Pressure Equipment in Operation: What Risks Can a Regular Inspection Reveal?
A pressure vessel that has maintained pressure without any problems for years may have a wall weakened by corrosion inside—a condition that no one is aware of—until it is detected during a routine inspection. Designated technical pressure equipment is among those where a failure does not result in merely a shutdown, but poses a real risk of explosion or a leak of the contained medium, which is precisely why the law establishes a separate inspection regime for such equipment, distinct from routine maintenance.
Pressure equipment can be found in manufacturing facilities, warehouses, and even ordinary commercial operations more often than one might think—air tanks for compressors, CO2 pressure vessels in food service establishments, steam and hot-water boilers, or pressure vessels in process distribution systems. If such equipment is classified as designated technical equipment under Act No. 250/2021 Coll., on occupational safety in connection with the operation of designated technical equipment, and the related Government Regulation No. 192/2022 Coll., on designated technical pressure equipment, specific obligations regarding periodic inspections apply to it—regardless of how reliably the equipment has functioned to date.
This article explains the basic concepts related to inspections, checks, and technical examinations Inspection, check, technical inspection, and technical test—what’s the difference?. A similar principle—that routine maintenance and independent inspections address different issues—also applies to gas equipment, as described in the article Gas Equipment Inspection vs. Boiler Maintenance. However, the risk of failure is an order of magnitude higher for pressure vessels, which is why we will examine them in greater detail.
What exactly is considered regulated pressure equipment?
The classification of designated pressure equipment depends on a combination of volume, operating pressure, and the hazardous nature of the medium—so it is not limited to large industrial boiler rooms. In practice, operators of commercial facilities most often encounter designated pressure equipment in the following situations:
• stable pressure vessels—air receivers for compressors in a production hall or workshop,
• pressure vessels for CO₂ or other industrial gases, typically in food service establishments and warehouses,
• steam and hot-water boilers and related pressurized piping systems in industrial facilities.
The classification of a specific vessel or boiler into a group—and thus the scope and frequency of inspections—is determined by the inspection technician; however, the operator should be aware that such equipment is present on the premises even before someone asks about it during an inspection.
What Risks Does an Audit Actually Reveal?
Unlike electrical wiring or gas lines, where the main risk is a malfunction or leak, with pressure equipment the primary concern is the mechanical integrity of the vessel or boiler itself—what an inspection reveals often shows no outward signs at all:
| Findings from the audit | Why Is This a Risk? |
| Corrosion or weakening of the vessel wall (both inside and outside) | It reduces the vessel’s ability to withstand operating pressure without this being visible from the outside. |
| Weld defect or mechanical damage | A location with reduced strength where the vessel may rupture under normal operating pressure. |
| A malfunctioning or improperly adjusted safety valve | The device is losing its last safety mechanism against overpressure. |
| Incorrectly Calibrated Pressure Gauge | The operator cannot see the actual operating pressure and is therefore unable to respond to a deviation in a timely manner. |
| Leaks in Fittings and Connections | A leak of a hazardous substance (steam, hot water, or gas) that poses a risk of burns or an explosion. |
That is precisely why inspections of pressure equipment include not only visual inspections and functional tests, but also—for certain types—internal inspections or pressure tests, which verify the condition of the vessel’s material directly, rather than indirectly through the equipment’s behavior during operation.
How often are inspections and tests conducted?
Government Regulation No. 192/2022, Coll. distinguishes between several types of inspections based on what they specifically verify:
| Type of Action | Approximate frequency |
| Operational Inspection (External) | Usually once a year |
| Internal Audit | Usually once every 5 years |
| Pressure Test | Usually once every 9 years |
| Technical inspection by operating personnel | According to local operating procedures, typically between inspections |
| Rule of thumb: The exact type and inspection interval for a specific vessel or boiler are determined by the inspection technician based on the equipment category, operating pressure, and medium. The table is intended as a general guide—for pressure equipment, it is not advisable to wait until the deadline has passed, because downtime due to an unscheduled inspection is usually more costly than a scheduled one. |
Who Is Authorized to Inspect Pressure Equipment
Inspections of designated pressure equipment may only be performed by a pressure equipment inspection technician who holds a certificate in accordance with Act No. 250/2021 Coll. and Government Regulation No. 194/2022 Coll. — This is a separate qualification, distinct from that of inspectors for electrical or gas equipment. Furthermore, for internal inspections and pressure tests, it is usually necessary to take the vessel out of service and make it accessible from the inside, which should be planned in advance rather than rushed after a problem is discovered.
