Skip to main content
MapTrack
Book a demo
Skip to download form

Free pressure relief valve inspection and 5-year overhaul record

Free pressure relief valve inspection template per AS 1271 and AS 3788. Annual visual check and 5-year bench test with set pressure verification.

Two ways to use it

Use in MapTrack →

Download the free PDF

Use it digitally instead

Unlimited users

These same 35 checks, already built.

G2 rating 4.9 out of 5
Capterra rating 5.0 out of 5GetApp rating 5.0 out of 5Software Advice rating 5.0 out of 5
All MapTrack reviews
  • Scan the asset’s QR tag with any phone
  • Submitted forms can trigger alerts
  • Photos on fails, audit-ready records
  • Export responses, PDF reports with your logo

Free trial. No credit card needed.

Trusted by teams across Australia and New Zealand

We respect your privacy. Unsubscribe anytime.

These templates are free general guides provided as-is. They do not constitute legal, safety or compliance advice. You are responsible for ensuring any form meets your specific workplace obligations, industry standards and applicable regulations.

Updated 26 Oct 2026

Pressure Relief Valve Inspection and 5-Year Overhaul Record

Annual visual inspection and periodic bench test per AS 1271 and AS 3788

Your logo here
0 of 35 checks

1. Documentation Review

1PRV data sheet available and current
2Previous inspection/test records reviewed
3Piping and instrumentation diagram (P&ID) reference confirmed
4Maintenance history reviewed

2. Annual Visual Inspection

5Body and bonnet condition (corrosion, erosion)
6Inlet/outlet piping condition
7Discharge piping unobstructed
8Body drain clear
9Cap/lever guard intact
10Lock wire/seal intact
11No evidence of leakage (weeping)
12Isolation valve position correct (locked open)

3. Operational Checks - Annual

13Lifting lever operates freely
14Valve reseats after manual lift
15No audible seat leakage
16Inlet pressure reading within normal range

4. 5-Year Bench Test - Disassembly

17PRV removed from service (isolation confirmed)
18Inlet/outlet blanked on vessel
19Visual condition of internals
20Spring condition and free length
21Seat and disc condition (lapping marks, erosion, corrosion)

5. 5-Year Bench Test - Set Pressure Verification

22Test medium appropriate (air/nitrogen/water as applicable)
23Set pressure achieved within tolerance (+/-3% per AS 1271)
24Blowdown within acceptable limits
25Reseat pressure verified
26Repeat test (minimum 3 lifts for consistency)

6. 5-Year Overhaul - Repair/Replace

27Seat lapped or replaced
28Spring replaced if corroded or fatigued
29O-rings and soft goods replaced
30Body cleaned and inspected (NDT if suspect)

7. Post-Overhaul Certification

31Final set pressure test passed
32Valve tag updated with new test date
33Calibration certificate issued
34Valve reinstalled correctly (torque values applied)
35Isolation valve returned to locked-open position

How to use: download the PDF, print or complete digitally on any device.

  • PDF format, ready to print or fill on screen
  • Use as-is or customise to suit your operation
  • Go digital in MapTrack for photos, reminders and audit trails

Don't just download it - use it live. Start a free workspace with this pressure relief valve inspection and 5-year overhaul record already built, so your crew can run it from a phone.

Jarrod Milford

Jarrod Milford

Co-Founder & Commercial Director

Updated 26 October 2026
Also see:Compliance and inspections →Best inspection software →MapTrack vs SafetyCulture →

Short answer

A pressure relief valve inspection record logs each valve's in-situ visual check and its periodic bench test and overhaul: tag and serial number, set pressure, as-found and as-left results, seat tightness and parts replaced. Maintenance fitters and pressure equipment inspectors complete it. AS/NZS 3788:2024 clause 4.6 covers inspection of pressure-relief devices, and regulation 224 of the model WHS Regulations requires regular competent-person inspection of pressure equipment.

