Pressure Vessel Registration Malaysia: DOSH Requirements, Certificate of Fitness & Compliance Guide
Every factory operating air receivers, heat exchangers, autoclaves, or storage tanks must register these pressure vessels with DOSH and maintain a valid Certificate of Fitness (CF). This guide covers which vessels require registration, the step-by-step process, exemptions, fees, and how to avoid compliance failures that can shut down your operations.
Disclaimer: This article provides general guidance based on publicly available information as of January 2025. Regulations and fees change periodically. Always verify current requirements with DOSH or authorised inspection bodies before making compliance decisions.
If your facility operates air compressors, you almost certainly have pressure vessels that require DOSH registration. The same applies to factories with autoclaves, heat exchangers, LPG storage, or any equipment holding gases or liquids under pressure.
Operating a pressure vessel without a valid Certificate of Fitness (CF) can result in fines up to RM100,000, operational shutdowns, and personal liability for directors.
This guide covers:
- Which pressure vessels require registration (and which are exempt)
- The complete registration process from design approval to CF issuance
- Renewal requirements and inspection cycles
- Common compliance failures and how to avoid them
What Counts as a Pressure Vessel Under Malaysian Law
A pressure vessel is any container designed to hold gases or liquids at pressures above atmospheric. Under DOSH regulations, these are classified as Unfired Pressure Vessels (UPV) because they don't generate pressure through combustion like boilers do.
| Equipment Type | Common Applications | Registration Required? |
|---|---|---|
| Air receivers | Compressed air systems, pneumatic tools | Yes (if above exemption threshold) |
| Heat exchangers | Cooling systems, HVAC, process heating | Yes |
| Autoclaves | Sterilisation, medical devices, laboratories | Yes |
| LPG storage tanks | Fuel storage, industrial heating | Yes |
| Refrigerant receivers | Cold storage, air conditioning systems | Yes |
| Vacuum tanks | Chemical processing, food manufacturing | Yes (if designed for pressure) |
| Surge tanks | Water treatment, pipeline systems | Yes |
| Process reactors | Chemical manufacturing, pharmaceuticals | Yes |
| Gas storage cylinders | Industrial gases, welding | Separate regulations apply |
The legal framework comes from the Occupational Safety and Health Act 1994 (as amended in 2022) and the Occupational Safety and Health (Plant Requiring Certificate of Fitness) Regulations 2024 (P.U.(A) 99/2024), which replaced provisions from the older Factories and Machinery Act 1967.
Pressure Vessel Exemptions: Which Equipment Doesn't Need CF
Not every pressure vessel requires a Certificate of Fitness. The Factories and Machinery (Exemption of Certificate of Fitness for Unfired Pressure Vessel) Order 2017 provides specific exemptions.
| Exemption Criteria | Details |
|---|---|
| Size threshold | Internal diameter, width, height, or diagonal cross-section not exceeding 6 inches (152.4mm), regardless of pressure or length |
| Design pressure threshold | Vessels where ID × Design Pressure ≤ 3000 psi-inch may have simplified requirements |
| Portable gas cylinders | Covered under separate gas cylinder regulations |
Practical Examples
| Equipment | Typical Size | Exempt? |
|---|---|---|
| Small workshop compressor (50L tank) | ~300mm diameter | No, requires CF |
| Large industrial air receiver (1000L) | ~800mm diameter | No, requires CF |
| Mini refrigerant receiver (2L) | ~100mm diameter | Yes, likely exempt |
| Heat exchanger shell | 400mm+ diameter | No, requires CF |
The exemption exists for genuinely small equipment where the stored energy risk is minimal. But here's what catches many facility managers: even a standard workshop air compressor typically has a receiver tank larger than 6 inches in diameter.
If you're unsure whether your equipment requires registration, assume it does. The consequences of non-compliance far outweigh the cost of verification.
