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| Boilerpipe Text | From Wikipedia, the free encyclopedia
Hydrostatic tester
A
hydrostatic test
is a way in which
pressure vessels
such as
pipelines
,
plumbing
,
gas cylinders
,
boilers
and fuel tanks can be tested for strength and leaks. The test involves filling the vessel or pipe system with a liquid, usually water, which may be dyed to aid in visual
leak detection
, and pressurization of the vessel to the specified test pressure. Pressure tightness can be tested by shutting off the supply valve and observing whether there is a pressure loss. The location of a leak can be visually identified more easily if the water contains a colorant. Strength is usually tested by measuring permanent deformation of the container.
Hydrostatic testing is the most common method employed for testing pipes and pressure vessels. Using this test helps maintain safety standards and durability of a vessel over time. Newly manufactured pieces are initially qualified using the hydrostatic test. They are then revalidated at regular intervals according to the relevant standard. In some cases where a hydrostatic test is not practicable a pneumatic pressure test may be an acceptable alternative.
[
1
]
Testing of pressure vessels for transport and storage of gases is very important because such containers can explode if they fail under pressure.
Hydrostatic tests are conducted under the constraints of either the industry's or the customer's specifications, or may be required by law. The vessel is filled with a nearly incompressible liquid – usually
water
or
oil
– pressurised to test pressure, and examined for leaks or permanent changes in shape.
Red
or
fluorescent
dyes
may be added to the water to make leaks easier to see. The test pressure is always considerably higher than the operating pressure to give a factor of safety. This factor of safety is typically 166.66%, 143% or 150% of the designed working pressure, depending on the regulations that apply. For example, if a cylinder was rated to DOT-2015 PSI (approximately 139 bar), it would be tested at around 3360 PSI (approximately 232 bar).
Water
is commonly used because it is cheap and easily available, and is usually harmless to the system to be tested. Hydraulic fluids and oils may be specified where contamination with water could cause problems. These fluids are nearly incompressible, therefore requiring relatively little work to develop a high pressure, and is therefore also only able to release a small amount of energy in case of a failure - only a small volume will escape under high pressure if the container fails. If
high pressure
gas
were used, then the gas would expand to V=(nRT)/p with its compressed volume resulting in an explosion, with the attendant risk of damage or injury.
Water jacket test
Small pressure vessels are normally tested using a water jacket test. The vessel is visually examined for defects and then placed in a container filled with water, and in which the change in volume of the vessel can be measured, usually by monitoring the water level in a calibrated tube. The vessel is then pressurised for a specified period, usually 30 or more seconds, and if specified, the expansion will be measured by reading off the amount of liquid that has been forced into the measuring tube by the volume increase of the pressurised vessel. The vessel is then depressurised, and the permanent volume increase due to plastic deformation while under pressure (
permanent set
) is measured by comparing the final volume in the measuring tube with the volume before pressurisation.
[
2
]
A leak will give a similar result to permanent set, but will be detectable by holding the volume in the pressurised vessel by closing the inlet valve for a period before depressurising, as the pressure will drop steadily during this period if there is a leak. In most cases a permanent set that exceeds the specified maximum will indicate failure. A leak may also be a failure criterion, but it may be that the leak is due to poor sealing of the test equipment. If the vessel fails, it will normally go through a condemning process marking the cylinder as unsafe.
[
2
]
[
3
]
The information needed to specify the test is stamped onto the cylinder. This includes the design standard, serial number, manufacturer, and manufacture date. After testing, the vessel or its nameplate will usually be stamp marked with the date of the successful test, and the test facility's identification mark.
[
3
]
A simpler test, that is also considered a hydrostatic test but does not require pressure pumps, is to pressurise the vessel by filling it with water to a hydrostatic head by using a riser pipe connected to the tank and to physically examine the outside for leaks. This type of test is suitable for containers such as boat fuel tanks, which are not pressure vessels but must work under the hydrostatic pressure of the contents. A hydrostatic test head is usually specified as a height above the tank top. The tank is pressurised by filling water to the specified height through a temporary standpipe if necessary. It may be necessary to seal vents and other outlets during the test.
