Pressure Testing and Leak Testing Safety

• Establish and enforce an exclusion zone before pressurising any system.
• Use hydrostatic testing in preference to pneumatic testing wherever possible.
• Ensure all test equipment is rated for the maximum test pressure applied.
• Restrain end caps, flanges, and joints against thrust forces during testing.
• Follow the approved test procedure and method statement at all times.
• Have a competent person supervise and authorise each stage of the test.
• Inspect all connections and joints at low pressure before full pressurisation.
• Record test results accurately including pressures, hold times, and outcomes.
• Depressurise systems safely and fully before disconnecting test equipment.
• Brief all personnel in the area about the test and exclusion zone limits.

• DON'T use pneumatic testing where hydrostatic testing is a viable alternative.
• DON'T enter the exclusion zone while any system is under test pressure.
• DON'T use test equipment rated below the maximum test pressure required.
• DON'T leave end caps or blanks unrestrained during pressure testing operations.
• DON'T pressurise a system without first checking all joints at low pressure.
• DON'T exceed the specified test pressure stated in the method statement.
• DON'T attempt to tighten fittings or repair leaks while the system is pressurised.
• DON'T carry out pressure tests without a competent person supervising the work.
• DON'T assume the system is depressurised; verify with gauges before disconnecting.
• DON'T skip recording test results or signing off the test documentation.

See also: Hydrostatic Pressure Testing | Pipeline Safety Awareness