Free pressure relief valve inspection and 5-year overhaul record
Free pressure relief valve inspection template per AS 1271 and AS 3788. Annual visual check and 5-year bench test with set pressure verification.
Updated 5 May 2026
Pressure Relief Valve Inspection and 5-Year Overhaul Record
Annual visual inspection and periodic bench test per AS 1271 and AS 3788
1. Documentation Review
2. Annual Visual Inspection
3. Operational Checks - Annual
4. 5-Year Bench Test - Disassembly
5. 5-Year Bench Test - Set Pressure Verification
6. 5-Year Overhaul - Repair/Replace
7. Post-Overhaul Certification
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Key takeaways
- The MapTrack pressure relief valve inspection and 5-year overhaul record contains 35 checks across 7 sections. Sections covered: 1. Documentation Review, 2. Annual Visual Inspection, 3. Operational Checks - Annual, 4. 5-Year Bench Test - Disassembly, 5. 5-Year Bench Test - Set Pressure Verification, 6. 5-Year Overhaul - Repair/Replace, 7. Post-Overhaul Certification.
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What is a pressure relief valve inspection and 5-year overhaul record?
A pressure relief valve (PRV) inspection template covers the dual-interval maintenance regime required for pressure relief devices protecting pressure vessels, boilers and process equipment. Under AS 3788 (Pressure equipment - In-service inspection) and AS 1271 (Safety valves, other valves, liquid level gauges and other fittings for boilers and unfired pressure vessels), PRVs must receive an annual visual inspection in situ and a comprehensive bench test and overhaul at intervals not exceeding 5 years. The annual inspection checks body condition, discharge piping, external corrosion, seal integrity, manual lift lever function and general condition. The 5-year overhaul requires removal from service, complete disassembly, cleaning, internal inspection of seat and disc, set pressure verification on a calibrated test bench (within plus or minus 3% of nameplate set pressure per AS 1271), lapping or replacement of seating surfaces, spring inspection, reassembly and final set pressure test.
PRVs are the last line of defence against catastrophic overpressure events. A failed or incorrectly set PRV can result in a pressure vessel rupture, which is one of the most violent and destructive industrial incidents possible. WHS Regulations 2011 classify most pressure vessels as registered plant, requiring documented maintenance regimes that include PRV testing. Insurance policies for pressure equipment universally require evidence of current PRV maintenance. This template documents both the annual visual inspection and the 5-year bench test in a single format, providing a complete maintenance history for each valve.
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Benefits of using this pressure relief valve inspection and 5-year overhaul record
- Overpressure protection: confirms that the last line of defence against vessel rupture is functional and set at the correct pressure, protecting personnel and equipment.
- Dual-interval tracking: manages both the annual visual inspection and the 5-year bench test overhaul on a single valve record, preventing either interval from being missed.
- Regulatory compliance: satisfies AS 3788 and AS 1271 requirements for documented PRV maintenance as part of the pressure equipment in-service inspection programme.
- Set pressure accuracy: the bench test verifies the valve opens within plus or minus 3% of the nameplate set pressure, ensuring protection activates before the vessel reaches its design limit.
- Insurance evidence: provides the documentary proof that insurers require before covering pressure equipment, as most policies condition coverage on current PRV certification.
- Failure prevention: identifies degraded seats, corroded internals, weakened springs and blocked discharge piping before they prevent the valve from operating when needed.
Benefits of digitising forms in MapTrack
When you digitise pressure relief valve 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 relief valve inspection and 5-year overhaul record
This pressure relief valve inspection and 5-year overhaul record covers 9 key areas:
- Valve identification: tag number, serial number, manufacturer, model, size, set pressure, discharge capacity, material of construction, protected equipment ID.
- Annual visual inspection: body condition (corrosion, leaks, damage), discharge piping (blockages, corrosion, correct routing), inlet piping (isolation valve position, blockages), cap and seal (intact, not tampered), manual lift test result.
- Test bench data (5-year overhaul): as-found set pressure, as-found blowdown, seat leakage before overhaul, internal condition assessment.
- Overhaul details: parts replaced (disc, seat, spring, seals), lapping performed, cleaning method, reassembly torque values.
- Post-overhaul test results: as-left set pressure (must be within plus or minus 3% of nameplate), as-left blowdown, seat leakage test (zero leakage required), back-pressure test if applicable.
- Test equipment: test bench identification, calibration certificate number and expiry date, test medium (air, nitrogen, water).
- Outcome: pass (return to service), fail (repair/replace), adjusted (now within tolerance).
- Technician details: name, qualifications, employer, signature, date.
- Next inspection due dates: next annual visual and next 5-year bench test.