[
4
]
Portable fire extinguishers are safety tools that are required in most public buildings. Fire extinguishers are also recommended in homes. Over time the conditions in which they are housed, and the manner in which they are handled affect the structural integrity of the extinguisher. A structurally weakened fire extinguisher can malfunction or even burst when it is needed the most. To maintain the quality and safety of this product, hydrostatic testing is utilized. All critical components of the fire extinguisher should be tested to ensure proper function.
Hydrotesting of pipes, pipelines and vessels is performed to expose defective materials that have missed prior detection, ensure that any remaining defects are insignificant enough to allow operation at design pressures, expose possible leaks and serve as a final validation of the integrity of the constructed system. ASME B31.3 requires this testing to ensure tightness and strength.
Buried high pressure oil and gas pipelines are tested for strength by pressurising them to at least 125% of their
maximum allowable working pressure
(MAWP) at any point along their length. Since many long distance transmission pipelines are designed to have a steel hoop stress of 80% of
specified minimum yield strength
(SMYS) at
Maximum allowable operating pressure
MAOP, this means that the steel is stressed to SMYS and above during the testing, and test sections must be selected to ensure that excessive plastic deformation does not occur.
[
citation needed
]
For piping built to ASME B31.3, if the design temperature is greater than the test temperature, then the test pressure must be adjusted for the related allowable stress at the design temperature. This is done by multiplying 1.5 MAWP by the ratio of the allowable stress at the test temperature to allowable stress at the design temperature per ASME B31.3 Section 345.4.2 Equation 24. Test pressures need not exceed a value that would produce a stress higher than yield stress at test temperature. ASME B31.3 section 345.4.2 (c)
Other codes require a more onerous approach. BS PD 8010-2 requires testing to 150% of the
design
pressure – which should not be less than the MAOP plus surge and other incidental effects that will occur during normal operation.
[
citation needed
]
Leak testing is performed by balancing changes in the measured pressure in the test section against the theoretical pressure changes calculated from changes in the measured temperature of the test section.
Australian standard AS2885.5 "Pipelines – Gas and liquid petroleum: Part 5: Field pressure testing" gives an excellent explanation of the factors involved.
[
clarification needed
]
In the aerospace industry, depending on the airline, company or customer, certain codes will need to be followed. For example, Bell Helicopter has a certain specification that will have to be followed for any parts that will be used in their helicopters.
[
citation needed
]
Most countries have legislation or pressure vessel codes which requires vessels to be regularly tested, for example every two years (with a visual inspection annually) for high pressure gas cylinders and every five or ten years for lower pressure ones such as used in
fire extinguishers
.
[
5
]
[
clarification needed
]
Gas cylinders which fail are normally destroyed as part of the testing protocol to avoid the dangers inherent in them being subsequently used.
[
6
]
These common US standard gas cylinders have the following requirements:
[
7
]
DOT-3AL gas cylinders must be tested every 5 years and have an unlimited life.
DOT-3HT gas cylinders must be tested every 3 years and have a 24-year life.
DOT-3AA gas cylinders must be tested every 5 years and have an unlimited life. (Unless stamped with a star (*) in which case the cylinder meets certain specifications and can have a 10-year hydrostatic test life).
Typically organizations such as DOT
PHMSA
,
ISO
,
ASTM
and
ASME
specify the guidelines for the different types of pressure vessels.
Hydraulic testing is a hazardous process and should be performed with caution by competent personnel. Adhering to prescribed procedures defined in relevant
technical standards
appropriate to the specific application and jurisdiction will usually reduce these risks to an acceptable level.
A leak of high pressure liquid can cut or penetrate the skin and inject itself into body tissues. This can cause serious direct injury to the operator, and if the fluid is toxic or contaminated there will be additional adverse effects.
A pressurised hose that is not securely attached or which fails under pressure may whip around spraying water or oil and could hit someone and cause injuries. A
whiplash arrestor
can be used to restrain such hoses.
Enclosing the components to be tested, hazard signage, use of appropriate
personal protective equipment
and providing barriers to access for non-essential personnel are common precautions.
Nondestructive testing
– Type of analysis technique
Testing and inspection of diving cylinders
– Periodical inspection and testing to revalidate fitness for service
^
"Proof-Pressure Test and Leak Detection Test in Metal Expansion Joints"
(PDF)
.
www.macoga.com
. Macoga SA
. Retrieved
24 September
2021
.
^
a
b
Sauta, Tom (1 Oct 2010).
