How often must pressure vessels be inspected under AS/NZS 3788?

AS/NZS 3788 specifies inspection intervals based on the risk category and condition of the vessel. For most pressure vessels, the standard requires an external inspection every 3 years and an internal inspection (or equivalent non-destructive examination) every 6 years, with a condition assessment every 12 years. However, these intervals may be shorter for higher-risk vessels, vessels in corrosive service, or where previous inspections have identified accelerated degradation. The inspection body or competent person may also recommend shorter intervals based on the vessel condition. Statutory requirements vary by state and territory, so always check with your local regulator.

Who can inspect a pressure vessel in Australia?

Pressure vessel inspections must be performed by a competent person with relevant qualifications and experience. In most Australian states and territories, this means a person registered or accredited as a pressure vessel inspector under the relevant dangerous goods or WHS legislation. Many organisations engage third-party inspection bodies accredited by NATA or recognised by the state regulator. The inspector must have knowledge of AS/NZS 3788, AS 1210 and the specific degradation mechanisms relevant to the vessel type and service.

What is thickness testing and why is it important for pressure vessels?

Thickness testing, typically performed using ultrasonic testing equipment, measures the wall thickness of a pressure vessel at designated points. By comparing current measurements to the original or minimum design thickness, inspectors can calculate the corrosion rate and estimate the remaining service life of the vessel. This information is critical for planning maintenance, determining fitness for continued service and scheduling replacements before the wall thickness reaches a dangerous level. AS/NZS 3788 requires thickness testing as part of the inspection programme.

Is this pressure vessel inspection checklist free to download?

Yes, this pressure vessel inspection checklist is completely free to download as a PDF. No account or signup is required. For teams wanting to move beyond paper forms, MapTrack offers a digital version that automates scheduling, sends overdue alerts, and stores completed records in the cloud for instant retrieval during audits.

Free pressure vessel inspection checklist

Q: What is a pressure vessel inspection?

A pressure vessel inspection is a systematic examination of a vessel that operates under pressure , such as boilers, air receivers, heat exchangers and process vessels , to verify its structural integrity, safety device function and fitness for continued service. The inspection covers external examination (shell, heads, welds, insulation, supports, nozzles), safety devices (safety/relief valves, pressure gauges, rupture discs), fittings (sight glasses, drain valves, level indicators), thickness testing (ultrasonic measurement at designated points), and internal examination where accessible. In Australia, pressure vessel inspections are governed by AS/NZS 3788 (In-service inspection of pressure equipment) and AS 1210 (Pressure vessels).

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Free pressure vessel inspection checklist (PDF-ready). Covers external and internal inspection, safety valves, gauges and corrosion checks. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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Updated 3 May 2026

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What is a pressure vessel inspection checklist?

A pressure vessel inspection checklist is a structured document used to conduct a systematic examination of a vessel that operates under pressure, verifying its structural integrity, safety device function and fitness for continued service. The inspection covers external examination (shell, heads, welds, insulation, supports, nozzles and flanges), safety devices (safety/relief valves, pressure gauges, rupture discs), fittings (sight glasses, drain valves, level indicators), thickness testing (ultrasonic measurement at designated points to determine corrosion rates), and internal examination where the vessel can be safely entered or examined with remote equipment. In Australia, pressure vessel inspections are governed by AS/NZS 3788 (In-service inspection of pressure equipment) and AS 1210 (Pressure vessels).

Pressure vessel failures can result in catastrophic explosions, fatalities, environmental contamination and extensive property damage. The consequences of failure make regular inspection essential for any organisation operating boilers, air receivers, heat exchangers, process vessels or other pressure equipment. AS/NZS 3788 establishes a risk-based inspection framework that determines the type and frequency of inspection based on the vessel risk category, operating conditions and degradation history. Documented inspection records are required by state and territory regulators, insurers and safety management systems to demonstrate that pressure equipment is being maintained in a safe condition. The WHS Regulations 2011, Chapter 5, further require that plant designed to operate under pressure is inspected by a competent person at the intervals specified by the relevant Australian Standard.

Learn more about compliance and inspections in MapTrack.

Benefits of using this pressure vessel inspection checklist

Safety: prevent catastrophic failure by identifying corrosion, cracking and other degradation before it reaches critical levels.
Regulatory compliance: meet AS/NZS 3788 inspection intervals and state/territory registration requirements for pressure equipment in your jurisdiction.
Operational continuity: planned inspections reduce unplanned shutdowns, costly emergency repairs and the associated production losses from equipment being out of service.
Corrosion trending: thickness testing at each inspection builds a corrosion rate history, enabling remaining-life calculations and proactive replacement planning.
Insurance compliance: many insurers require documented pressure vessel inspections as a condition of coverage, and claims may be denied if records are missing or incomplete.
Audit trail: documented inspections provide verifiable evidence for state regulators, insurers, internal safety audits and incident investigations involving pressure equipment.

