Free pressure vessel annual inspection record
Free annual pressure vessel inspection record (printable PDF). Use when a competent person approves a 12-month review. Record scope, findings and actions.
Updated 15 Aug 2026
Pressure Vessel Annual Inspection Record
Use when an approved inspection plan sets a 12-month review
External Visual Inspection
Fittings / Instruments
Nameplate / Records
NDT / Thickness Testing
Risk Assessment / Compliance
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Key takeaways
- The MapTrack pressure vessel annual inspection record contains 17 checks across 5 sections. Sections covered: External Visual Inspection, Fittings / Instruments, Nameplate / Records, NDT / Thickness Testing, Risk Assessment / Compliance.
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What is a pressure vessel annual inspection record?
A pressure vessel annual inspection record is a schedule-specific form for a 12-month review only when a competent person or inspection body has approved that interval in the equipment inspection plan. It records the agreed scope, external observations, safety-device evidence, nameplate and operating history, thickness readings where required, findings, corrective actions and the basis for the next due date. The current Australian edition is AS 3788:2024, Pressure equipment - In-service inspection. It superseded AS/NZS 3788:2006. This free record does not reproduce the standard, set an inspection interval or certify compliance or fitness for service.
The model WHS Regulations require pressure equipment to be inspected on a regular basis by a competent person, but they do not set a blanket annual interval. The applicable strategy, scope, interval, acceptance criteria and fitness-for-service decision depend on the equipment, its service history, degradation mechanisms, manufacturer information, the current standard and the law in the state or territory where it operates. Use this annual record only after a competent person confirms that a 12-month review is appropriate. Keep the completed form with measurements, certificates, photographs, repair records and corrective actions so the next reviewer can trace the decision history.
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Benefits of using this pressure vessel annual inspection record
- Safety: pressure vessel failure can be catastrophic. Regular inspection identifies corrosion, cracking and wall thinning before they reach dangerous levels.
- Traceable interval basis: record why a 12-month review applies instead of presenting annual inspection as a universal rule.
- Reduced downtime: identifying deterioration early allows planned repairs or replacement instead of emergency shutdowns.
- Action ownership: assign each defect, recommendation and supporting test to an owner and due date.
- Equipment history: retain wall-thickness readings, findings, repairs and operating changes beside the vessel record.
- Review evidence: show what was examined, which method was used, who made the decision and what happens next.
Benefits of digitising forms in MapTrack
When you digitise pressure vessel service procedures 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).
- Trigger work orders automatically when a fault is logged during an inspection.
- Track service intervals by hours, kilometres or calendar date in one place.
- Attach supplier invoices and parts receipts to each maintenance record.
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What to include in a pressure vessel annual inspection record
This pressure vessel annual inspection record covers 5 key areas:
- External visual inspection: examine vessel body for corrosion, bulging, dents, cracks and paint condition; inspect nozzles, connections, insulation/lagging, foundations, supports, welds, bolted connections and flanges.
- Fittings / instruments: record pressure-gauge calibration status, safety-relief-valve test or certification evidence, drain valve condition and sight glass or level-gauge condition.
- Nameplate / records: verify nameplate data matches records, review operating log for pressure/temperature excursions, verify compliance labels and inspection stickers.
- NDT / thickness: ultrasonic thickness testing if due per inspection schedule or risk assessment.
- Decision basis: record the approved inspection plan, applicable edition, scope, findings, acceptance decision, actions and next due date.
How to use this pressure vessel annual inspection record
- Confirm the vessel is safe to approach. If the vessel is in service, coordinate with operations for safe access. Record vessel details: description, registration number, serial number, design pressure, contents and location.: Check with operations that the vessel is in a safe, stable condition before approaching. If the vessel is pressurised, ensure appropriate exclusion zones are maintained. Record the vessel description, state registration number, serial number, design pressure, MAWP, operating temperature, contents and physical location on the inspection form.
- Perform the external visual inspection: examine the entire vessel surface for corrosion, bulging, dents, cracks and paint deterioration. Inspect all nozzles, connections, insulation and lagging.: Walk around the entire vessel and systematically inspect every visible surface. Look for general corrosion, localised pitting, bulging (indicating overpressure or creep), dents (indicating impact), cracking at weld toes and paint deterioration. Remove insulation covers at designated inspection points and check for corrosion under insulation (CUI). Inspect all nozzles and connections for leaks.
- Check foundations and supports for corrosion, settlement or cracks. Inspect all welds visually (use dye penetrant testing if any concerns are identified). Inspect bolted connections and flanges for leaks and gasket condition.: Inspect saddle supports, skirts and legs for corrosion, cracking and settlement. Check anchor bolts for looseness. Visually inspect all accessible welds for cracking, porosity and undercut. If any visual indication is found, apply dye penetrant testing (DPT) to confirm. Check all flanged connections for leak staining and gasket condition.
