Product Overview

Summary: This Leak Detection Safe Operating Procedure sets out a clear, step-by-step method for safely identifying, assessing and responding to leaks in Australian workplaces. It helps businesses control environmental, fire, health and asset risks associated with gas, chemical, water and fuel leaks, while demonstrating compliance with WHS obligations and industry best practice.

Leaks of gas, chemicals, water or fuels can quickly escalate from a minor nuisance to a serious safety, environmental and business continuity incident. This Leak Detection Safe Operating Procedure provides a structured approach for recognising early warning signs, using appropriate detection equipment, and implementing immediate controls to protect workers, the public and the environment. It is designed to suit a wide range of Australian workplaces, including manufacturing plants, warehouses, commercial buildings, laboratories, healthcare facilities and utilities.

The SOP outlines how to plan and conduct routine leak inspections, respond safely to suspected or confirmed leaks, and escalate issues in line with WHS and environmental requirements. It clarifies roles and responsibilities, specifies required personal protective equipment (PPE), and details isolation, communication and reporting steps. By standardising leak detection practices, this procedure reduces reliance on informal knowledge, supports consistent training, and gives PCBUs a defensible framework to demonstrate due diligence under Australian WHS law.

Key Benefits

• Reduce the risk of fire, explosion and exposure incidents arising from undetected gas or vapour leaks.
• Ensure consistent, documented leak detection practices across shifts, sites and contractors.
• Support compliance with Australian WHS, environmental and dangerous goods regulations.
• Minimise downtime, product loss and property damage through early identification and isolation of leaks.
• Improve worker confidence by providing clear guidance on when and how to escalate suspected leaks and emergencies.

Who is this for?

• WHS Managers
• Maintenance Supervisors
• Facilities Managers
• Operations Managers
• Site Supervisors
• Process Engineers
• HVAC Technicians
• Plumbers
• Gas Fitters
• Laboratory Managers
• Environmental, Health and Safety (EHS) Coordinators

Hazards Addressed

• Flammable gas and vapour leaks leading to fire or explosion
• Toxic gas or chemical vapour exposure to workers and building occupants
• Leaks of refrigerants contributing to asphyxiation risks and environmental harm
• Water leaks causing slips, trips and falls or electrical hazards
• Fuel and oil leaks resulting in ground and water contamination
• Corrosive chemical leaks damaging plant, equipment and infrastructure
• Confined space atmospheric hazards due to undetected leaks
• Mould growth and indoor air quality issues from persistent moisture leaks

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities
• 4.0 Leak Types, Systems and Risk Profile
• 5.0 Required Training, Competency and Authorisations
• 6.0 Required Tools, Instruments and Personal Protective Equipment (PPE)
• 7.0 Pre-Inspection Planning and Risk Assessment
• 8.0 Routine Leak Inspection Procedure
• 9.0 Response to Suspected or Confirmed Leaks
• 10.0 Isolation, Evacuation and Notification Requirements
• 11.0 Use, Calibration and Maintenance of Leak Detection Equipment
• 12.0 Environmental Protection and Spill Containment Considerations
• 13.0 Communication, Reporting and Recordkeeping
• 14.0 Incident Investigation and Corrective Actions
• 15.0 Review, Audit and Continuous Improvement
• 16.0 Appendices – Checklists, Inspection Forms and Example Risk Controls

Legislation & References

• Work Health and Safety Act 2011 (Cth) and mirror WHS Acts in Australian states and territories
• Work Health and Safety Regulations 2011 (Cth) – Hazardous chemicals, hazardous atmospheres and confined spaces
• Safe Work Australia – Code of Practice: Managing risks of hazardous chemicals in the workplace
• Safe Work Australia – Code of Practice: Managing the work environment and facilities
• AS/NZS 60079 series: Explosive atmospheres (for flammable gas and vapour leak risk areas)
• AS/NZS 4343: Pressure equipment – Hazard levels (where applicable to pressurised systems)
• AS/NZS 3666 series: Air-handling and water systems of buildings – Microbial control (for HVAC-related leaks)
• AS/NZS 5149 series: Refrigerating systems and heat pumps – Safety and environmental requirements