Benefits of digitising forms in MapTrack

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

Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
Automatically get alerts when faults are identified.
Link every form digitally as a PDF to the relevant asset, location or person.
Receive a digital PDF copy with every submission to your email.
Ability to share forms digitally.
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.
Restrict permissions (who can view, complete or approve).
Build forms with AI (describe what you need and MapTrack suggests the form).
Set recurring audit schedules with automatic reminders and escalation.
Produce regulator-ready PDF compliance packs in one click.
Track corrective actions from finding to close-out with full audit trail.

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What to include in a pressure vessel inspection checklist

This pressure vessel inspection checklist covers 8 key areas:

Vessel details: date, vessel ID/tag number, description, location, design pressure, operating pressure, inspector, registration number.
External inspection: 7 pass/fail checks covering shell, corrosion, welds, insulation, supports, nozzles and nameplates.
Safety devices: 5 pass/fail checks covering safety/relief valve, pressure gauge, rupture disc and isolation valves.
Fittings and connections: 4 pass/fail checks covering sight glasses, drain valves, level indicators and gaskets.
Thickness testing: table with location, minimum design thickness, measured thickness, corrosion rate and next measurement due.
Internal inspection: 4 pass/fail checks covering internal surfaces, lining/coating, internals and sediment.
Compliance: registration status, next statutory inspection, design verification document.
Declaration and signatures: inspector and plant manager sign-off with AS/NZS 3788 fitness declaration.

How to use this pressure vessel inspection checklist

Complete the vessel details, including ID/tag number, description, location, design and operating pressure, inspector and registration number.: Confirm the vessel identity against the plant register and verify the registration number with the state or territory regulator. Record the design pressure and current operating pressure for comparison during the inspection.
Conduct the external inspection. Check the shell, heads, welds, insulation, supports, nozzles and nameplates. Mark pass or fail for each item.: Look for visible corrosion, bulging, cracking, weld defects, insulation damage, loose supports, leaking nozzles and illegible nameplates. Photograph any defects for inclusion in the inspection report.
Check all safety devices, including safety/relief valve set pressure, pressure gauge calibration, rupture disc and isolation valves.: Verify the safety/relief valve set pressure matches the design specification. Check the pressure gauge calibration date is current. Confirm the rupture disc is intact and isolation valves operate freely without leaking.
Inspect fittings and connections, including sight glasses, drain valves, level indicators and gaskets.: Check sight glasses for clarity and correct level indication. Operate drain valves to confirm they open and close fully. Inspect gaskets and flange faces for signs of leakage, corrosion or deterioration.
Conduct thickness testing at designated locations. Record measured thickness, calculate corrosion rate and determine next measurement date.: Use calibrated ultrasonic thickness testing equipment at each designated measurement point. Compare readings to the minimum design thickness and calculate the corrosion rate from previous readings. Schedule the next measurement based on remaining life.
If an internal inspection is performed, check internal surfaces, lining, internals and remove any sediment or deposits.: Where the vessel can be safely entered, inspect internal surfaces for pitting, erosion, cracking or lining failure. Check internal components such as baffles and trays. Remove sediment or deposits that could accelerate corrosion.
Complete the compliance section, including registration status, next statutory inspection and design verification.: Confirm the vessel registration is current with the relevant state or territory authority. Record the next statutory inspection due date and verify the design verification document is on file and accessible.
The inspector and plant manager sign the fitness declaration.: The inspector signs a declaration confirming the vessel is fit for continued service (or requires action) under AS/NZS 3788. The plant manager acknowledges the findings and accepts responsibility for implementing any corrective actions.

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

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How often should you complete this checklist?

AS/NZS 3788 specifies inspection intervals based on the risk category and condition of the pressure vessel. For most vessels, the standard requires an external inspection every 3 years and an internal inspection (or equivalent non-destructive examination) every 6 years. A condition assessment is required every 12 years. These intervals may be shorter for higher-risk vessels, vessels in corrosive service, or where previous inspections have identified accelerated degradation. State and territory regulations may impose additional requirements , always verify with your local regulator. Safety/relief valves should be tested or replaced every 3 to 5 years depending on service conditions.

Frequently asked questions

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS/NZS 3788
AS 1210
AS/NZS 1200
WHS Regulations 2011, Chapter 5

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