"Hydro-Test Water Jacket Cylinder Test System Setup.wmv"
. www.hydrotest.com
. Retrieved
29 July
2025
– via YouTube.
^
a
b
Angel (17 May 2022).
"How to Hydro Test a scuba tank"
. Scuba Tech Key Largo
. Retrieved
29 July
2025
– via YouTube.
^
Kim; An, Tae-Hyun; Lee, Tak-Kee (April 2022).
"Preliminary Study on Deformation During Hydrostatic Testing in a Deep Tank }first1=Geun-Gon"
.
J. Ocean Eng. Technol
.
36
(2):
115–
124.
doi
:
10.26748/KSOE.2021.075
.
^
"Federal Register :: Request Access"
.
^
"Federal Register :: Request Access"
.
^
"Federal Register :: Request Access"
.
"OSHA"
. Retrieved
2006-10-05
. |
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- [1 Testing procedures](https://en.wikipedia.org/wiki/Hydrostatic_test#Testing_procedures)
- [2 Examples](https://en.wikipedia.org/wiki/Hydrostatic_test#Examples)
- [3 Pipeline testing](https://en.wikipedia.org/wiki/Hydrostatic_test#Pipeline_testing)
- [4 Testing frequency](https://en.wikipedia.org/wiki/Hydrostatic_test#Testing_frequency)
- [5 Safety](https://en.wikipedia.org/wiki/Hydrostatic_test#Safety)
- [6 See also](https://en.wikipedia.org/wiki/Hydrostatic_test#See_also)
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# Hydrostatic test
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Non-destructive test of pressure vessels
For the autopsy procedure, see [lung float test](https://en.wikipedia.org/wiki/Lung_float_test "Lung float test").
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[](https://en.wikipedia.org/wiki/File:Hydrostatic_Tester.jpg)
Hydrostatic tester
A **hydrostatic test** is a way in which [pressure vessels](https://en.wikipedia.org/wiki/Pressure_vessel "Pressure vessel") such as [pipelines](https://en.wikipedia.org/wiki/Pipeline_transport "Pipeline transport"), [plumbing](https://en.wikipedia.org/wiki/Plumbing "Plumbing"), [gas cylinders](https://en.wikipedia.org/wiki/Gas_cylinder "Gas cylinder"), [boilers](https://en.wikipedia.org/wiki/Boiler "Boiler") and fuel tanks can be tested for strength and leaks. The test involves filling the vessel or pipe system with a liquid, usually water, which may be dyed to aid in visual [leak detection](https://en.wikipedia.org/wiki/Leak_detection "Leak detection"), and pressurization of the vessel to the specified test pressure. Pressure tightness can be tested by shutting off the supply valve and observing whether there is a pressure loss. The location of a leak can be visually identified more easily if the water contains a colorant. Strength is usually tested by measuring permanent deformation of the container.
Hydrostatic testing is the most common method employed for testing pipes and pressure vessels. Using this test helps maintain safety standards and durability of a vessel over time. Newly manufactured pieces are initially qualified using the hydrostatic test. They are then revalidated at regular intervals according to the relevant standard. In some cases where a hydrostatic test is not practicable a pneumatic pressure test may be an acceptable alternative.[\[1\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-Proof-1)
Testing of pressure vessels for transport and storage of gases is very important because such containers can explode if they fail under pressure.
## Testing procedures
\[[edit](https://en.wikipedia.org/w/index.php?title=Hydrostatic_test&action=edit§ion=1 "Edit section: Testing procedures")\]
Hydrostatic tests are conducted under the constraints of either the industry's or the customer's specifications, or may be required by law. The vessel is filled with a nearly incompressible liquid – usually [water](https://en.wikipedia.org/wiki/Water "Water") or [oil](https://en.wikipedia.org/wiki/Oil "Oil") – pressurised to test pressure, and examined for leaks or permanent changes in shape. [Red](https://en.wikipedia.org/wiki/Red "Red") or [fluorescent](https://en.wikipedia.org/wiki/Fluorescent "Fluorescent") [dyes](https://en.wikipedia.org/wiki/Dye "Dye") may be added to the water to make leaks easier to see. The test pressure is always considerably higher than the operating pressure to give a factor of safety. This factor of safety is typically 166.66%, 143% or 150% of the designed working pressure, depending on the regulations that apply. For example, if a cylinder was rated to DOT-2015 PSI (approximately 139 bar), it would be tested at around 3360 PSI (approximately 232 bar).