- Review the pressure gauge calibration status and safety relief valve test or certification evidence. Inspect the drain valve and sight glass or level gauge within the approved scope.: Record the pressure gauge range, condition and current calibration evidence. Record the safety relief valve identifier, set pressure and current test or certification evidence. Any functional or bench testing must follow the approved procedure and be performed by competent personnel. Record the drain valve and sight glass or level-gauge condition without operating equipment outside the authorised test scope.
- Verify nameplate data is legible and matches records. Review the operating log for any pressure or temperature excursions. Verify compliance labels and inspection stickers are current.: Read the nameplate and confirm all data (manufacturer, serial number, MAWP, design temperature, test pressure) matches the vessel file records. Review the operating log or SCADA data for any pressure or temperature events that exceeded design limits since the last inspection. Check that the state inspection sticker and compliance labels are current.
- If ultrasonic thickness testing is due (per inspection schedule or risk assessment), perform UT measurements at the specified test points and record readings.: Prepare the vessel surface at each designated test point by grinding to bare metal. Apply couplant gel and use a calibrated UT gauge to measure wall thickness at each point. Record readings and compare to the minimum calculated wall thickness for the vessel design conditions. Flag any readings approaching the minimum and schedule follow-up.
- Review the approved inspection plan and decision basis. Record any changes to operating conditions, contents, environment or degradation history and update the vessel inspection register.: Record the current standard edition, jurisdictional requirements, approved inspection strategy and any changes to operating pressure, temperature, contents, corrosion rate or environment. The competent person should document the acceptance or fitness-for-service decision and any conditions, repairs, testing or interval changes. A blank or completed checklist does not itself certify compliance.
- Record defects, recommendations and corrective actions. Have the competent person approve the next due date and sign the decision record.: Document findings, measurements, supporting certificates and defects. Assign every corrective action to an owner and due date. Record the next inspection date only after the competent person or inspection body has approved it from the current inspection plan and findings. Obtain the inspector and equipment owner acknowledgements.
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Get the free templateEnter your email above to download the full pressure vessel annual inspection record as a PDF.Back to download formHow often should you complete this service procedure?
Use this annual record only when a competent person or inspection body has approved a 12-month review in the equipment inspection plan. AS 3788:2024 requires the inspection strategy, scope and interval to be determined from the equipment, its condition, service, degradation history, inspection findings and risk assessment. It does not support copying fixed three-to-six-year or six-to-twelve-year intervals from a generic page or the superseded 2006 edition.
The model WHS Regulations require pressure equipment to be inspected on a regular basis by a competent person. They do not set a blanket annual frequency. Also check the manufacturer instructions, design documentation, registration conditions and the current law in the state or territory where the equipment operates. Record the approved interval basis and next due date on the completed inspection report so later reviewers can see who made the decision and why.
Frequently asked questions
Applicable regulatory standards
This is a general record, not an inspection plan or certification of compliance. Annual applies only where a competent person or inspection body has approved a 12-month review. Confirm the current standard and amendments, jurisdictional requirements, inspection strategy, scope, acceptance criteria, interval and fitness-for-service decision before use.
- AS 1210:2010 - Pressure Vessels
- AS 3788:2024 - Pressure equipment - In-service inspection, including current amendments
- Model WHS Regulations, regulation 224 - Pressure equipment
- Safe Work Australia Code of Practice: Managing Risks of Plant in the Workplace
Pressure vessel annual inspection record preview
The numbers behind this pressure vessel annual inspection record
Every figure below is sourced and dated, so you can quote it in a toolbox talk, a budget case or a board paper without having to chase the original report.
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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 annual inspection 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;">External visual inspection: examine vessel body for corrosion, bulging, dents, cracks and paint condition; inspect nozzles, connections, insulation/lagging, foundations, supports, welds, bolted connections and flanges.</li>
<li style="margin:4px 0;">Fittings / instruments: record pressure-gauge calibration status, safety-relief-valve test or certification evidence, drain valve condition and sight glass or level-gauge condition.</li>
<li style="margin:4px 0;">Nameplate / records: verify nameplate data matches records, review operating log for pressure/temperature excursions, verify compliance labels and inspection stickers.</li>
<li style="margin:4px 0;">NDT / thickness: ultrasonic thickness testing if due per inspection schedule or risk assessment.</li>
<li style="margin:4px 0;">Decision basis: record the approved inspection plan, applicable edition, scope, findings, acceptance decision, actions and next due date.</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-annual-inspection" style="color:#071D49;font-weight:600;text-decoration:none;">Pressure vessel annual inspection 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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The MapTrack pressure vessel annual inspection record contains 17 checks across 5 sections.
- Short attribution
- MapTrack Pressure vessel annual inspection record, https://www.maptrack.com/templates/pressure-vessel-annual-inspection
- Reference list
- MapTrack. (2026). Pressure vessel annual inspection record [Checklist template]. Retrieved from https://www.maptrack.com/templates/pressure-vessel-annual-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-vessel-annual-inspection.
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