Product Overview

Summary: This SOP provides a clear, step-by-step framework for the safe use, inspection and maintenance of pressure equipment, including boilers, pressure vessels, air receivers and associated pipework. It is designed to help Australian workplaces control high-risk energy sources, prevent catastrophic failures, and demonstrate compliance with WHS legislation and relevant Australian Standards.

Pressure equipment such as boilers, steam systems, air compressors, autoclaves and pressure vessels present significant risks if not designed, operated and maintained correctly. Uncontrolled release of stored energy can result in explosions, serious burns, flying debris and long-term plant downtime. This Pressure Equipment Use and Maintenance Safe Operating Procedure provides a structured, practical approach to controlling those risks across the full lifecycle of the equipment – from pre-start checks and normal operation through to isolation, inspection, routine servicing and decommissioning.

Tailored for Australian workplaces, the SOP aligns with WHS obligations for managing high-risk plant and incorporates good practice drawn from key Australian Standards for pressure equipment. It helps businesses move beyond ad‑hoc maintenance and informal “tribal knowledge” by formalising how pressure systems are used, monitored and maintained. By implementing this procedure, organisations can demonstrate due diligence, support competency-based training for operators and maintenance personnel, reduce unplanned outages, and provide clear guidance on what to do if abnormal conditions, alarms or suspected faults occur.

Key Benefits

• Ensure consistent, safe operation of boilers, pressure vessels and compressed air systems across all shifts and locations.
• Reduce the likelihood of catastrophic pressure equipment failure, protecting workers, contractors and visitors from serious harm.
• Demonstrate compliance with WHS regulations and relevant Australian Standards for pressure equipment design, inspection and maintenance.
• Extend asset life and minimise unplanned downtime through structured inspections, preventative maintenance and defect reporting.
• Standardise training and competency assessment for operators and maintenance teams using clear, documented procedures.

Who is this for?

• Plant Managers
• Maintenance Supervisors
• WHS Managers
• Mechanical Fitters
• Boiler Operators
• Production Supervisors
• Facilities Managers
• Engineering Managers
• Authorised Persons for Pressure Equipment
• Health and Safety Representatives (HSRs)

Hazards Addressed

• Explosion or rupture of boilers, pressure vessels and air receivers
• Sudden release of compressed air, steam or process gases
• Burns and scalds from hot surfaces, steam and condensate
• Impact injuries from flying debris or component failure
• Noise exposure from high-pressure discharge and compressor operation
• Exposure to hazardous process media (e.g. refrigerants, chemicals, flammable gases)
• Stored energy hazards during maintenance and servicing (failure to isolate and de‑pressurise)
• Over‑pressurisation due to failed controls or blocked relief devices
• Manual handling strains during component replacement and maintenance
• Slips, trips and falls around wet or oily plant areas associated with pressure systems

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Pressure Equipment
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Manufacturer Requirements
• 5.0 Hazard Identification and Risk Assessment for Pressure Systems
• 6.0 Pre‑Start Inspections and Safety Checks
• 7.0 Normal Operation of Pressure Equipment
• 8.0 Monitoring, Alarms and Abnormal Operating Conditions
• 9.0 Isolation, Lockout/Tagout and Depressurisation Procedures
• 10.0 Routine Maintenance, Servicing and Calibration
• 11.0 In‑Service Inspection, Testing and Certification Requirements
• 12.0 Management of Defects, Non‑Conformances and Repairs
• 13.0 Emergency Response for Pressure Equipment Incidents
• 14.0 Housekeeping, Access and Environmental Controls around Pressure Plant
• 15.0 Training, Induction and Competency Assessment for Operators and Maintainers
• 16.0 Recordkeeping, Logs and Maintenance Documentation
• 17.0 Review, Audit and Continuous Improvement of the SOP

Legislation & References

• Model Work Health and Safety Act
• Model Work Health and Safety Regulations – Part 5: Plant and Structures
• Safe Work Australia – Managing Risks of Plant in the Workplace Code of Practice
• AS/NZS 1200: Pressure equipment
• AS 3788: Pressure equipment – In-service inspection
• AS 2593: Boilers – Safety management and supervision systems
• AS 4343: Pressure equipment – Hazard levels
• AS/NZS 3788: Pressure equipment – In-service inspection (where applicable by jurisdiction)
• AS/NZS 3000: Electrical installations (for associated electrical controls and interlocks)
• AS/NZS 4024 series: Safety of machinery (for guarding and control systems where integrated with pressure plant)