Legal Requirements: What the Law Actually Says
The regulatory framework for pressure vessels changed significantly on 1 June 2024 when the OSHA amendments took effect and the Factories and Machinery Act 1967 was repealed.
| Regulation | What It Covers |
|---|---|
| OSHA 1994 (as amended 2022) | Overall framework, employer duties, penalties |
| P.U.(A) 99/2024 | Certificate of Fitness requirements for pressure vessels, boilers, lifting equipment |
| FM (Steam Boiler & UPV) Regulations 1970 | Design standards, inspection requirements (still referenced for technical standards) |
| Exemption Order 2017 | Which vessels don't need CF |
Key Legal Obligations for Facility Owners
| Requirement | Legal Basis | Your Obligation |
|---|---|---|
| Design approval before installation | Section 27B OSHA 1994 | Submit design drawings to DOSH before fabrication or import |
| Certificate of Fitness before operation | P.U.(A) 99/2024 Clause 3 | Cannot operate without valid CF |
| Periodic inspection and renewal | FM Regulations 1970 Reg. 25 | Renew CF before expiry (typically every 15 months) |
| Competent person supervision | Section 27D OSHA 1994 | Registered competent person must oversee operation |
| Record keeping | Various | Maintain maintenance logs, inspection reports, CF documents |
Penalties for Non-Compliance
| Offence | Penalty |
|---|---|
| Operating without valid CF | Up to RM100,000 fine and/or 1 year imprisonment |
| Failure to comply with safety notices | Up to RM500,000 fine and/or 2 years imprisonment |
| Continuing offence | Additional RM1,000 per day |
| Director/officer liability | Personal prosecution possible under Section 52 OSHA |
These penalties apply to the facility owner or occupier. "I didn't know" isn't a defence.
The Registration Process: Step by Step
Registering a new pressure vessel involves four stages. Skip any stage, and you can't legally operate the equipment.
Stage 1: Design Approval
Before your pressure vessel is manufactured (if local) or imported, you need DOSH design approval from the Unfired Pressure Vessel Unit at DOSH Headquarters in Putrajaya.
| Document Required | Purpose |
|---|---|
| Design drawings | Shows vessel construction, dimensions, materials |
| Design calculations | Proves vessel can safely handle specified pressure |
| Material certificates | Confirms materials meet required standards |
| Manufacturer's data report | For imported vessels, from the original manufacturer |
| ASME certification (if applicable) | For ASME-coded vessels |
Where to submit: DOSH Headquarters, Putrajaya (for design approval)
Processing time: DOSH targets 15 working days for unfired pressure vessel design approvals
Stage 2: Installation
Once design approval is granted, you can install the equipment. But installation itself has requirements.
| Requirement | Details |
|---|---|
| Follow approved design | Any deviation requires notification to DOSH |
| Qualified installers | Must have relevant competency |
| Documentation | Keep installation records for future inspections |
| Safety devices | Pressure relief valves, gauges must be fitted correctly |
Stage 3: Initial Inspection
After installation, request an inspection from DOSH or a licensed inspection body.
| Inspection Element | What Inspectors Check |
|---|---|
| Physical condition | No visible damage, corrosion, or defects |
| Safety devices | Pressure relief valves, gauges functioning correctly |
| Installation compliance | Matches approved design |
| Supporting documentation | Design approval, material certificates, manufacturer data |
| Pressure test | Hydrostatic test may be required |
Stage 4: Certificate of Fitness Issuance
If inspection passes, DOSH issues the Certificate of Fitness (CF). This is your legal authority to operate.
| CF Details | Information |
|---|---|
| Form | Form B (Sixth Schedule, FM Regulations 1970) |
| Validity | Typically 15 calendar months from inspection date |
| Extended validity | Up to 3 years at Chief Inspector's discretion for well-maintained equipment |
| Display requirement | Keep CF on-site, available for inspection |
The CF is also known as PMT (Perakuan Mesin Tekanan) in Malay. The old term "PMA" (Perakuan Memperbolehkan Alat) was used under the repealed Factories and Machinery Act but has been replaced by the standardised "Certificate of Fitness" terminology under OSHA 1994.
Renewal Process and Inspection Cycles
Your CF expires. Operating with an expired CF is the same as operating without one: illegal.
When to Apply for Renewal
| Timeline | Action Required |
|---|---|
| 60 days before expiry | Submit renewal application to state DOSH office |
| 30 days before expiry | Minimum lead time (may face delays if left this late) |
| Before expiry date | Inspection must be completed and new CF issued |
| After expiry | Cannot legally operate until new CF issued |
Pre-Inspection Preparation
DOSH inspectors (or licensed inspection bodies) will examine your equipment. Preparation matters.
| Preparation Task | Why It Matters |
|---|---|
| Internal and external cleaning | Allows proper visual inspection |
| Drain condensate | Ensures accurate assessment of vessel condition |
| Check safety valves | Must be functional, may need calibration certificates |
| Check pressure gauges | Must be accurate and readable |
| Prepare maintenance records | Inspectors want to see 15-month maintenance history |
| Arrange vessel access | Manways, inspection ports must be accessible |
Non-Destructive Testing (NDT) Requirements
For older vessels or those with suspected degradation, inspectors may require NDT before renewing the CF.
