A pressure vessel inspection checklist is used by engineers and boiler inspectors to help ensure that pressure vessels are safe to hold liquids and gases under pressure. It is used when conducting external and internal inspection of pressure vessels, as well as inspecting safety devices and piping systems. This SafetyCulture (formerly iAuditor) template is created based on a document on the inspection of unfired pressure vessels. Inspectors can use this to:
A pressure vessel inspection, also known as a boiler inspection, is a regular safety check to ensure vessels are in proper working condition. It involves visually inspecting the vessels to confirm they can safely hold liquids or gases under pressure, preventing failures that could lead to costly property damage, harm to business reputation, or loss of life.
Boilers and pressure vessels vary by shape, construction materials, working pressure, vessel threads, safety features, and maintenance features. Engineers, safety officers, or boiler inspectors use pressure vessel inspection checklists to help maintain the good working condition of pressure vessels and their safety accessories which keep liquid and gas pressure in check. Boilers are common devices for industrial heating and humidification applications, and pressure vessels are used to hold liquids, vapors, or gases at high pressures.
Below are the general items to check during pressure vessel inspections:
External Inspection
Internal Inspection
Safety Devices
Piping Systems
Generally, pressure vessels should be inspected at least once every two years and tested at least once every five years. Visual examinations of pressure vessels, or storage tanks/vessels that operate at pressures above 15 psig (pound-force per square inch gauge), should also be conducted after installation, before operation, and during maintenance to detect potential cracks and ensure boiler and pressure vessel safety. This also applies to high-pressure vessels that will require regular inspections and monitoring.
Inspection requirements for pressure vessels depend on country-specific regulations such as the Pressure Systems Safety Regulations of 2000 ( PSSR ) in the UK, regional guidelines such as the Pressure Equipment Directive of 2014 ( PED ) from the European Commission, and applicable industry standards such as the Boiler and Pressure Vessel Code of the American Society of Mechanical Engineers ( ASME ).
There are several causes of pressure vessel failure that can have dangerous consequences if not caught early and immediately corrected during routine inspections. Consider these common reasons why pressure vessels become unfit for use and watch out for them during routine inspections.
Error in vessel design, plate material used, construction, or installation can cause cracks and erosion on boilers and pressure vessels that could lead to leakage or rupture. Compliance with industry standards for the manufacture of boiler pressure vessel valves can help prevent failures and other hardware issues.
Welding, coating, and other methods of pressure vessel repair that do not conform with standards may not properly address issues and render the vessel unsafe for use. Periodic inspections should be conducted by engineers or boiler inspectors to proactively determine if boilers, pressure vessels, and safety devices are still in good working condition or already in need of repair or replacement.
Prolonged use of pressure vessels without periodic maintenance or routine inspections can lead to catastrophic accidents. Whether inspections are done annually or every 4 hours, they can help keep the vessels at optimal condition and prevent unforeseen accidents if they are conducted by competent personnel.
Wrong material used and lack of internal audits contributed to the rupture of a pressure vessel in 2009 that caused injury, damage to nearby businesses, and loss of life in the state of Illinois.
SafetyCulture can help engineers and inspectors conduct external and internal inspections of pressure vessels to determine their soundness to withstand pressure while holding liquids or gases. With SafetyCulture, you can:
This pressure vessel safety checklist is used for routine inspections of pressure vessels in a German-owned discount supermarket chain with over 10,000 stores in 20 countries. Use this checklist to record details of compressor packs, system racks, and enthalpy units and take photos of the low temperature receiver, pressure relief valve discharge point, and medium temperature receiver. Easily customize this checklist to meet your business needs using SafetyCulture’s drag-and-drop template editor.
Inspection template Powered byA boiler inspection checklist is used for inspecting oil or gas-fired boilers before issuance of certification. Use this checklist to perform an internal, external, and operational inspection of boilers and specify boiler efficiency details such as Oxygen %, Stack Temp., PSI, and more. Converted using SafetyCulture, select Safe-At Risk-N/A when inspecting insulation, safety relief valve, and combustion control system, among others.
Inspection template Powered byA boiler log sheet is used to document the daily inspection of boilers to make sure that the pressure and temperature are within the recommended range. Use this log template to record scheduled daily inspection or multiple inspections within a day to maintain the safety of boilers. Utilize SafetyCulture’s scheduling feature and don’t miss another periodic boiler inspection.
Inspection template Powered byUse this pressure vessel risk assessment template when a new boiler, pressure vessel, or new equipment is to be installed and determine possible risks from a new equipment and changes in processes within the workplace.
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SafetyCulture Content TeamThe SafetyCulture content team is dedicated to providing high-quality, easy-to-understand information to help readers understand complex topics and improve workplace safety and quality. Our team of writers have extensive experience at producing articles for different fields such as safety, quality, health, and compliance.
This pressure vessel safety checklist is used for routine inspections of pressure vessels in a German-owned discount supermarket chain with over 10,000 stores in 20 countries. Use this checklist to record details of compressor packs, system racks, and enthalpy units and take photos of the low temperature receiver, pressure relief valve discharge point, and medium temperature receiver. Easily customize this checklist to meet your business needs using SafetyCulture’s drag-and-drop template editor.
A boiler inspection checklist is used for inspecting oil or gas-fired boilers before issuance of certification. Use this checklist to perform an internal, external, and operational inspection of boilers and specify boiler efficiency details such as Oxygen %, Stack Temp., PSI, and more. Converted using SafetyCulture, select Safe-At Risk-N/A when inspecting insulation, safety relief valve, and combustion control system, among others.
A boiler log sheet is used to document the daily inspection of boilers to make sure that the pressure and temperature are within the recommended range. Use this log template to record scheduled daily inspection or multiple inspections within a day to maintain the safety of boilers. Utilize SafetyCulture’s scheduling feature and don’t miss another periodic boiler inspection.
Use this pressure vessel risk assessment template when a new boiler, pressure vessel, or new equipment is to be installed and determine possible risks from a new equipment and changes in processes within the workplace.