[Water](https://en.wikipedia.org/wiki/Water "Water") is commonly used because it is cheap and easily available, and is usually harmless to the system to be tested. Hydraulic fluids and oils may be specified where contamination with water could cause problems. These fluids are nearly incompressible, therefore requiring relatively little work to develop a high pressure, and is therefore also only able to release a small amount of energy in case of a failure - only a small volume will escape under high pressure if the container fails. If [high pressure](https://en.wikipedia.org/wiki/High_pressure "High pressure") [gas](https://en.wikipedia.org/wiki/Gas "Gas") were used, then the gas would expand to V=(nRT)/p with its compressed volume resulting in an explosion, with the attendant risk of damage or injury.
[](https://en.wikipedia.org/wiki/File:Water_jacket_test_diagram.jpg)
Water jacket test
Small pressure vessels are normally tested using a water jacket test. The vessel is visually examined for defects and then placed in a container filled with water, and in which the change in volume of the vessel can be measured, usually by monitoring the water level in a calibrated tube. The vessel is then pressurised for a specified period, usually 30 or more seconds, and if specified, the expansion will be measured by reading off the amount of liquid that has been forced into the measuring tube by the volume increase of the pressurised vessel. The vessel is then depressurised, and the permanent volume increase due to plastic deformation while under pressure (permanent set) is measured by comparing the final volume in the measuring tube with the volume before pressurisation.[\[2\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-Sauta_2010-2)
A leak will give a similar result to permanent set, but will be detectable by holding the volume in the pressurised vessel by closing the inlet valve for a period before depressurising, as the pressure will drop steadily during this period if there is a leak. In most cases a permanent set that exceeds the specified maximum will indicate failure. A leak may also be a failure criterion, but it may be that the leak is due to poor sealing of the test equipment. If the vessel fails, it will normally go through a condemning process marking the cylinder as unsafe.[\[2\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-Sauta_2010-2)[\[3\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-Hydro_Key_Largo-3)
The information needed to specify the test is stamped onto the cylinder. This includes the design standard, serial number, manufacturer, and manufacture date. After testing, the vessel or its nameplate will usually be stamp marked with the date of the successful test, and the test facility's identification mark.[\[3\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-Hydro_Key_Largo-3)
A simpler test, that is also considered a hydrostatic test but does not require pressure pumps, is to pressurise the vessel by filling it with water to a hydrostatic head by using a riser pipe connected to the tank and to physically examine the outside for leaks. This type of test is suitable for containers such as boat fuel tanks, which are not pressure vessels but must work under the hydrostatic pressure of the contents. A hydrostatic test head is usually specified as a height above the tank top. The tank is pressurised by filling water to the specified height through a temporary standpipe if necessary. It may be necessary to seal vents and other outlets during the test.[\[4\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-4)
## Examples
\[[edit](https://en.wikipedia.org/w/index.php?title=Hydrostatic_test&action=edit§ion=2 "Edit section: Examples")\]
Portable fire extinguishers are safety tools that are required in most public buildings. Fire extinguishers are also recommended in homes. Over time the conditions in which they are housed, and the manner in which they are handled affect the structural integrity of the extinguisher. A structurally weakened fire extinguisher can malfunction or even burst when it is needed the most. To maintain the quality and safety of this product, hydrostatic testing is utilized. All critical components of the fire extinguisher should be tested to ensure proper function.
## Pipeline testing
\[[edit](https://en.wikipedia.org/w/index.php?title=Hydrostatic_test&action=edit§ion=3 "Edit section: Pipeline testing")\]
Hydrotesting of pipes, pipelines and vessels is performed to expose defective materials that have missed prior detection, ensure that any remaining defects are insignificant enough to allow operation at design pressures, expose possible leaks and serve as a final validation of the integrity of the constructed system. ASME B31.3 requires this testing to ensure tightness and strength.
