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Free pressure vessel inspection checklist
Free pressure vessel inspection checklist (PDF-ready). Covers external and internal inspection, safety valves, gauges and corrosion checks. Download free.
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20 checks · 3 sections · Sign-off
20 checks
The fields in the printable form, in a view that fits your screen.
- Date
- Vessel ID / Tag no.
- Description
- Location
- Design pressure
- Operating pressure
- Inspector
- Registration no.
External Inspection
Safety Devices
Fittings & Connections
Declaration
This pressure vessel has been inspected in accordance with AS/NZS 3788 and is / is not (circle one) fit for continued service. Any items marked as Fail require corrective action before the vessel may be returned to service.
Inspector Sign-off
Signature · Print name · Date
Plant Manager Sign-off
Signature · Print name · Date
The MapTrack pressure vessel inspection checklist contains 20 checks across 3 sections.
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Key takeaways
- The MapTrack pressure vessel inspection checklist contains 20 checks across 3 sections. Sections covered: External Inspection, Safety Devices, Fittings & Connections.
- 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.
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.
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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.
What to include in a pressure vessel inspection checklist
- 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.
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.
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Frequently asked questions
Practical answers about the form, record keeping and using MapTrack.
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).
Link to this answerAS/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.
Link to this answerPressure 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.
Link to this answerThickness 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.
Link to this answerYes, 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 schedules each inspection, emails the assigned person in the week before it falls due, and stores completed records in the cloud for instant retrieval during audits.
Link to this answerApplicable regulatory standards
This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.
- AS/NZS 3788
- AS 1210
- AS/NZS 1200
- WHS Regulations 2011, Chapter 5
MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.
The numbers behind this pressure vessel inspection checklist
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The MapTrack pressure vessel inspection checklist contains 20 checks across 3 sections.
- Short attribution
- MapTrack Pressure vessel inspection checklist, https://www.maptrack.com/templates/pressure-vessel-inspection-checklist
- Reference list
- MapTrack. (2026). Pressure vessel inspection checklist [Checklist template]. Retrieved from https://www.maptrack.com/templates/pressure-vessel-inspection-checklist
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-vessel-inspection-checklist.
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<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 vessel inspection checklist</p>
<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Vessel details: date, vessel ID/tag number, description, location, design pressure, operating pressure, inspector, registration number.</li>
<li style="margin:4px 0;">External inspection: 7 pass/fail checks covering shell, corrosion, welds, insulation, supports, nozzles and nameplates.</li>
<li style="margin:4px 0;">Safety devices: 5 pass/fail checks covering safety/relief valve, pressure gauge, rupture disc and isolation valves.</li>
<li style="margin:4px 0;">Fittings and connections: 4 pass/fail checks covering sight glasses, drain valves, level indicators and gaskets.</li>
<li style="margin:4px 0;">Thickness testing: table with location, minimum design thickness, measured thickness, corrosion rate and next measurement due.</li>
<li style="margin:4px 0;">Internal inspection: 4 pass/fail checks covering internal surfaces, lining/coating, internals and sediment.</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-vessel-inspection-checklist" style="color:#071D49;font-weight:600;text-decoration:none;">Pressure vessel inspection checklist</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.
About the author
Co-Founder & Commercial Director
Jarrod has spent over a decade in technology consulting and asset management, including roles at Accenture (mining and heavy industry) and CGI as an Asset Management Consultant. He co-founded MapTrack and built and scaled its original platform, then rebuilt it with Lachlan and Alex from thousands of customer conversations and 300+ user research sessions with field teams. His consulting background gives him deep insight into the operational and compliance challenges facing asset-intensive Australian businesses.
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