Product Overview

Summary: This Safe Operating Procedure provides a clear, step-by-step method for safely pressure testing drilling equipment in Australian drilling, mining and oil & gas operations. It focuses on controlling high-pressure hazards, preventing catastrophic equipment failure, and demonstrating compliance with WHS duties and industry expectations.

Pressure testing of drilling equipment is one of the highest-risk activities on a rig or in a drilling workshop. Uncontrolled release of stored energy from high-pressure systems can result in fatal injuries, major equipment damage and extended downtime. This Safe Operating Procedure provides a structured, defensible method for planning and conducting pressure tests on drill strings, BOP components, hoses, valves and associated equipment, whether performed on-site, in a yard, or in a specialised test bay. It guides your team through pre-test inspections, test setup, exclusion zone management, communication protocols, controlled pressurisation, monitoring, depressurisation and post-test documentation.

By implementing this SOP, your business establishes a consistent and auditable approach to pressure testing that aligns with Australian WHS laws and recognised industry practice. It helps you eliminate ad-hoc testing methods, reduce reliance on “tribal knowledge”, and ensure that contractors and employees are working to the same standard. The procedure directly supports your duty of care by embedding risk assessment, permit-to-work integration, PPE requirements, and emergency response planning into every test. This not only reduces the likelihood of serious incidents, but also improves equipment reliability, extends asset life, and supports strong safety culture on every drilling project.

Key Benefits

• Reduce the risk of high-pressure failures, line-of-fire incidents and serious injuries during drilling equipment testing.
• Ensure pressure testing activities are consistent, documented and aligned with Australian WHS legislation and industry expectations.
• Improve reliability of drilling equipment by embedding thorough inspection, test acceptance criteria and defect management.
• Streamline training and onboarding for new drill crew, supervisors and contractors with a clear, step-by-step procedure.
• Demonstrate due diligence to clients, regulators and auditors through robust records, permits and sign-off requirements.

Who is this for?

• Drilling Supervisors
• Rig Managers
• Driller and Assistant Drillers
• Field Engineers
• Maintenance Supervisors
• WHS Managers and Advisors
• HSE Coordinators
• Oil & Gas Operations Managers
• Mining Production Supervisors
• Workshop Leading Hands (Drilling Equipment)

Hazards Addressed

• High-pressure fluid and gas release leading to injection injuries or impact trauma
• Projectile hazards from failed components, fittings or test plugs
• Line-of-fire exposure around pressurised hoses, pipes and connections
• Stored energy hazards during pressurisation and depressurisation
• Equipment failure due to incorrect assembly, incompatible components or over-pressurisation
• Noise exposure from sudden pressure release or equipment failure
• Slips, trips and falls in congested test areas with hoses, tools and equipment
• Chemical exposure from drilling fluids, test media or hydraulic oils
• Manual handling injuries when positioning heavy test equipment or components
• Environmental contamination from uncontrolled release of test fluids

Included Sections

• 1.0 Purpose and Scope – Pressure Testing of Drilling Equipment
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (Supervisors, Test Operators, Spotters, WHS Personnel)
• 4.0 Required Competencies, Training and Authorisations
• 5.0 Equipment, Tools and Test Media Requirements
• 6.0 Pre-Test Planning and Risk Assessment (JSA/SWMS, permits, SIMOPS review)
• 7.0 Site Preparation and Test Area Setup (barriers, signage, exclusion zones)
• 8.0 Pre-Use Inspection of Drilling Equipment and Test Apparatus
• 9.0 Connection, Assembly and Verification of Test Setup
• 10.0 Personal Protective Equipment (PPE) Requirements
• 11.0 Communication Protocols and Pre-Test Briefing (Toolbox Talk)
• 12.0 Step-by-Step Pressure Testing Procedure (pressurisation, hold, monitoring, acceptance criteria)
• 13.0 Depressurisation, Isolation and Making Safe
• 14.0 Management of Defects, Non-Conformances and Failed Tests
• 15.0 Emergency Response Procedures for High-Pressure Incidents
• 16.0 Environmental Controls and Waste Management for Test Fluids
• 17.0 Post-Test Documentation, Records and Reporting Requirements
• 18.0 Inspection, Maintenance and Storage of Test Equipment
• 19.0 Review, Audit and Continuous Improvement of the Procedure

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulations 2011 (Cth and relevant state/territory variants)
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• AS/NZS 3788: Pressure equipment – In-service inspection
• AS/NZS 1200: Pressure equipment
• AS/NZS 4024 series: Safety of machinery (relevant parts for hydraulic and pneumatic systems)
• AS 2865: Confined spaces (where pressure testing interfaces with confined space work)
• ISO 10423 / API 6A (as referenced industry standards for wellhead and Christmas tree equipment, where applicable)