QMS/General/TBT-QMS-007

Pressure Testing and Leak Testing Safety

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Pressure Testing and Leak Testing Safety

Toolbox Talk Record

Ref: TBT-QMS-007  |  Issue: 1  |  Date: March 2026
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What?

  • Pressure testing verifies the integrity of pipelines, vessels, and systems before they enter service.
  • Hydrostatic testing uses water under pressure; pneumatic testing uses compressed air or gas.
  • Pneumatic tests carry significantly higher risk because compressed gas stores far more energy than water.
  • A catastrophic failure during a pneumatic test can propel pipe sections and fittings like projectiles.
  • Test pressures often exceed normal operating pressure by 50% or more, increasing failure risk.
  • The Pressure Systems Safety Regulations 2000 require a written scheme of examination for pressure systems.
  • All personnel must be excluded from the test zone before pressurisation begins.
  • Joints, flanges, and end caps must be restrained against thrust forces generated during the test.
  • Test equipment including gauges, pumps, and hoses must be rated for the test pressure applied.
  • A competent person must supervise the test and authorise pressurisation at each stage.

Why?

Prevent fatal injuriesCatastrophic pipe failures under test pressure have caused deaths from projectile impacts and blast overpressure on UK sites.
Stored energy riskCompressed air stores vastly more energy than water at the same pressure, making pneumatic test failures explosive.
Legal complianceThe Pressure Systems Safety Regulations 2000 and PUWER 1998 require safe systems of work for all pressure testing.
Do Don't
  • 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
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