Buried high pressure oil and gas pipelines are tested for strength by pressurising them to at least 125% of their [maximum allowable working pressure](https://en.wikipedia.org/wiki/Maximum_allowable_working_pressure "Maximum allowable working pressure") (MAWP) at any point along their length. Since many long distance transmission pipelines are designed to have a steel hoop stress of 80% of [specified minimum yield strength](https://en.wikipedia.org/wiki/Specified_minimum_yield_strength "Specified minimum yield strength") (SMYS) at [Maximum allowable operating pressure](https://en.wikipedia.org/wiki/Maximum_allowable_operating_pressure "Maximum allowable operating pressure") MAOP, this means that the steel is stressed to SMYS and above during the testing, and test sections must be selected to ensure that excessive plastic deformation does not occur.\[*[citation needed](https://en.wikipedia.org/wiki/Wikipedia:Citation_needed "Wikipedia:Citation needed")*\]
For piping built to ASME B31.3, if the design temperature is greater than the test temperature, then the test pressure must be adjusted for the related allowable stress at the design temperature. This is done by multiplying 1.5 MAWP by the ratio of the allowable stress at the test temperature to allowable stress at the design temperature per ASME B31.3 Section 345.4.2 Equation 24. Test pressures need not exceed a value that would produce a stress higher than yield stress at test temperature. ASME B31.3 section 345.4.2 (c)
Other codes require a more onerous approach. BS PD 8010-2 requires testing to 150% of the *design* pressure – which should not be less than the MAOP plus surge and other incidental effects that will occur during normal operation.\[*[citation needed](https://en.wikipedia.org/wiki/Wikipedia:Citation_needed "Wikipedia:Citation needed")*\]
Leak testing is performed by balancing changes in the measured pressure in the test section against the theoretical pressure changes calculated from changes in the measured temperature of the test section.
Australian standard AS2885.5 "Pipelines – Gas and liquid petroleum: Part 5: Field pressure testing" gives an excellent explanation of the factors involved.\[*[clarification needed](https://en.wikipedia.org/wiki/Wikipedia:Please_clarify "Wikipedia:Please clarify")*\]
In the aerospace industry, depending on the airline, company or customer, certain codes will need to be followed. For example, Bell Helicopter has a certain specification that will have to be followed for any parts that will be used in their helicopters.\[*[citation needed](https://en.wikipedia.org/wiki/Wikipedia:Citation_needed "Wikipedia:Citation needed")*\]
## Testing frequency
\[[edit](https://en.wikipedia.org/w/index.php?title=Hydrostatic_test&action=edit§ion=4 "Edit section: Testing frequency")\]
Most countries have legislation or pressure vessel codes which requires vessels to be regularly tested, for example every two years (with a visual inspection annually) for high pressure gas cylinders and every five or ten years for lower pressure ones such as used in [fire extinguishers](https://en.wikipedia.org/wiki/Fire_extinguisher "Fire extinguisher").[\[5\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-5) \[*[clarification needed](https://en.wikipedia.org/wiki/Wikipedia:Please_clarify "Wikipedia:Please clarify")*\] Gas cylinders which fail are normally destroyed as part of the testing protocol to avoid the dangers inherent in them being subsequently used.[\[6\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-6)
These common US standard gas cylinders have the following requirements:[\[7\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-7)
- DOT-3AL gas cylinders must be tested every 5 years and have an unlimited life.
- DOT-3HT gas cylinders must be tested every 3 years and have a 24-year life.
- DOT-3AA gas cylinders must be tested every 5 years and have an unlimited life. (Unless stamped with a star (\*) in which case the cylinder meets certain specifications and can have a 10-year hydrostatic test life).
Typically organizations such as DOT [PHMSA](https://en.wikipedia.org/wiki/PHMSA "PHMSA"), [ISO](https://en.wikipedia.org/wiki/ISO "ISO"), [ASTM](https://en.wikipedia.org/wiki/ASTM "ASTM") and [ASME](https://en.wikipedia.org/wiki/ASME "ASME") specify the guidelines for the different types of pressure vessels.
## Safety
\[[edit](https://en.wikipedia.org/w/index.php?title=Hydrostatic_test&action=edit§ion=5 "Edit section: Safety")\]
Hydraulic testing is a hazardous process and should be performed with caution by competent personnel. Adhering to prescribed procedures defined in relevant [technical standards](https://en.wikipedia.org/wiki/Technical_standards "Technical standards") appropriate to the specific application and jurisdiction will usually reduce these risks to an acceptable level.
- A leak of high pressure liquid can cut or penetrate the skin and inject itself into body tissues. This can cause serious direct injury to the operator, and if the fluid is toxic or contaminated there will be additional adverse effects.
