MBS/General/TBT-MBS-017

Pressurised System Safety Awareness

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Pressurised systems including boilers, air receivers, pressurised pipework, and hydraulic circuits store significant energy that can cause fatal injuries if released uncontrolled. Construction workers installing, modifying, or working near pressurised systems must understand the risks. This talk explains the hazards of stored pressure energy, the legal requirements for pressurised systems, and the controls needed to work safely.

Key Hazards

Catastrophic failure releasing high-pressure fluid causing fatal impact injuries

Scalding from steam or hot water escaping through failed joints or seals

Injection injuries from high-pressure hydraulic oil penetrating the skin

Pneumatic energy release launching fittings or components as projectiles

Control Measures

Ensure all pressurised systems have a current written scheme of examination before use.
Depressurise and isolate the system completely before carrying out any maintenance or modification.
Verify zero pressure at the point of work using calibrated pressure gauges before opening any joint.
Use the correct pressure rating for all fittings, valves, hoses, and connectors installed in the system.
Never search for hydraulic leaks using your hands — use cardboard or a leak detection spray.
Ensure pressure relief devices are installed, correctly set, and tested as the design requires.
Brief all operatives on the system pressure, isolation points, and emergency venting procedures.
Keep clear of pressurised hoses and connections and position yourself away from potential failure points.
Report any signs of leakage, unusual noise, or vibration in pressurised systems immediately.

Emergency / Rescue

If a pressurised system fails, evacuate the area immediately. Do not attempt to stop the leak. Isolate the supply from a safe upstream point if trained to do so. Call for emergency assistance and treat any injuries.

Remember

All pressurised systems must have a current written scheme of examination before being used
Depressurise and isolate the system completely before any maintenance or modification work
Verify zero pressure at the point of work using a calibrated gauge before opening any joint
Never search for hydraulic leaks with your hands — use cardboard or leak detection spray
Report any signs of leakage, unusual noise, or vibration in pressurised systems immediately

Applicable Legislation: Pressure Systems Safety Regulations 2000 · PUWER 1998 · Health and Safety at Work etc. Act 1974 · Pressure Equipment (Safety) Regulations 2016

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