| NDT Method | Purpose | Typical Application |
|---|---|---|
| Ultrasonic Thickness Testing (UTT) | Measures wall thickness to detect corrosion | Required for vessels >5 years old |
| Radiographic Testing (RT) | Inspects weld quality | After repairs or modifications |
| Magnetic Particle Inspection (MPI) | Detects surface cracks in ferromagnetic materials | After suspected damage |
| Dye Penetrant Inspection (DPI) | Detects surface cracks in non-magnetic materials | Stainless steel vessels |
NDT must be conducted by qualified NDE Level II inspectors. Keep the reports; you'll need them for the CF renewal application.
Fees and Costs
DOSH fees for pressure vessel registration and renewal are set by regulation. Third-party services like inspection and NDT are market-priced.
DOSH Official Fees
| Fee Type | Estimated Range |
|---|---|
| Design approval | Varies by vessel size and complexity |
| Certificate of Fitness (initial) | Set by regulation |
| CF renewal | Set by regulation |
Note: DOSH fees are updated periodically. Check current fees at the state DOSH office or MyKKP portal.
Third-Party Service Costs
| Service | Estimated Cost Range |
|---|---|
| Pre-inspection servicing | RM500 – RM2,000 per vessel |
| Ultrasonic thickness testing | RM300 – RM800 per vessel |
| Safety valve calibration | RM150 – RM400 per valve |
| Full compliance package (inspection + NDT + documentation) | RM1,500 – RM5,000 per vessel |
These are rough estimates. Actual costs depend on vessel size, location, urgency, and the service provider.
How to Register and Renew: The MyKKP Portal
All DOSH applications now go through the MyKKP online system.
| Portal | URL |
|---|---|
| MyKKP Single Sign-On | https://mykkp.dosh.gov.my |
Registration Steps
- Create an account on MyKKP (if you don't have one)
- Register your premises with DOSH (required before machinery registration)
- Submit design approval application (for new vessels)
- After installation, submit CF application
- Schedule inspection through the portal
- Pay fees through the portal
- Download CF once approved
Renewal Steps
- Log into MyKKP
- Navigate to machinery renewal section
- Upload inspection report and NDT results (if required)
- Pay renewal fees
- Inspection scheduled automatically or manually
- New CF issued after successful inspection
Common Compliance Failures (And How to Avoid Them)
These are the mistakes that get facilities into trouble.
| Mistake | Consequence | How to Avoid |
|---|---|---|
| Expired CF | Immediate shutdown order, fines up to RM100,000 | Set calendar reminders 90 days before every CF expiry |
| Missing design approval | Cannot obtain CF, vessel must be taken out of service | Never install without checking design approval status |
| No maintenance records | CF renewal may be refused | Implement 15-month maintenance log for every vessel |
| Safety valve not tested | Inspection failure | Annual calibration, keep certificates |
| Unregistered premises | Cannot register any machinery | Ensure factory registration (Pendaftaran Kilang) is current |
| Using wrong inspector | Invalid inspection, wasted time and money | Verify inspector is DOSH-licensed for pressure vessels |
| Modifications without approval | Original CF void, full re-registration required | Any modification requires DOSH notification |
The Hidden Cost of Non-Compliance
Beyond fines, consider what happens when DOSH issues a stop-work order on your pressure vessels.
If your air compressor system is shut down, your pneumatic tools, automated equipment, and packaging lines stop. If your autoclave is shut down, your sterilisation process halts. If your heat exchangers are shut down, your cooling systems fail.
One expired CF can cascade into an entire production shutdown.
Pressure Vessel Compliance Checklist
Use this to assess your current compliance status.
| Category | Checkpoint | Status |
|---|---|---|
| Inventory | Complete list of all pressure vessels on-site | ☐ |
| Inventory | Each vessel identified by serial number and location | ☐ |
| Documentation | Design approval on file for each vessel | ☐ |
| Documentation | Current CF on file for each vessel | ☐ |
| Documentation | CF expiry dates tracked in calendar/system | ☐ |
| Documentation | Maintenance logs current for each vessel | ☐ |
| Safety devices | Safety valves tested and calibrated | ☐ |
| Safety devices | Pressure gauges accurate and readable | ☐ |
| Safety devices | Drain valves functional | ☐ |
| Condition | No visible corrosion, damage, or leaks | ☐ |
| Condition | NDT conducted for vessels >5 years old | ☐ |
| Personnel | Competent person registered for operation | ☐ |
| Premises | Factory registered with DOSH | ☐ |
| Insurance | Boiler and pressure vessel insurance in place | ☐ |
If you have any unchecked boxes, you have compliance gaps to address.
