Product Overview

Summary: This Pressure Testing Safe Operating Procedure provides a clear, step-by-step method for safely conducting pressure tests on pipes, vessels, hoses and other plant. It helps Australian businesses control high-risk energy hazards, maintain compliance with WHS duties, and prevent catastrophic failures, leaks and serious injuries during testing activities.

Pressure testing is a critical verification activity used across construction, mining, oil and gas, manufacturing, utilities and facilities management to confirm the integrity of pipes, pressure vessels, hoses and other pressurised systems. When poorly planned or executed, it can result in sudden component failure, flying debris, hose whip, chemical release and serious or even fatal injuries. This Pressure Testing Safe Operating Procedure sets out a robust, repeatable process for planning, preparing, conducting and documenting pressure tests in a way that is both safe and compliant with Australian WHS expectations.

The procedure guides your team through risk assessment, selection of appropriate test media (e.g. hydrostatic vs pneumatic), isolation and tagging, test boundary definition, barricading and exclusion zones, pressure ramp-up and hold periods, and controlled depressurisation. It clarifies roles and responsibilities, required competencies, and the specific PPE and equipment checks needed before any test begins. By implementing this SOP, businesses can demonstrate due diligence, reduce reliance on informal “tribal knowledge”, and ensure that every pressure test—from small workshop hose tests to large-scale pipeline and vessel tests—is carried out to a consistent, auditable standard.

This document is designed specifically for the Australian regulatory environment, aligning with relevant AS/NZS standards and Safe Work Australia guidance. It helps organisations integrate pressure testing into their broader WHS management system, improve contractor control, and provide clear, practical instructions that can be used for training, toolbox talks and incident prevention.

Key Benefits

• Reduce the risk of high‑energy failures, hose whip and projectile incidents during pressure testing.
• Ensure pressure testing activities are planned and carried out in line with Australian WHS legislation and relevant AS/NZS standards.
• Standardise how pressure tests are prepared, executed, monitored and documented across all sites and contractors.
• Improve competency and confidence of operators and supervisors through clear, step‑by‑step instructions and checklists.
• Minimise costly rework, unplanned downtime and damage to plant by detecting defects safely and systematically.

Who is this for?

• WHS Managers
• Maintenance Supervisors
• Mechanical Supervisors
• Project Engineers
• Commissioning Engineers
• Plant Operators
• Mechanical Fitters
• Pipeline Technicians
• Facility Managers
• Hydrostatic Testing Contractors

Hazards Addressed

• Sudden rupture of pipes, vessels, hoses or fittings under pressure
• Hose whip and movement of unsecured lines during testing
• Flying debris and projectiles from component failure
• Exposure to hazardous test media (e.g. chemicals, hot fluids, compressed gases)
• Stored energy release during pressurisation and depressurisation
• Noise from sudden releases or failures
• Slips, trips and falls around wet or congested test areas
• Manual handling strains from positioning heavy test equipment
• Contact with high‑pressure leaks or pinhole jets
• Inadequate isolation leading to inadvertent pressurisation

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and References
• 5.0 Types of Pressure Testing (Hydrostatic, Pneumatic, Combined)
• 6.0 Pre‑Test Planning and Risk Assessment
• 7.0 Test Area Setup, Barricading and Signage
• 8.0 Isolation, Lockout/Tagout and Test Boundary Definition
• 9.0 Required Tools, Equipment and Calibration Requirements
• 10.0 Personal Protective Equipment (PPE) Requirements
• 11.0 Pre‑Use Inspection and System Integrity Checks
• 12.0 Step‑by‑Step Pressure Testing Procedure
• 13.0 Monitoring, Communication and Control During Testing
• 14.0 Depressurisation and Making the System Safe
• 15.0 Post‑Test Inspection, Acceptance Criteria and Rectification
• 16.0 Documentation, Test Records and Traceability
• 17.0 Emergency Response and Incident Reporting
• 18.0 Training, Induction and Toolbox Talk Guidance
• 19.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory equivalents)
• Work Health and Safety Regulations 2011 (Cth and relevant state/territory equivalents)
• 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 4343: Pressure equipment – Hazard levels
• AS/NZS 4024 series: Safety of machinery (for associated test equipment and guarding)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1801: Occupational protective helmets
• AS/NZS 2210.1: Safety, protective and occupational footwear