Free AS 3788 pressure vessel inspection checklist
Free AS 3788:2024 pressure vessel inspection record (printable PDF). Scope, findings, thickness readings, safety devices and sign-off. Download free.
Updated 10 Aug 2026
AS 3788 Pressure Vessel Inspection Checklist
General in-service inspection record referencing AS 3788:2024
| # | Basis | Inspection Item | S | U | N/A | Observations / Defects |
|---|---|---|---|---|---|---|
| e.g. | - | - | - | - | - | - |
| 1 | ||||||
| 2 | ||||||
| 3 | ||||||
| 4 | ||||||
| 5 |
The PDF includes all 34 numbered rows, ready to print or fill on screen.
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Key takeaways
- Records the in-service inspection of a pressure vessel: identification, external and internal condition, corrosion, fittings and the inspector verdict.
- Built around AS 3788 in-service inspection of pressure equipment, with the vessel identified by its design registration and serial number.
- External inspections monitor between internal ones. The internal inspection, with the vessel opened, is where wall condition is actually established.
- Under the model WHS Regulations, pressure equipment is plant with registration duties, and inspection records are part of keeping it lawfully in service.
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What is a AS 3788 pressure vessel inspection checklist?
An AS 3788 pressure vessel inspection record is a structured form for documenting the scope, methods, observations, measurements, findings and follow-up actions from an in-service pressure equipment inspection. The current Australian edition is AS 3788:2024, Pressure equipment - In-service inspection. Standards Australia states that it superseded AS/NZS 3788:2006 and revised inspection management and inspection requirements, including risk-based inspection. This free record keeps practical fields for external and internal observations, thickness readings, safety devices, equipment history and the competent person's decision basis. It does not reproduce the standard or certify that an inspection complies with it.
Pressure equipment can deteriorate through corrosion, erosion, fatigue, creep and other service-specific mechanisms. The applicable inspection strategy, scope, interval, acceptance criteria and fitness-for-service decision depend on the equipment, its history, operating conditions, degradation mechanisms, current standard and jurisdictional requirements. A competent person must set and verify those requirements before using this record. Keep the completed form with the vessel file, supporting measurements, test certificates, photographs, repair records and corrective actions so the owner has a traceable history for future inspection planning and regulatory review.
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Benefits of using this AS 3788 pressure vessel inspection checklist
- Traceable decision basis: record the applicable edition, inspection strategy, scope, methods and competent-person decision without treating a blank form as proof of compliance.
- Early defect visibility: document corrosion, cracking, distortion, thinning and safety-device concerns with observations, measurements, photographs and follow-up actions.
- Equipment history: keep current findings beside earlier inspections, repairs, operating changes and thickness readings so deterioration trends remain visible.
- Corrective-action ownership: assign each defect or further investigation to an owner, due date and verification step before the record is closed.
- Inspection planning: capture the competent person's interval basis and next due date instead of relying on an obsolete generic schedule.
- Asset-linked evidence: store the signed record, test certificates and supporting files against the pressure equipment asset for practical retrieval and review.
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 AS 3788 pressure vessel inspection checklist
This AS 3788 pressure vessel inspection checklist covers 11 key areas:
- Vessel identification: asset ID, serial number, registration number, make and manufacturer, design standard (e.g. AS 1210, AS/NZS 1200), design pressure and temperature, maximum allowable working pressure (MAWP), contents or service and location.
- Inspection basis: current standard edition and amendments checked, jurisdictional requirements, inspection strategy, scope, interval basis, previous inspection date and competent person.
- External visual examination: inspection of external surfaces for corrosion, pitting, bulging, dents, paint condition, insulation condition, foundation and support condition, external piping connections, earthing and cathodic protection status.
- Internal visual examination: inspection of internal surfaces for corrosion, erosion, cracking, pitting, lining or coating condition, baffle and tray condition (for columns), and deposits or scaling.
- Thickness measurements: ultrasonic thickness readings at designated monitoring points, comparison with previous readings and minimum required thickness calculations. Record wall thickness, nominal thickness and corrosion rate.
- Non-destructive testing (NDT): method, location, equipment and calibration details, results, acceptance basis and any further investigation required.
- Safety fittings: inspection and testing of pressure relief valves, safety valves, bursting discs, pressure gauges, level indicators, isolation valves and emergency shutdown systems.
- Welded joints and nozzles: examination of longitudinal and circumferential welds, nozzle welds, reinforcement pads, manway and handhole flanges for cracking, corrosion or distortion.
- Condition assessment: overall condition, remaining-life basis where determined, operating limitations, next inspection due date and recommended follow-up.
