UTL/Gas/TBT-UTL-025

Gas Main PE Pipe Replacement Safety

Utilities & Network InfrastructureGasGas Main PE Pipe Replacement Safety

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Gas Main PE Pipe Replacement Safety

TBT-UTL-025

Replacing metallic gas mains with polyethylene pipe is a major ongoing programme across the UK's gas distribution network. The work involves excavation near live gas infrastructure, cutting into pressurised mains, and fusion jointing of PE pipe in open trenches. A gas escape during replacement can cause explosion, fire, and evacuation of surrounding properties. This talk covers the hazards and controls specific to gas main PE pipe replacement.

Key Hazards
Gas explosion from uncontrolled escape during cutting into live gas mains
Asphyxiation from gas accumulating in excavations or nearby enclosed spaces
Burns from PE pipe fusion equipment operating at high temperatures in trenches
Public safety risk from gas migrating into properties near the work area
Control Measures
  • Ensure only gas-safe registered and network-authorised operatives carry out live gas main work.
  • Monitor the atmosphere continuously for gas in the excavation and surrounding area during all work.
  • Establish a no-smoking and no-ignition-source exclusion zone around the work area as specified.
  • Use the network operator's approved procedures for cutting, stopping, and connecting to the live main.
  • Ensure PE fusion equipment is calibrated and the operator holds current fusion jointing competency.
  • Brief the team on the gas emergency procedure and the location of the nearest emergency control valve.
  • Notify local properties before work begins and provide emergency contact details for the gas network.
  • Test all completed joints and the new main for integrity before commissioning and bringing into service.
  • Keep fire extinguishers immediately available at the working point throughout all live gas operations.
Emergency / Rescue

If a gas escape occurs, evacuate the excavation and surrounding area immediately. Eliminate all ignition sources. Call the National Gas Emergency number 0800 111 999 and 999. Do not re-enter until declared safe by the gas network.

Remember
  • Only gas-safe registered and network-authorised operatives may work on live gas mains
  • Monitor for gas continuously in the excavation and surrounding area throughout all work
  • Use the network operator's approved procedures for all cutting and connection operations
  • Notify local properties before work begins and provide emergency contact information
  • If a gas escape occurs, evacuate immediately and call 0800 111 999 and 999
Applicable Legislation: Gas Safety (Installation and Use) Regulations 1998 · DSEAR 2002 · CDM Regulations 2015 · Health and Safety at Work etc. Act 1974
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