Checked against AS/NZS 3788:2024 (incl. Amd 1:2025) on by the MapTrack templates team. How we check templates

Key takeaways

  • The MapTrack pressure relief valve inspection and 5-year overhaul record contains 35 checks across 7 sections. Sections covered: 1. Documentation Review, 2. Annual Visual Inspection, 3. Operational Checks - Annual, 4. 5-Year Bench Test - Disassembly, 5. 5-Year Bench Test - Set Pressure Verification, 6. 5-Year Overhaul - Repair/Replace, 7. Post-Overhaul Certification.
  • The template keeps two intervals on one valve record: an annual visual inspection in place and a bench test and overhaul at intervals of up to five years.
  • Test and record the set pressure before touching the valve. If it opens outside tolerance, it was not giving correct protection during the previous service period.
  • Confirm the inlet isolation valve, where fitted, is locked open, and that the discharge piping is clear and routed to a safe place.
  • Fit a new seal wire and lead seal after reinstallation so the set pressure cannot be adjusted without it showing.
  • Valves in corrosive service, valves that have lifted and valves on critical equipment may need testing more often.

Enter your email below to download this pressure relief valve inspection and 5-year overhaul record as a ready-to-use PDF.

Used by construction, mining and field service teams

Saunders InternationalMineral ResourcesSupagasHacer GroupMetro TunnelUltrabuilt

What is a pressure relief valve inspection and 5-year overhaul record?

A pressure relief valve (PRV) inspection template covers the dual-interval maintenance regime required for pressure relief devices protecting pressure vessels, boilers and process equipment. AS/NZS 3788:2024 (Pressure equipment - In-service inspection) sets the test interval for pressure-relief devices (clause 4.6.5.2), and AS 1271 (Safety valves, other valves, liquid level gauges and other fittings for boilers and unfired pressure vessels) covers their design, construction and testing. This template uses a common regime of an annual visual inspection in situ and a comprehensive bench test and overhaul at intervals of up to 5 years; confirm it against the current AS/NZS 3788 and your inspection body. The annual inspection checks body condition, discharge piping, external corrosion, seal integrity, manual lift lever function and general condition. The 5-year overhaul requires removal from service, complete disassembly, cleaning, internal inspection of seat and disc, set pressure verification on a calibrated test bench (this template uses plus or minus 3% of nameplate set pressure; confirm the tolerance against AS 1271 and the valve data), lapping or replacement of seating surfaces, spring inspection, reassembly and final set pressure test.

PRVs are the last line of defence against catastrophic overpressure events. A failed or incorrectly set PRV can result in a pressure vessel rupture, which is one of the most violent and destructive industrial incidents possible. Under the WHS Regulations 2011, pressure vessels of hazard level A, B or C (other than gas cylinders, automotive LP Gas fuel vessels and serially produced vessels) are registered plant (Schedule 5), and pressure equipment must be inspected regularly by a competent person (regulation 224). Insurance policies for pressure equipment universally require evidence of current PRV maintenance. This template documents both the annual visual inspection and the 5-year bench test in a single format, providing a complete maintenance history for each valve.

Learn more about compliance and inspections in MapTrack.

Get the free template

Enter your email above to download the full pressure relief valve inspection and 5-year overhaul record as a PDF.

Download free PDF

Benefits of using this pressure relief valve inspection and 5-year overhaul record

  • Overpressure protection: confirms that the last line of defence against vessel rupture is functional and set at the correct pressure, protecting personnel and equipment.
  • Dual-interval tracking: manages both the annual visual inspection and the 5-year bench test overhaul on a single valve record, preventing either interval from being missed.
  • Regulatory compliance: satisfies AS 3788 and AS 1271 requirements for documented PRV maintenance as part of the pressure equipment in-service inspection programme.
  • Set pressure accuracy: the bench test verifies the valve opens within plus or minus 3% of the nameplate set pressure, ensuring protection activates before the vessel reaches its design limit.
  • Insurance evidence: provides the documentary proof that insurers require before covering pressure equipment, as most policies condition coverage on current PRV certification.
  • Failure prevention: identifies degraded seats, corroded internals, weakened springs and blocked discharge piping before they prevent the valve from operating when needed.