What Are the Risks of Not Having a Valid Inspection?
Operating designated pressure equipment without a valid inspection has three main consequences:
• is at risk during an inspection by the State Labor Inspection Office or a regional labor inspectorate sanctions and corrective measures,
• In the event of a claim (container rupture, media leak, burn injury), the insurance company may reduce or deny coverage if the equipment did not have a valid inspection,
• Without an independent inspection, the operator has no information about the actual condition of the vessel’s interior—and with pressure vessels, this is precisely the risk that does not manifest externally until a failure occurs.
Checklist: Do You Have Your Pressure Equipment Under Control?
☐ Overview of All Pressure Equipment in the Building
Including less obvious ones, such as compressor air tanks or CO2 pressure vessels used in food service operations.
☐ Common classifications and timeframes for individual devices
Operational inspections, internal inspections, and pressure tests have different deadlines, and it’s easy to overlook one of them.
☐ Certified Inspection Technician Qualification
A certification specifically for the inspection of pressure equipment, not just general technical training.
☐ Scheduled Outage for Internal Audit
The container must be moved aside and made accessible from the inside—without prior arrangement, this means an unplanned service interruption.
☐ Previous inspection reports and documentation of defect corrections
It will allow us to follow up on the most recent status and verify that previous defects have indeed been corrected.
☐ Functioning safety valves and calibrated pressure gauges
The final safety valve against overpressure, which is always checked during inspections.
FAQ
Does the air tank on the compressor need to be inspected even if it’s just a small tank?
If a vessel meets the criteria for designated technical pressure equipment under Government Regulation No. 192/2022 Coll. based on its volume and pressure, it is subject to inspections regardless of the fact that it is “merely” a compressor air tank. Classification is verified by an inspection technician.
What is the difference between an external audit and an internal audit?
An external (operational) inspection is performed during operation or with minimal downtime and primarily assesses the external condition and functionality of safety components. An internal inspection requires the vessel to be shut down and opened so that a technician can assess the condition of the material from the inside—therefore, it takes longer and must be planned in advance.
What happens if an inspection reveals a defect in the vessel?
In the event of safety-related defects, operation of the equipment is suspended until it is repaired or replaced. For less serious findings, the inspection report sets a deadline for correction, after which a follow-up inspection is usually conducted.
Can we have our in-house maintenance technician perform the inspection of the pressure vessel?
No. Inspections may only be performed by an inspection technician who is specifically certified for pressure equipment, not by just any technically qualified employee or maintenance worker.
Do inspections still apply automatically even after the equipment has been moved or modified?
No. Moving a pressure vessel, making changes to the piping system, or altering operating parameters constitutes grounds for an extraordinary inspection, regardless of when the last regular inspection took place.
Inspections of pressure equipment linked to the technical registry, not just to a calendar
Compared to other designated equipment, pressure equipment is unique in that there are often multiple types of it in a building (vessels, boilers, piping systems) with different inspection deadlines—and this is precisely where it’s easy to miss a deadline. INTECHI Client Portal That is why inspections of all pressure equipment in the building are conducted on a per-piece basis, rather than just generally for the building as a whole:
• Tracking Deadlines — The system tracks the deadlines for operational inspections, internal inspections, and pressure tests for each piece of equipment separately and will notify you by email well in advance so that none of them go unnoticed.
• Pairing with Device Cards — Inspection reports and logs are stored directly for a specific tank or boiler, not for the facility as a whole, so you can access the history of a single piece of equipment with just a few clicks.
• Automation of Follow-Up Steps — You enter the detected defect directly into the system as a repair request; the INTECHI dispatch center sees it immediately and schedules a technician as well as a follow-up inspection.
• Importing CAD Files and Drawings — You can upload wiring diagrams and technical data sheets for tanks directly into the system and link them to a specific piece of equipment.
• Document Processing and Archiving — Inspection reports, pressure test records, and defect rectification documentation are all stored digitally in one place, where they can be easily accessed for audits, insurance purposes, and SÚIP inspections.
How INTECHI Handles It
INTECHI provides inspections of designated pressure equipment for commercial facilities throughout the Czech Republic—from individual compressors in production halls to pressure vessels in food service establishments and boiler rooms in shopping centers. You can find a clear overview of all scheduled operational and internal inspections and pressure tests in one place in the client portal, including the equipment history and documentation for any potential audits.
