What is a pressure vessel annual inspection under AS 3788?

AS 3788 (Pressure Equipment - In-service Inspection) requires pressure vessels to be inspected at regular intervals to confirm they remain safe for continued operation. The annual inspection includes external visual examination for corrosion, bulging, dents and cracking, inspection of all nozzles and connections, pressure gauge verification, safety relief valve testing, drain valve check, nameplate and records verification, foundation and support inspection, weld inspection, ultrasonic thickness testing (if due), risk assessment review and compliance documentation. The inspection must be performed by a competent person as defined by AS 3788.

Who can perform a pressure vessel inspection?

Under AS 3788, a pressure vessel inspection must be performed by a competent person. A competent person is someone who has acquired, through training, qualification or experience (or a combination of these), the knowledge and skills to carry out the inspection. In most Australian jurisdictions, this means a qualified pressure equipment inspector, a mechanical engineer with relevant experience, or a person accredited by a recognised inspection body. The inspector must be independent of the operator for statutory inspections.

How often does a pressure vessel need to be inspected?

AS 3788 specifies inspection intervals based on a risk-based approach. As a general guide: annual external visual inspections, internal inspections every 3-6 years (depending on service conditions and risk assessment), and hydrostatic or proof tests as determined by the risk assessment. Higher-risk vessels (corrosive contents, high temperature, high pressure) may require more frequent inspection. The vessel owner and inspector must establish an inspection plan based on the specific vessel conditions.

Is the template free to use without MapTrack?

Yes. Download and use the pressure vessel annual inspection checklist for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want to digitise your pressure vessel inspection register with scheduling, alerts and compliance tracking linked to each vessel, we would be happy to show you MapTrack.

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Free pressure vessel annual inspection checklist (AS 3788)

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A step-by-step annual inspection checklist for pressure vessels per AS 3788 and AS 1210. Covers external visual inspection, nozzle and connection checks, pressure gauge verification, safety relief valve testing, drain and sight glass inspection, nameplate verification, operating log review, foundation and support checks, weld inspection, ultrasonic thickness testing (if due), risk assessment review and compliance documentation. Includes vessel detail fields, inspector sign-off and next inspection scheduling. This page explains what the inspection involves, how to perform it, and offers a free PDF-ready form you can download straight away.

Last updated: 2026-03-26 · MapTrack

Jarrod Milford

Commercial Director

Updated 26 March 2026

How to use: Fill in vessel details (description, registration, serial number, design pressure, contents). Work through each inspection action. Tick Done as each item is completed. Record findings and defects in the notes column. Set the next inspection date and sign off.

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What is a pressure vessel annual inspection?

A pressure vessel annual inspection is a systematic examination required under AS 3788 (Pressure Equipment - In-service Inspection) to confirm that a pressure vessel remains safe for continued operation. The inspection covers the external condition of the vessel (corrosion, bulging, dents, cracking), all fittings and instruments (pressure gauge, safety relief valve, drain valve, sight glass), nameplate verification, operating records review, foundation and support condition, weld integrity, and compliance documentation. If the inspection schedule or risk assessment requires it, ultrasonic thickness testing is also performed. The inspection must be carried out by a competent person as defined by AS 3788 and the results documented in the vessel inspection register.

Benefits of systematic pressure vessel inspection

Safety: pressure vessel failure can be catastrophic. Regular inspection identifies corrosion, cracking and wall thinning before they reach dangerous levels.
Regulatory compliance: AS 3788 compliance is a legal requirement in Australian jurisdictions. Documented inspections demonstrate compliance to WHS regulators and insurers.
Reduced downtime: identifying deterioration early allows planned repairs or replacement instead of emergency shutdowns.
Insurance: insurers require current inspection records for pressure equipment coverage. Lapsed inspections can void insurance cover.
Extended vessel life: a well-maintained and regularly inspected vessel can operate safely for decades. Neglected vessels may need early retirement.
Accurate records: a consistent inspection checklist builds a history of wall thickness measurements, defect findings and corrective actions that inform future risk assessments.