- Findings and corrective actions: list of all defects found, severity classification, corrective action required, responsible person, due date and follow-up verification requirements.
- Decision and sign-off: competent-person decision, limitations, signature, qualifications and date, plus owner or operator acknowledgement and corrective-action acceptance.
How to use this AS 3788 pressure vessel inspection checklist
- Confirm the current requirements and prepare the inspection basis before starting work.: A competent person should verify the current AS 3788 edition and amendments, applicable jurisdictional requirements, equipment file, inspection strategy, scope, interval basis and acceptance criteria. Record that basis separately from this template.
- Review the vessel identity, design records, operating history, previous inspections, repairs and known degradation mechanisms.: Confirm the registration number, serial number, design pressure, maximum allowable working pressure and service against the nameplate and equipment file. Identify operating changes, recurring defects and areas needing focused examination.
- Complete the planned external and internal examinations using the required safety controls and inspection methods.: Record accessible surfaces, welds, nozzles, supports, insulation, fittings and internal components examined. Follow isolation and confined-space procedures where applicable, and clearly note anything outside the planned scope or not accessible.
- Record measurements and non-destructive examination results against identified locations and the approved acceptance basis.: Capture equipment and calibration details, measurement point IDs, previous and current readings, calculated rates and the competent person's interpretation. Attach reports or marked-up drawings where the form is not detailed enough.
- Check pressure-relief devices, gauges, controls and safeguards within the approved inspection scope.: Record device identification, certificates, calibration or test evidence, observed condition and any limitations. Do not infer a test interval from this template; use the current inspection programme and competent-person decision.
- Document findings, corrective actions, operating limitations, the next inspection decision and sign-off.: The competent person should record the decision basis and any conditions for continued operation. Assign every action to an owner and due date, attach supporting evidence, and obtain owner or operator acknowledgement.
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 AS 3788 pressure vessel inspection checklist as a PDF.Back to download formHow often should you complete this checklist?
Do not set a pressure vessel inspection interval from this template or from the superseded 2006 edition. Under AS 3788:2024, selecting the inspection strategy and determining the inspection date or interval are part of the inspection process. The competent person or inspection body should determine the applicable approach from the current standard, equipment type, condition, service, degradation history, inspection findings and risk assessment.
Also check the legislation and registration requirements for the state or territory where the equipment operates, plus manufacturer instructions, design documentation, insurer conditions and any operating limitations. Record the approved interval basis and next due date on the completed inspection report so future reviewers can see how the decision was made.
Frequently asked questions
Applicable regulatory standards
This is a general record template, not a certification of compliance. A competent person must confirm the current standard and amendments, applicable jurisdictional requirements, inspection strategy, scope, acceptance criteria, interval and fitness-for-service decision.
- AS 3788:2024 (Pressure equipment - In-service inspection), including current amendments
- AS 1210 (Pressure vessels - Design)
- AS/NZS 1200 (Pressure equipment - General)
- WHS Regulations 2011 (Chapter 5 - Plant and structures)
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AS 3788 pressure vessel inspection checklist preview
The numbers behind this AS 3788 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;">AS 3788 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 identification: asset ID, serial number, registration number, make and manufacturer, design standard (e.g. AS 1210, AS/NZS 1200), design pressure and temperature, maximum allowable working pressure (MAWP), contents or service and location.</li>
<li style="margin:4px 0;">Inspection basis: current standard edition and amendments checked, jurisdictional requirements, inspection strategy, scope, interval basis, previous inspection date and competent person.</li>
<li style="margin:4px 0;">External visual examination: inspection of external surfaces for corrosion, pitting, bulging, dents, paint condition, insulation condition, foundation and support condition, external piping connections, earthing and cathodic protection status.</li>
<li style="margin:4px 0;">Internal visual examination: inspection of internal surfaces for corrosion, erosion, cracking, pitting, lining or coating condition, baffle and tray condition (for columns), and deposits or scaling.</li>
<li style="margin:4px 0;">Thickness measurements: ultrasonic thickness readings at designated monitoring points, comparison with previous readings and minimum required thickness calculations. Record wall thickness, nominal thickness and corrosion rate.</li>
<li style="margin:4px 0;">Non-destructive testing (NDT): method, location, equipment and calibration details, results, acceptance basis and any further investigation required.</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/as-3788-pressure-vessel-inspection" style="color:#071D49;font-weight:600;text-decoration:none;">AS 3788 pressure vessel inspection checklist</a> by MapTrack</p>
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- MapTrack. (2026). AS 3788 pressure vessel inspection checklist [Checklist template]. Retrieved from https://www.maptrack.com/templates/as-3788-pressure-vessel-inspection
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