Benefits of digitising forms in MapTrack

When you digitise pressure relief valve checklists in MapTrack, you get:

  • Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
  • Email the right people when a form is submitted, with an automation you set up.
  • File every completed form against the asset, location or person it covers.
  • Download any completed form as a PDF, with failed answers listed at the top.
  • Fill in forms offline; they upload when the device is back online.
  • Build conditional logic (show or hide questions based on answers).
  • Take pictures or attach photos. Not possible with a paper-based form.
  • Electronic signatures.
  • Edit forms later without reprinting.
  • Set who can view, fill in or edit forms with user roles.
  • Upload a paper form (PDF, Word, Excel or a photo) and MapTrack's AI builds a digital version for you to check.
  • Assign audits and send reminder emails to the people doing them.
  • Keep every audit, inspection and sign-off against the asset or site it covers.
  • Track corrective actions as work orders from finding to close-out, with each change in the activity log.

Book a demo to see how MapTrack handles pressure relief valve checklists.

Try MapTrack free

Full access to every feature. No credit card required. Per-asset pricing so you scale as your fleet grows.

Start free trial
  • No credit card required

1-2 days/week saved

“Bloody amazing! We used to spend 1-2 days a week tracking and managing our generators alone.”
Saunders International

Steve McAllister

Asset Coordinator, Saunders International

What to include in a pressure relief valve inspection and 5-year overhaul record

This pressure relief valve inspection and 5-year overhaul record covers 9 key areas:

  • Valve identification: tag number, serial number, manufacturer, model, size, set pressure, discharge capacity, material of construction, protected equipment ID.
  • Annual visual inspection: body condition (corrosion, leaks, damage), discharge piping (blockages, corrosion, correct routing), inlet piping (isolation valve position, blockages), cap and seal (intact, not tampered), manual lift test result.
  • Test bench data (5-year overhaul): as-found set pressure, as-found blowdown, seat leakage before overhaul, internal condition assessment.
  • Overhaul details: parts replaced (disc, seat, spring, seals), lapping performed, cleaning method, reassembly torque values.
  • Post-overhaul test results: as-left set pressure (must be within plus or minus 3% of nameplate), as-left blowdown, seat leakage test (zero leakage required), back-pressure test if applicable.
  • Test equipment: test bench identification, calibration certificate number and expiry date, test medium (air, nitrogen, water).
  • Outcome: pass (return to service), fail (repair/replace), adjusted (now within tolerance).
  • Technician details: name, qualifications, employer, signature, date.
  • Next inspection due dates: next annual visual and next 5-year bench test.

How to use this pressure relief valve inspection and 5-year overhaul record

  1. Perform the annual visual inspection with the valve in situ on the pressure equipment.: Inspect the valve body externally for corrosion, mechanical damage and evidence of leakage (staining, deposits). Check the discharge piping for blockages, corrosion and correct routing to a safe location. Verify the inlet isolation valve (if fitted) is locked open. Confirm the cap and seal wire are intact and have not been tampered with. If the valve has a manual lift lever, operate it briefly to confirm the valve lifts and reseats.
  2. At the 5-year interval, remove the valve from service and perform as-found testing on the test bench.: Isolate and depressurise the protected equipment. Remove the PRV. Mount the valve on a calibrated test bench and determine the as-found set pressure (the pressure at which the valve actually opens). Record the as-found blowdown and check for seat leakage below set pressure. Compare the as-found set pressure to the nameplate. Deviation beyond plus or minus 3% indicates the valve was not providing correct protection.
  3. Disassemble, inspect internals, clean and recondition the valve.: Fully disassemble the valve. Inspect the disc and nozzle seat for wear, pitting, erosion and corrosion. Check the spring for corrosion, permanent set and cracking. Inspect the body bore, guide surfaces and bellows (if fitted). Lap the seat and disc if wear is minor. Replace any component that does not meet the manufacturer serviceability criteria. Record all parts replaced.
  4. Reassemble the valve and perform the set pressure verification test.: Reassemble the valve with new seals and gaskets. Mount on the test bench and adjust the set pressure to the nameplate value. Verify that the valve opens within plus or minus 3% of the nameplate set pressure. Verify the blowdown is within the manufacturer specification. Perform a seat leakage test below set pressure to confirm zero leakage. Record all test data.
  5. Reinstall the valve, apply seals, update records and set next due dates.: Reinstall the valve on the protected equipment. Apply a new seal wire and lead seal to prevent unauthorised adjustment. Verify the inlet isolation valve is locked open. Complete the inspection record with all test data, technician details and certification. Set the next annual visual inspection and 5-year bench test due dates in the maintenance system.

