Where the hazard occurs
The hazard occurs in air networks, gas lines, hydraulic equipment and pumping systems. Compressed gases can release substantial energy as they expand. Alongside impact from the hose, the fluid may cause burns, chemical exposure, fire or a High-pressure fluid injection injury.
A blockage does not mean the complete circuit is depressurised. Cleaning, testing and disconnection also need assessment. Pump status or one gauge cannot necessarily establish how much energy remains trapped in every part of the system or behind an obstruction.
Select a compatible assembly
Hose, end fittings, couplings and accessories must suit the intended fluid, pressure, temperature and movement. Two parts fitting together does not demonstrate compatibility. An apparently equivalent replacement may fail because of differences in material, crimping or service rating.
Routing should avoid unsuitable bend radii, crushing, abrasion and tensile loading. Identify assemblies so their authorised service and inspections can be traced. Items withdrawn because of damage must not be mixed back into the stock available for use.
Restrain and separate
Where restraint is needed, design or select it for the assembly and expected failure mode. Safety cables do not all control the same energy. Anchor points must also withstand the loads; an improvised attachment may break away with the coupling itself.
A restraint does not replace other safeguards or make close proximity safe during a pressure test. Minimise the presence of people within the hose’s possible travel area. Holding it with hands or body weight is not an effective control measure.
Inspect and intervene under control
Checks should identify cuts, distortion, corrosion, loosening crimps and damaged restraints. Frequency depends on service conditions and applicable instructions. Recording a defect only helps if the assembly is withdrawn or corrected before people are exposed to it again.
If leakage or abnormal behaviour occurs, follow the planned stopping and isolation procedure. Competent personnel must confirm safe conditions before disconnecting or repairing equipment. Verification of residual energy is part of the task; loosening a fitting to see what happens is not a substitute.