Benefits of digitising forms in MapTrack

When you move from paper or static PDFs to digital forms 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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Restrict permissions (who can view, complete or approve).
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Inspection actions included

This inspection checklist covers 17 actions across 5 inspection areas:

External visual inspection: examine vessel body for corrosion, bulging, dents, cracks and paint condition; inspect nozzles, connections, insulation/lagging, foundations, supports, welds, bolted connections and flanges.
Fittings / instruments: verify pressure gauge calibration and range, test safety relief valve (pop test or bench test), inspect drain valve and sight glass/level gauge.
Nameplate / records: verify nameplate data matches records, review operating log for pressure/temperature excursions, verify compliance labels and inspection stickers.
NDT / thickness: ultrasonic thickness testing if due per inspection schedule or risk assessment.
Risk / compliance: review and update risk assessment, verify compliance documentation per AS 3788, update vessel inspection register.

How to perform a pressure vessel annual inspection

Confirm the vessel is safe to approach. If the vessel is in service, coordinate with operations for safe access. Record vessel details: description, registration number, serial number, design pressure, contents and location.
Perform the external visual inspection: examine the entire vessel surface for corrosion, bulging, dents, cracks and paint deterioration. Inspect all nozzles, connections, insulation and lagging.
Check foundations and supports for corrosion, settlement or cracks. Inspect all welds visually (use dye penetrant testing if any concerns are identified). Inspect bolted connections and flanges for leaks and gasket condition.
Verify the pressure gauge is in calibration, readable and of the correct range. Test the safety relief valve by pop test to rated pressure (or remove for bench testing). Inspect the drain valve and sight glass/level gauge.
Verify nameplate data is legible and matches records. Review the operating log for any pressure or temperature excursions. Verify compliance labels and inspection stickers are current.
If ultrasonic thickness testing is due (per inspection schedule or risk assessment), perform UT measurements at the specified test points and record readings.
Review the risk assessment and update if there have been any changes to operating conditions, contents or environment. Complete all compliance documentation per AS 3788 and update the vessel inspection register.
Record any defects, recommendations or corrective actions in the notes section. Set the next inspection date and sign off.

In MapTrack, you can register every pressure vessel, schedule annual and internal inspections, complete inspection forms on mobile, attach photos and track compliance status across your entire fleet of pressure equipment. Book a demo to see how.

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Frequently asked questions

What is a pressure vessel annual inspection under AS 3788?: AS 3788 (Pressure Equipment - In-service Inspection) requires pressure vessels to be inspected at regular intervals to confirm they remain safe for continued operation. The annual inspection includes external visual examination for corrosion, bulging, dents and cracking, inspection of all nozzles and connections, pressure gauge verification, safety relief valve testing, drain valve check, nameplate and records verification, foundation and support inspection, weld inspection, ultrasonic thickness testing (if due), risk assessment review and compliance documentation. The inspection must be performed by a competent person as defined by AS 3788.
Who can perform a pressure vessel inspection?: Under AS 3788, a pressure vessel inspection must be performed by a competent person. A competent person is someone who has acquired, through training, qualification or experience (or a combination of these), the knowledge and skills to carry out the inspection. In most Australian jurisdictions, this means a qualified pressure equipment inspector, a mechanical engineer with relevant experience, or a person accredited by a recognised inspection body. The inspector must be independent of the operator for statutory inspections.
How often does a pressure vessel need to be inspected?: AS 3788 specifies inspection intervals based on a risk-based approach. As a general guide: annual external visual inspections, internal inspections every 3-6 years (depending on service conditions and risk assessment), and hydrostatic or proof tests as determined by the risk assessment. Higher-risk vessels (corrosive contents, high temperature, high pressure) may require more frequent inspection. The vessel owner and inspector must establish an inspection plan based on the specific vessel conditions.
Is the template free to use without MapTrack?: Yes. Download and use the pressure vessel annual inspection checklist for free. Open the file and use your browser's Print, then Save as PDF. No MapTrack account required. If you later want to digitise your pressure vessel inspection register with scheduling, alerts and compliance tracking linked to each vessel, we would be happy to show you MapTrack.

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Register every pressure vessel in MapTrack. Schedule annual and internal inspections, complete inspection forms on mobile, attach photos, track wall thickness trends and get automatic alerts before inspections are overdue.

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