In MapTrack, you can automate compliance tracking and audit trails. Each submission is stored as a timestamped PDF against the asset record.

Get the free templateEnter your email above to download the full pressure relief valve inspection and 5-year overhaul record as a PDF.Back to download form

How often should you complete this checklist?

This template schedules an annual visual inspection for every PRV in service and a comprehensive bench test and overhaul at intervals of up to 5 years. AS/NZS 3788:2024 sets the test interval for pressure-relief devices (clause 4.6.5.2), so confirm the schedule against the current edition. More frequent testing may be required for valves in corrosive service, valves that have operated (lifted), or valves protecting critical equipment. Some insurers require 3-year bench testing for specific applications. In MapTrack, dual-interval scheduling manages both the annual and 5-year cycles independently, ensuring neither is missed while maintaining the complete service history for each valve across its installed life.

Try MapTrack free

Full access to every feature. No credit card required. Per-asset pricing so you scale as your fleet grows.

Start free trial
  • No credit card required

Frequently asked questions

AS/NZS 3788:2024 sets the test interval for pressure-relief devices (clause 4.6.5.2). A common regime is an annual visual inspection in situ and a bench test at intervals of up to 5 years; check the current edition for the interval that applies to your equipment. The bench test requires removal from service, disassembly, overhaul and set pressure verification on a calibrated test bench. Some insurers and site-specific risk assessments may require more frequent bench testing, particularly for valves in corrosive or high-cycling applications.

This template uses a set pressure tolerance of plus or minus 3% of the nameplate set pressure after testing and adjustment, or plus or minus 2 kPa for valves set below 70 kPa. Confirm the tolerance against AS 1271 and the valve manufacturer data. If the as-found set pressure is outside these tolerances during bench testing, the valve was not providing correct protection during the preceding service period and a risk assessment of the protected equipment may be required.

The annual visual inspection is performed in situ. However, the 5-year bench test and overhaul cannot be performed in situ because it requires disassembly, internal inspection, seat reconditioning and set pressure verification on a calibrated test bench under controlled conditions. The valve must be removed from service. During removal, a temporary blanking arrangement or spare valve must protect the vessel.

PRV testing and overhaul must be performed by a person competent in the maintenance and testing of the specific valve types. In practice, this means a qualified mechanical tradesperson with specific training in PRV maintenance, access to calibrated test equipment, manufacturer service documentation and relevant Australian Standards. Some valve manufacturers offer certified technician programmes. The technician must understand set pressure adjustment, seat lapping, spring selection and blowdown adjustment.

If the as-found set pressure is outside the AS 1271 tolerance of plus or minus 3% of the nameplate value, the valve was not providing correct protection during the preceding service period and the protected vessel must be reviewed for any signs of overpressure damage before being returned to service. The valve itself must be adjusted, repaired or replaced and then re-tested until the as-left set pressure is within tolerance, with zero seat leakage below set pressure. WHS Regulations 2011 Chapter 5 require that registered pressure plant be maintained in a safe condition, so the failed test result, the remedial work and the final pass result must all be recorded against the valve and the protected vessel in the asset register.

Applicable regulatory standards

This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.

  • Pressure equipment - In-service inspection

    Edition: AS/NZS 3788:2024 (incl. Amd 1:2025)

    Covers inspecting pressure-relief devices, time-based inspection intervals by equipment type, and the history record kept for each item.

    • 4.6: Inspection of pressure-relief devices
    • 4.4: Time-based intervals between pressure equipment inspections
    • 8.6: Keeping a history record for each item of pressure equipment

    Standards Australia and Standards New ZealandSold by the publisher

  • Safety valves, other valves, liquid level gauges and other fittings for boilers and unfired pressure vessels

    Edition: AS 1271-2003 (incl. Amd 1)

    Australian standard for safety valves, other valves and fittings on boilers and unfired pressure vessels; the edition in force is AS 1271-2003.

    Standards AustraliaSold by the publisher

  • Model Work Health and Safety Regulations

    Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)

    Regular competent-person inspection of pressure equipment; records for plant that must be registered, as listed in Schedule 5.

