Overview of Hydrostatic Testing

Contribute to Definition

Hydrostatic (Hydro) Testing is a process where components such as piping systems,

gas cylinders, boilers, and pressure vessels are tested for strength and leaks. Hydro
tests are often required after shutdowns and repairs in order to validate that equipment
will operate under desired conditions once returned to service.

Furthermore, hydrostatic testing cannot be performed during normal operations and

cannot monitor equipment for leaks after the test has been performed. On-stream
equipment integrity is best managed by an effective fixed equipment mechanical
integrity program.

Although hydrostatic testing is considered to be a nondestructive testing method,

equipment can rupture and fail if the inspection exceeds a specified test pressure or if a
small crack propagates rapidly.

How does it work?

Hydrostatic testing is a type of pressure test that works by completely filling the
component with water, removing the air contained within the unit, and pressurizing the
system up to 1.5 times the design pressure limit the of the unit. The pressure is then
held for a specific amount of time to visually inspect the system for leaks. Visual
inspection can be enhanced by applying either tracer or fluorescent dyes to the liquid to
determine where cracks and leaks are originating.

Common Methods
There are three common hydrostatic testing techniques that are used to test small
pressure vessels and cylinders: the water jacket method, the direct expansion method,
and the proof testing method.