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Pressure Testing: Staying Safe Around Stored Energy
Never enter a pressure test exclusion zone because a failure releases force like an explosion.
Why this matters
- Pressure testing is used to check if pipes and tanks are strong. This process creates what we call stored energy. When a pipe is filled with high pressure air or water, it is like a coiled spring waiting to snap.
- If a joint, bolt, or pipe fails during the test, the energy is released in a split second. This can turn heavy metal parts into flying objects that travel hundreds of metres. You cannot see the danger until it is too late, which is why distance is your only real protection.
Talking points
- Always check for red warning tape or hard barriers before starting work in any piping area.
- Look for warning signs that state: Danger: Pressure Testing in Progress. Do not ignore them.
- Never cross into an exclusion zone unless you are an authorized member of the testing team with a specific Permit.
- Stay clear of 'line of fire' areas, such as the ends of pipes, flanges, and valves, while the system is under pressure.
- Never attempt to tighten a bolt or fix a leaking joint while the system is pressurized. The pressure must be bled off first.
- If you see an unauthorized person inside a taped-off area, stop them from a safe distance and alert the supervisor.
- Wait for the official 'all clear' signal from the testing lead before returning to the area after a test is finished.
Ask the crew
- Where is the exclusion zone located for today's pressure test?
- What should you do if you notice a hissing sound coming from a pressurized pipe?
- Why is it forbidden to adjust a flange while the system is under pressure?
Download the PDF with attendance sheet
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Matching safety poster: Pressure Testing Safety
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