How to use this pressure relief valve inspection and 5-year overhaul record
- Perform the annual visual inspection with the valve in situ on the pressure equipment.: Inspect the valve body externally for corrosion, mechanical damage and evidence of leakage (staining, deposits). Check the discharge piping for blockages, corrosion and correct routing to a safe location. Verify the inlet isolation valve (if fitted) is locked open. Confirm the cap and seal wire are intact and have not been tampered with. If the valve has a manual lift lever, operate it briefly to confirm the valve lifts and reseats.
- At the 5-year interval, remove the valve from service and perform as-found testing on the test bench.: Isolate and depressurise the protected equipment. Remove the PRV. Mount the valve on a calibrated test bench and determine the as-found set pressure (the pressure at which the valve actually opens). Record the as-found blowdown and check for seat leakage below set pressure. Compare the as-found set pressure to the nameplate. Deviation beyond plus or minus 3% indicates the valve was not providing correct protection.
- Disassemble, inspect internals, clean and recondition the valve.: Fully disassemble the valve. Inspect the disc and nozzle seat for wear, pitting, erosion and corrosion. Check the spring for corrosion, permanent set and cracking. Inspect the body bore, guide surfaces and bellows (if fitted). Lap the seat and disc if wear is minor. Replace any component that does not meet the manufacturer serviceability criteria. Record all parts replaced.
- Reassemble the valve and perform the set pressure verification test.: Reassemble the valve with new seals and gaskets. Mount on the test bench and adjust the set pressure to the nameplate value. Verify that the valve opens within plus or minus 3% of the nameplate set pressure. Verify the blowdown is within the manufacturer specification. Perform a seat leakage test below set pressure to confirm zero leakage. Record all test data.
- Reinstall the valve, apply seals, update records and set next due dates.: Reinstall the valve on the protected equipment. Apply a new seal wire and lead seal to prevent unauthorised adjustment. Verify the inlet isolation valve is locked open. Complete the inspection record with all test data, technician details and certification. Set the next annual visual inspection and 5-year bench test due dates in the maintenance system.
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Get the free templateEnter your email above to download the full pressure relief valve inspection and 5-year overhaul record as a PDF.Back to download formHow often should you complete this checklist?
Annual visual inspections are required every 12 months for all PRVs in service. The comprehensive bench test and overhaul is required at intervals not exceeding 5 years per AS 3788. More frequent testing may be required for valves in corrosive service, valves that have operated (lifted), or valves protecting critical equipment. Some insurers require 3-year bench testing for specific applications. In MapTrack, dual-interval scheduling manages both the annual and 5-year cycles independently, ensuring neither is missed while maintaining the complete service history for each valve across its installed life.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- AS 1271 Safety valves, other valves, liquid level gauges and other fittings for boilers and unfired pressure vessels
- AS 3788 Pressure equipment - In-service inspection
- AS 4343 Pressure equipment - Hazard levels
- WHS Regulations 2011, Chapter 5 (registered plant - pressure equipment)
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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 relief valve inspection and 5-year overhaul record</p>
<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Valve identification: tag number, serial number, manufacturer, model, size, set pressure, discharge capacity, material of construction, protected equipment ID.</li>
<li style="margin:4px 0;">Annual visual inspection: body condition (corrosion, leaks, damage), discharge piping (blockages, corrosion, correct routing), inlet piping (isolation valve position, blockages), cap and seal (intact, not tampered), manual lift test result.</li>
<li style="margin:4px 0;">Test bench data (5-year overhaul): as-found set pressure, as-found blowdown, seat leakage before overhaul, internal condition assessment.</li>
<li style="margin:4px 0;">Overhaul details: parts replaced (disc, seat, spring, seals), lapping performed, cleaning method, reassembly torque values.</li>
<li style="margin:4px 0;">Post-overhaul test results: as-left set pressure (must be within plus or minus 3% of nameplate), as-left blowdown, seat leakage test (zero leakage required), back-pressure test if applicable.</li>
<li style="margin:4px 0;">Test equipment: test bench identification, calibration certificate number and expiry date, test medium (air, nitrogen, water).</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-relief-valve-inspection" style="color:#071D49;font-weight:600;text-decoration:none;">Pressure relief valve inspection and 5-year overhaul record</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.
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Writing about this topic? You’re welcome to quote this checklist. Here’s the wording to use so your readers can find the original.
The MapTrack pressure relief valve inspection and 5-year overhaul record contains 35 checks across 7 sections.
- Short attribution
- MapTrack Pressure relief valve inspection and 5-year overhaul record, https://www.maptrack.com/templates/pressure-relief-valve-inspection
- Reference list
- MapTrack. (2026). Pressure relief valve inspection and 5-year overhaul record [Checklist template]. Retrieved from https://www.maptrack.com/templates/pressure-relief-valve-inspection
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-relief-valve-inspection.
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