- A pressurised hose that is not securely attached or which fails under pressure may whip around spraying water or oil and could hit someone and cause injuries. A [whiplash arrestor](https://en.wikipedia.org/wiki/Glossary_of_underwater_diving_terminology:_T%E2%80%93Z#whiplash_arrestor "Glossary of underwater diving terminology: T–Z") can be used to restrain such hoses.
- Enclosing the components to be tested, hazard signage, use of appropriate [personal protective equipment](https://en.wikipedia.org/wiki/Personal_protective_equipment "Personal protective equipment") and providing barriers to access for non-essential personnel are common precautions.
## See also
\[[edit](https://en.wikipedia.org/w/index.php?title=Hydrostatic_test&action=edit§ion=6 "Edit section: See also")\]
- [Nondestructive testing](https://en.wikipedia.org/wiki/Nondestructive_testing "Nondestructive testing") – Type of analysis technique
- [Testing and inspection of diving cylinders](https://en.wikipedia.org/wiki/Testing_and_inspection_of_diving_cylinders "Testing and inspection of diving cylinders") – Periodical inspection and testing to revalidate fitness for service
## References
\[[edit](https://en.wikipedia.org/w/index.php?title=Hydrostatic_test&action=edit§ion=7 "Edit section: References")\]
1. **[^](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-Proof_1-0)**
["Proof-Pressure Test and Leak Detection Test in Metal Expansion Joints"](https://www.macoga.com/documents/en/metal-expansion-joints/proof-pressure-test-leak-detection-test.pdf) (PDF). *www.macoga.com*. Macoga SA. Retrieved 24 September 2021.
2. ^ [***a***](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-Sauta_2010_2-0) [***b***](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-Sauta_2010_2-1)
Sauta, Tom (1 Oct 2010). ["Hydro-Test Water Jacket Cylinder Test System Setup.wmv"](https://www.youtube.com/watch?v=KLrV0vGBZEk). www.hydrotest.com. Retrieved 29 July 2025 – via YouTube.
3. ^ [***a***](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-Hydro_Key_Largo_3-0) [***b***](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-Hydro_Key_Largo_3-1)
Angel (17 May 2022). ["How to Hydro Test a scuba tank"](https://www.youtube.com/watch?v=Bwd-GFCtLl8). Scuba Tech Key Largo. Retrieved 29 July 2025 – via YouTube.
4. **[^](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-4)**
Kim; An, Tae-Hyun; Lee, Tak-Kee (April 2022). ["Preliminary Study on Deformation During Hydrostatic Testing in a Deep Tank }first1=Geun-Gon"](https://doi.org/10.26748%2FKSOE.2021.075). *J. Ocean Eng. Technol*. **36** (2): 115–124\. [doi](https://en.wikipedia.org/wiki/Doi_\(identifier\) "Doi (identifier)"):[10\.26748/KSOE.2021.075](https://doi.org/10.26748%2FKSOE.2021.075).
5. **[^](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-5)**
["Federal Register :: Request Access"](https://www.ecfr.gov/current/title-49/subtitle-B/chapter-I/subchapter-C/part-180#p-180.209\(j\)).
6. **[^](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-6)**
["Federal Register :: Request Access"](https://www.ecfr.gov/current/title-49/subtitle-B/chapter-I/subchapter-C/part-180#p-180.205\(i\)).
7. **[^](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-7)**
["Federal Register :: Request Access"](https://www.ecfr.gov/current/title-49/section-180.209).
## External links
\[[edit](https://en.wikipedia.org/w/index.php?title=Hydrostatic_test&action=edit§ion=8 "Edit section: External links")\]
- ["OSHA"](https://www.osha.gov/SLTC/etools/evacuation/portable_hydro.html). Retrieved 2006-10-05.