Industries Most Affected by Pressure Vessel Regulations
Almost every manufacturing and industrial facility has at least one pressure vessel. Some industries have many.
| Industry | Common Pressure Vessels | Typical Quantity |
|---|---|---|
| Food manufacturing | Autoclaves, steam vessels, refrigerant receivers | 5-20+ per facility |
| Pharmaceutical | Autoclaves, reactors, storage tanks | 10-50+ per facility |
| Chemical manufacturing | Reactors, storage tanks, heat exchangers | 20-100+ per facility |
| Electronics (E&E) | Cleanroom air systems, autoclaves | 5-15 per facility |
| Oil & gas | Separators, storage tanks, heat exchangers | 50-200+ per facility |
| Palm oil processing | Heat exchangers, storage vessels | 20-50 per facility |
| Any facility with compressed air | Air receivers | 1-10 per facility |
For manufacturing facilities, pressure vessel compliance is often just one part of a broader equipment registration obligation that includes lifting equipment (cranes, hoists) and steam boilers.
FAQ
What is a Certificate of Fitness (CF) for pressure vessels?
A Certificate of Fitness is an official document issued by DOSH confirming that a pressure vessel is safe to operate. Without a valid CF, operating the vessel is illegal and can result in fines up to RM100,000. The CF is issued after inspection confirms the vessel meets safety standards.
How long is a pressure vessel CF valid?
The standard validity period is 15 calendar months from the date of inspection. The Chief Inspector may extend this to up to 3 years for well-maintained equipment with good inspection history. Apply for renewal at least 30-60 days before expiry to avoid gaps.
Which pressure vessels are exempt from CF requirements?
Pressure vessels with an internal diameter, width, height, or diagonal cross-section not exceeding 6 inches (152.4mm) are generally exempt, regardless of pressure or length. This covers genuinely small equipment. Most industrial air receivers, heat exchangers, and autoclaves exceed this threshold and require registration.
How much does pressure vessel registration cost?
DOSH fees are set by regulation and vary by vessel size. Third-party costs for inspection, NDT testing, and compliance services typically range from RM1,500 to RM5,000 per vessel, depending on size, condition, and testing requirements. Check current DOSH fees at the MyKKP portal.
What happens if I operate with an expired CF?
Operating without a valid CF is an offence under OSHA 1994. Penalties include fines up to RM100,000 and/or imprisonment up to 1 year. DOSH can issue immediate stop-work orders. Directors and officers can face personal prosecution. Insurance claims may also be affected if equipment wasn't legally certified.
Do I need separate registration for the premises and the equipment?
Yes. Your factory or premises must be registered with DOSH (Pendaftaran Kilang) before you can register machinery. This is a common oversight: facilities try to register equipment without having valid premises registration, which delays the entire process.
Can any inspector conduct pressure vessel inspections?
No. Inspections must be conducted by DOSH officers or licensed inspection bodies authorised under OSHA 1994. Using an unlicensed inspector makes the inspection invalid. Verify your inspector's DOSH registration before engaging them.
What is the difference between PMT, PMD, and PMA?
PMT (Perakuan Mesin Tekanan) refers to unfired pressure vessels. PMD (Perakuan Mesin Dandang) refers to steam boilers. PMA (Perakuan Mesin Angkat) refers to lifting equipment like cranes and hoists. All three require separate CF registration with DOSH.
Foundation Conclusion
Pressure vessel compliance protects your operations from shutdowns, your personnel from catastrophic equipment failures, and your business from regulatory penalties. Most facilities have more pressure vessels than they realise, from the air receiver behind the compressor to heat exchangers in process cooling systems.
But compliance alone doesn't protect you from the financial consequences of equipment failure. A pressure vessel explosion or rupture can cause property damage, business interruption, and third-party liability claims that far exceed any regulatory fine.
Boiler and pressure vessel insurance covers the risks that compliance can't prevent: sudden equipment breakdown, explosion damage, and the resulting business interruption. This specialised cover complements your industrial property insurance to ensure your high-risk equipment is properly protected.
Talk to Foundation about pressure vessel coverage for your facility
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