Free pressure vessel inspection checklist
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A pressure vessel inspection checklist is used to examine vessels operating under pressure , boilers, air receivers, heat exchangers and process vessels , to verify structural integrity, safety device function and fitness for continued service. This page explains what to include, how to use the checklist, and offers a free PDF-ready template you can download and use straight away. No sign-up required.
Last updated: 2026-04-10 · MapTrack
Commercial Director
How to use: Complete vessel details → external inspection → check safety devices → fittings → thickness testing → internal inspection (if applicable) → compliance check → save as PDF.
- ✓ PDF-ready. Open and print to PDF
- ✓ Covers external/internal inspection, safety valves, gauges, corrosion and compliance
- ✓ Free to use with or without MapTrack
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What is a pressure vessel inspection?
A pressure vessel inspection is a systematic examination of a vessel that operates under pressure to verify 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).
Benefits of regular pressure vessel inspections
- 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.
- Operational continuity: planned inspections reduce unplanned shutdowns and costly emergency repairs.
- 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.
- Audit trail: documented inspections provide evidence for regulators, insurers and internal safety audits.
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Book a demo to see digital pressure vessel tracking with inspection scheduling in MapTrack.
What to include in a pressure vessel inspection checklist
Our free pressure vessel inspection checklist includes:
- 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 the pressure vessel inspection checklist
- Complete the vessel details , ID/tag number, description, location, design and operating pressure, inspector and registration number.
- Conduct the external inspection. Check the shell, heads, welds, insulation, supports, nozzles and nameplates. Mark pass or fail for each item.
- Check all safety devices , safety/relief valve set pressure, pressure gauge calibration, rupture disc and isolation valves.
- Inspect fittings and connections , sight glasses, drain valves, level indicators and gaskets.
- Conduct thickness testing at designated locations. Record measured thickness, calculate corrosion rate and determine next measurement date.
- If an internal inspection is performed, check internal surfaces, lining, internals and remove any sediment or deposits.
- Complete the compliance section , registration status, next statutory inspection and design verification.
- The inspector and plant manager sign the fitness declaration.
In MapTrack, you can digitise pressure vessel inspections with thickness trending, photo evidence and automated compliance reminders. Book a demo to see how.
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Back to download formInspection intervals under AS/NZS 3788
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
- 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).
- 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 , always check with your local regulator.
- What safety devices must be checked on a pressure vessel?
- Safety devices on a pressure vessel that must be checked include: safety/relief valves (confirm set pressure is correct, no leakage or fouling, and the valve can lift freely), pressure gauges (calibrated, readable, and accurately reflecting operating pressure), rupture discs (intact and not bulged, if fitted), isolation valves (operational and not seized), and any other protective devices such as level alarms, temperature sensors or automatic shutdown systems. Safety/relief valves must be tested or replaced at intervals specified in AS/NZS 3788 and the valve manufacturer's recommendations , typically every 3 years for process service and every 5 years for clean, non-corrosive service.
- Is the template free to use without MapTrack?
- Yes. You can download and use the pressure vessel inspection checklist for free. Open the file and use your browser's Print → Save as PDF to keep a copy. No MapTrack account required. If you later want digital pressure vessel tracking with inspection scheduling, thickness trend analysis and automated compliance reminders, we'd be happy to show you MapTrack.
Need digital pressure vessel tracking with inspection scheduling?
Digitise your pressure vessel inspections in MapTrack. Schedule inspections, track thickness trends, attach photos and get automated reminders when the next statutory inspection is due.