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| Technology | [Brazing](https://en.wikipedia.org/wiki/Brazing "Brazing") [British Standard Pipe](https://en.wikipedia.org/wiki/British_Standard_Pipe "British Standard Pipe") (BSP) [Cast iron pipe](https://en.wikipedia.org/wiki/Cast_iron_pipe "Cast iron pipe") [Chemical drain cleaners](https://en.wikipedia.org/wiki/Chemical_drain_cleaners "Chemical drain cleaners") [Compression fitting](https://en.wikipedia.org/wiki/Compression_fitting "Compression fitting") [Copper tubing](https://en.wikipedia.org/wiki/Copper_tubing "Copper tubing") [Crimp (joining)](https://en.wikipedia.org/wiki/Crimp_\(joining\) "Crimp (joining)") [Drain-waste-vent system](https://en.wikipedia.org/wiki/Drain-waste-vent_system "Drain-waste-vent system") [Ductile iron pipe](https://en.wikipedia.org/wiki/Ductile_iron_pipe "Ductile iron pipe") [Flare fitting](https://en.wikipedia.org/wiki/Flare_fitting "Flare fitting") [Garden Hose Thread](https://en.wikipedia.org/wiki/Garden_hose_thread "Garden hose thread") (GHT) [Gasket](https://en.wikipedia.org/wiki/Gasket "Gasket") [Hydronics](https://en.wikipedia.org/wiki/Hydronics "Hydronics") [Leak detection](https://en.wikipedia.org/wiki/Leak_detection "Leak detection") [National pipe thread](https://en.wikipedia.org/wiki/National_pipe_thread "National pipe thread") (NPT) [Nominal Pipe Size](https://en.wikipedia.org/wiki/Nominal_Pipe_Size "Nominal Pipe Size") (NPS) [O-ring](https://en.wikipedia.org/wiki/O-ring "O-ring") [Oakum](https://en.wikipedia.org/wiki/Oakum "Oakum") [Pipe (fluid conveyance)](https://en.wikipedia.org/wiki/Pipe_\(fluid_conveyance\) "Pipe (fluid conveyance)") [Pipe dope](https://en.wikipedia.org/wiki/Pipe_dope "Pipe dope") [Pipe support](https://en.wikipedia.org/wiki/Pipe_support "Pipe support") [Plastic pipework](https://en.wikipedia.org/wiki/Plastic_pipework "Plastic pipework") [Push-to-pull compression fittings](https://en.wikipedia.org/wiki/Push-to-pull_compression_fittings "Push-to-pull compression fittings") [Putty](https://en.wikipedia.org/wiki/Putty "Putty") [Sealant](https://en.wikipedia.org/wiki/Sealant "Sealant") [Sewage pumping](https://en.wikipedia.org/wiki/Sewage_pumping "Sewage pumping") [Soldering](https://en.wikipedia.org/wiki/Soldering "Soldering") [Solvent welding](https://en.wikipedia.org/wiki/Solvent_welding "Solvent welding") [Swaging](https://en.wikipedia.org/wiki/Swaging "Swaging") [Thread seal tape](https://en.wikipedia.org/wiki/Thread_seal_tape "Thread seal tape") [Threaded pipe](https://en.wikipedia.org/wiki/Threaded_pipe "Threaded pipe") [Tube bending](https://en.wikipedia.org/wiki/Tube_bending "Tube bending") [Water heat recycling](https://en.wikipedia.org/wiki/Water_heat_recycling "Water heat recycling") |
| Components | [Atmospheric vacuum breaker](https://en.wikipedia.org/wiki/Atmospheric_vacuum_breaker "Atmospheric vacuum breaker") [Automatic bleeding valve](https://en.wikipedia.org/wiki/Automatic_bleeding_valve "Automatic bleeding valve") [Automatic faucet](https://en.wikipedia.org/wiki/Automatic_faucet "Automatic faucet") [Backflow prevention device](https://en.wikipedia.org/wiki/Backflow_prevention_device "Backflow prevention device") [Ball valve](https://en.wikipedia.org/wiki/Ball_valve "Ball valve") [Bleed screw](https://en.wikipedia.org/wiki/Bleed_screw "Bleed screw") [Booster pump](https://en.wikipedia.org/wiki/Booster_pump "Booster pump") [Butterfly valve](https://en.wikipedia.org/wiki/Butterfly_valve "Butterfly valve") [Check valve](https://en.wikipedia.org/wiki/Check_valve "Check valve") [Chemigation valve](https://en.wikipedia.org/wiki/Chemigation_valve "Chemigation