Pressure Vessel Inspection Mistakes That End Badly

Overview

Pressure vessels store enormous energy. When they fail, they can fail violently, which is why AS 3788 sets out requirements and guidance for 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 pressure-equipment failure can have serious safety and operational consequences. Overdue or poorly scoped inspections can also create unplanned downtime while condition is assessed.

Inspection planning should consider the equipment classification, service history, applicable requirements and advice from appropriately qualified personnel.

Why Use Appropriately Qualified Personnel

• In-service inspection planned with reference to AS 3788 where applicable
• Ultrasonic thickness testing tracks corrosion rates over time
• Crack detection at nozzles, welds and stress points
• Engineering assessment where remaining-life evaluation is within scope
• Clear records of the completed inspection scope, findings and limitations