Pressure Vessel Inspection Mistakes That End Badly
Pressure equipment fails violently. The inspection mistakes that put plants at risk — and why AS 3788 in-service inspection needs certified professionals.
Overview
Pressure vessels store enormous energy. When they fail, they fail violently — which is why AS 3788 mandates systematic in-service inspection by competent people.
These are the pressure equipment inspection mistakes we encounter across Australian plants, and how professional inspection keeps you compliant and safe.
The Most Common Mistakes
- No inspection program at all — vessels running years past their last documented inspection
- External-only checks — internal corrosion and cracking develop unseen
- No wall thickness monitoring — corrosion rates can't be managed if they're never measured
- Ignoring 'minor' air receivers — small vessels are still pressure equipment under AS 3788
- Unassessed repairs and alterations — welding on pressure equipment without engineering review
- Missing documentation — no design registration, no inspection records, no defensible history
What These Mistakes Cost
A ruptured vessel can demolish a plant room. Even without catastrophe: SafeWork notices, refused insurance claims, and forced shutdowns while overdue inspections are completed.
AS 3788 places the responsibility squarely on the owner. An inspection program run by certified professionals is how that duty is discharged.
Why Use a Certified Professional
- In-service inspection to AS 3788 by certified inspectors
- Ultrasonic thickness testing tracks corrosion rates over time
- Crack detection at nozzles, welds and stress points
- Remaining-life assessment and clear inspection intervals
- Documentation that satisfies regulators and insurers
Frequently Asked Questions
Related Services
NDT Australia provides these services nationwide with certified, mobile inspectors and clear, compliant reporting.