    • reg 224: Pressure equipment must be inspected regularly by a competent person; inspected gas cylinders carry a current inspection mark.
    • reg 237: Records of tests, inspections, maintenance and alterations must be kept for plant required to be registered.
    • Schedule 5: Plant requiring registration: plant designs (Part 1) and items of plant (Part 2), such as boilers and tower cranes.

    Safe Work Australia (drafted by the Parliamentary Counsel's Committee)

  • Pressure equipment - Hazard levels

    Edition: AS 4343:2014

    Assigns hazard levels A to E to pressure equipment, which affect registration and inspection planning for the protected vessel.

    • 2.1: Assigns hazard levels A to E to pressure equipment

    Standards AustraliaSold by the publisher

Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.

Check the current source

Pressure relief valve inspection and 5-year overhaul record preview

Pressure relief valve inspection and 5-year overhaul record template preview showing fields and layout

The numbers behind this pressure relief valve inspection and 5-year overhaul record

The pages below gather the figures behind this kind of check. Each figure on them carries its source and date, so you can quote it in a toolbox talk, a budget case or a board paper without chasing the original report.

Get the free template

Enter your email above to download the full pressure relief valve inspection and 5-year overhaul record as a PDF.

Download free PDF

Embed this free template on your website

Run an industry blog, trade association site, or training resource? Drop a preview of this free pressure relief valve inspection and 5-year overhaul record straight into your page. The snippet is self-contained, needs no scripts, and links readers back to the full free template.

<div style="max-width:480px;font-family:system-ui,-apple-system,'Segoe UI',Roboto,sans-serif;border:1px solid #E5E7EB;border-radius:12px;padding:20px;background:#ffffff;">
  <p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
  <p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Pressure relief valve inspection and 5-year overhaul record</p>
  <ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
    <li style="margin:4px 0;">Valve identification: tag number, serial number, manufacturer, model, size, set pressure, discharge capacity, material of construction, protected equipment ID.</li>
    <li style="margin:4px 0;">Annual visual inspection: body condition (corrosion, leaks, damage), discharge piping (blockages, corrosion, correct routing), inlet piping (isolation valve position, blockages), cap and seal (intact, not tampered), manual lift test result.</li>
    <li style="margin:4px 0;">Test bench data (5-year overhaul): as-found set pressure, as-found blowdown, seat leakage before overhaul, internal condition assessment.</li>
    <li style="margin:4px 0;">Overhaul details: parts replaced (disc, seat, spring, seals), lapping performed, cleaning method, reassembly torque values.</li>
    <li style="margin:4px 0;">Post-overhaul test results: as-left set pressure (must be within plus or minus 3% of nameplate), as-left blowdown, seat leakage test (zero leakage required), back-pressure test if applicable.</li>
    <li style="margin:4px 0;">Test equipment: test bench identification, calibration certificate number and expiry date, test medium (air, nitrogen, water).</li>
  </ul>
  <p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/pressure-relief-valve-inspection" style="color:#071D49;font-weight:600;text-decoration:none;">Pressure relief valve inspection and 5-year overhaul record</a> by MapTrack</p>
</div>

Free to reuse, including commercially. This template is published under a Creative Commons Attribution 4.0 licence. Copy it, adapt it, put it on your own site or in your own docs. All we ask is that you credit MapTrack with a link back to this page. The snippet above already includes that credit, so if you use it as-is you’re covered.

Cite this template

Writing about this topic? You’re welcome to quote this checklist. Here’s the wording to use so your readers can find the original.

The MapTrack pressure relief valve inspection and 5-year overhaul record contains 35 checks across 7 sections.

Short attribution
MapTrack Pressure relief valve inspection and 5-year overhaul record, https://www.maptrack.com/templates/pressure-relief-valve-inspection
Reference list
MapTrack. (2026). Pressure relief valve inspection and 5-year overhaul record [Checklist template]. Retrieved from https://www.maptrack.com/templates/pressure-relief-valve-inspection

Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/pressure-relief-valve-inspection.

Need to automate compliance tracking and audit trails?

Register every pressure relief valve in MapTrack, attach digital forms, and get a complete history of every inspection, service and compliance record.

Start free trialBook a demo

Compliance and inspections · All templates · Pricing · Book a demo