT Level II), inspection type (external, internal, on-stream), inspection interval reference per AS 3788 Table 8.1 and previous inspection date.
External visual examination: inspection of external surfaces for corrosion, pitting, bulging, dents, paint condition, insulation condition, foundation and support condition, external piping connections, earthing and cathodic protection status.
Internal visual examination: inspection of internal surfaces for corrosion, erosion, cracking, pitting, lining or coating condition, baffle and tray condition (for columns), and deposits or scaling.
Thickness measurements: ultrasonic thickness readings at designated monitoring points, comparison with previous readings and minimum required thickness calculations. Record wall thickness, nominal thickness and corrosion rate.
Non-destructive testing (NDT): results of any NDT performed, including method (UT, MPI, DPI, RT), location, findings and acceptance criteria per AS 3788 Section 8.
Safety fittings: inspection and testing of pressure relief valves, safety valves, bursting discs, pressure gauges, level indicators, isolation valves and emergency shutdown systems.
Welded joints and nozzles: examination of longitudinal and circumferential welds, nozzle welds, reinforcement pads, manway and handhole flanges for cracking, corrosion or distortion.
Condition assessment: overall condition rating (good, acceptable, requires attention, unserviceable), remaining life estimate, next inspection due date and recommended inspection interval.
Findings and corrective actions: list of all defects found, severity classification, corrective action required, responsible person, due date and follow-up verification requirements.
Declaration and sign-off: inspector signature, print name, qualifications, employer, date, and owner or operator acknowledgement with signature and date.

How to use this as 3788 pressure vessel inspection checklist

Review the vessel records, including design documentation, previous inspection reports, maintenance history, repair records, process conditions and any fitness-for-service assessments.: Confirm the vessel identification (registration number, serial number, MAWP) against the nameplate. Review the inspection history to identify recurring defects or areas requiring focused attention. Check the applicable inspection interval per AS 3788 Table 8.1.
Conduct the external visual examination, inspecting all accessible external surfaces, supports, foundations, insulation, piping connections and cathodic protection systems.: Look for corrosion, paint degradation, bulging, dents, cracking in welds, leaking flanges, damaged insulation, foundation settlement and corroded support steelwork. Note any areas where insulation should be removed for further examination (corrosion under insulation is a common failure mode).
Conduct the internal visual examination (where the vessel can be safely entered or inspected with remote equipment), examining internal surfaces, welds, nozzles, internals and fittings.: Inspect for internal corrosion, erosion, pitting, cracking, lining deterioration, deposit build-up and damage to internal components such as baffles, trays or heating coils. Follow confined space entry procedures where applicable. Use adequate lighting and, where necessary, remote inspection tools.
Perform thickness measurements at designated monitoring points using calibrated ultrasonic thickness gauges, and compare readings with previous results.: Record the wall thickness at each monitoring point and calculate the corrosion rate based on previous readings. Compare the measured thickness against the minimum required thickness for the design pressure. Flag any readings that are approaching or below the minimum required thickness.
Inspect and test all safety fittings, including pressure relief valves, safety valves, bursting discs, pressure gauges and emergency shutdown devices.: Verify that pressure relief valves are set to the correct relief pressure and have current test certificates. Check bursting disc condition and expiry. Confirm pressure gauges are within calibration and reading accurately. Record the set pressure, capacity and test date for each safety device.
Complete the condition assessment, record all findings, assign corrective actions, determine the next inspection date and obtain sign-off from the inspector and the vessel owner or operator.: Classify the vessel condition (good, acceptable, requires attention, unserviceable). List all defects with severity classifications and corrective actions. Calculate the remaining life estimate based on corrosion rates. Set the next inspection interval in accordance with AS 3788. Ensure the inspector and owner or operator sign the completed report.

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How often should you complete this checklist?

AS 3788:2006 Table 8.1 specifies maximum inspection intervals based on the type of pressure equipment, its operating conditions and the consequences of failure. For most pressure vessels, the maximum interval for an external inspection is typically 3 years, and for an internal inspection it is typically 6 years, though these intervals may be shorter depending on the corrosion rate, service conditions, previous findings and risk assessment outcomes. On-stream inspections using non-invasive techniques can supplement or, in some cases, extend the interval between internal inspections where supported by a risk-based inspection (RBI) programme.

State and territory WHS Regulations and pressure equipment registration requirements may impose additional or more frequent inspection intervals. Always check the requirements of your jurisdiction, the original design standard, the manufacturer recommendations, and any conditions imposed by your insurer or the registration authority. Vessels in corrosive or high-temperature service, or those with a history of defects, should be inspected more frequently than the maximum intervals specified in the standard.

Frequently asked questions

What is an AS 3788 pressure vessel inspection?: It is an in-service inspection conducted in accordance with Australian Standard AS 3788:2006, Pressure equipment - In-service inspection. The standard covers external visual examinations, internal visual examinations, thickness measurements, non-destructive testing, safety fitting checks and condition assessments for pressure vessels, boilers, heat exchangers, air receivers and similar equipment. The inspection determines whether the vessel is fit for continued service at its rated pressure and temperature.
Who can inspect pressure vessels under AS 3788?: AS 3788 requires inspections to be carried out by a competent person with appropriate qualifications and experience in pressure equipment inspection. This typically means a qualified pressure equipment inspector holding relevant certifications such as API 510 (Pressure Vessel Inspector), AINDT Level II in the applicable NDT methods, or equivalent qualifications recognised by the state or territory regulator. Some jurisdictions require inspectors to be registered or authorised by the regulatory authority.
What is the maximum inspection interval for pressure vessels?: AS 3788:2006 Table 8.1 sets maximum intervals that vary by equipment type and inspection type. For most pressure vessels, the maximum external inspection interval is 3 years and the maximum internal inspection interval is 6 years. These intervals can be reduced based on corrosion rates, service conditions, previous defect history or regulatory requirements. Risk-based inspection programmes may allow interval adjustments where supported by a documented assessment.
What is the difference between external and internal inspections?: An external inspection covers the outside surfaces of the vessel, its supports, foundations, insulation, piping connections and cathodic protection without requiring entry into the vessel. An internal inspection involves examining the inside surfaces, welds, nozzles and internal components, which usually requires the vessel to be taken out of service, drained, cleaned and made safe for entry. Internal inspections provide a more thorough assessment but require more preparation and downtime.
Can I manage AS 3788 inspections digitally?: Yes. Digital inspection platforms allow inspectors to record findings on a tablet, capture photos of defects, log thickness readings against monitoring point maps, attach NDT reports and automatically calculate corrosion rates. MapTrack supports pressure equipment inspection workflows with digital checklists, automated scheduling, defect tracking and compliance dashboards. Book a demo to see how it works for your pressure equipment fleet.

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS 3788:2006 (Pressure equipment - In-service inspection) Section 8
AS 1210 (Pressure vessels - Design)
AS/NZS 1200 (Pressure equipment - General)
WHS Regulations 2011 (Chapter 5 - Plant and structures)

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