valve") [Chopper pump](https://en.wikipedia.org/wiki/Chopper_pump "Chopper pump") [Circulator pump](https://en.wikipedia.org/wiki/Circulator_pump "Circulator pump") [Cistern](https://en.wikipedia.org/wiki/Cistern "Cistern") [Closet flange](https://en.wikipedia.org/wiki/Closet_flange "Closet flange") [Concentric reducer](https://en.wikipedia.org/wiki/Concentric_reducer "Concentric reducer") [Condensate pump](https://en.wikipedia.org/wiki/Condensate_pump "Condensate pump") [Coupling (piping)](https://en.wikipedia.org/wiki/Coupling_\(piping\) "Coupling (piping)") [Diaphragm valve](https://en.wikipedia.org/wiki/Diaphragm_valve "Diaphragm valve") [Dielectric union](https://en.wikipedia.org/wiki/Dielectric_union "Dielectric union") [Double check valve](https://en.wikipedia.org/wiki/Double_check_valve "Double check valve") [Eccentric reducer](https://en.wikipedia.org/wiki/Eccentric_reducer "Eccentric reducer") [Expansion tank](https://en.wikipedia.org/wiki/Expansion_tank "Expansion tank") [Faucet aerator](https://en.wikipedia.org/wiki/Faucet_aerator "Faucet aerator") [Float switch](https://en.wikipedia.org/wiki/Float_switch "Float switch") [Float valve](https://en.wikipedia.org/wiki/Ballcock "Ballcock") [Floor drain](https://en.wikipedia.org/wiki/Floor_drain "Floor drain") [Flow limiter](https://en.wikipedia.org/wiki/Flow_limiter "Flow limiter") [Flushing trough](https://en.wikipedia.org/wiki/Flushing_trough "Flushing trough") [Flushometer](https://en.wikipedia.org/wiki/Flushometer "Flushometer") [Gate valve](https://en.wikipedia.org/wiki/Gate_valve "Gate valve") [Globe valve](https://en.wikipedia.org/wiki/Globe_valve "Globe valve") [Grease trap](https://en.wikipedia.org/wiki/Grease_trap "Grease trap") [Grinder pump](https://en.wikipedia.org/wiki/Grinder_pump "Grinder pump") [Hose coupling](https://en.wikipedia.org/wiki/Hose_coupling "Hose coupling") [Manifold](https://en.wikipedia.org/wiki/Manifold_\(fluid_mechanics\) "Manifold (fluid mechanics)") [Needle valve](https://en.wikipedia.org/wiki/Needle_valve "Needle valve") [Nipple (plumbing)](https://en.wikipedia.org/wiki/Nipple_\(plumbing\) "Nipple (plumbing)") [Pinch valve](https://en.wikipedia.org/wiki/Pinch_valve "Pinch valve") [Piping and plumbing fitting](https://en.wikipedia.org/wiki/Piping_and_plumbing_fitting "Piping and plumbing fitting") [Plug (sanitation)](https://en.wikipedia.org/wiki/Plug_\(sanitation\) "Plug (sanitation)") [Pressure regulator](https://en.wikipedia.org/wiki/Pressure_regulator "Pressure regulator") [Pressure vacuum breaker](https://en.wikipedia.org/wiki/Pressure_vacuum_breaker "Pressure vacuum breaker") [Pressure-balanced valve](https://en.wikipedia.org/wiki/Pressure-balanced_valve "Pressure-balanced valve") [Pump](https://en.wikipedia.org/wiki/Pump "Pump") [Radiator (heating)](https://en.wikipedia.org/wiki/Radiator_\(heating\) "Radiator (heating)") [Reduced pressure zone device](https://en.wikipedia.org/wiki/Reduced_pressure_zone_device "Reduced pressure zone device") [Reducer](https://en.wikipedia.org/wiki/Reducer "Reducer") [Relief valve](https://en.wikipedia.org/wiki/Relief_valve "Relief valve") [Riser clamp](https://en.wikipedia.org/wiki/Riser_clamp "Riser clamp") [Rooftop water tower](https://en.wikipedia.org/wiki/Rooftop_water_tower "Rooftop water tower") [Safety valve](https://en.wikipedia.org/wiki/Safety_valve "Safety valve") [sewage pumping](https://en.wikipedia.org/wiki/Sewage_pumping "Sewage pumping") [Street elbow](https://en.wikipedia.org/wiki/Street_elbow "Street elbow") [Submersible pump](https://en.wikipedia.org/wiki/Submersible_pump "Submersible pump") [Tap (valve)](https://en.wikipedia.org/wiki/Tap_\(valve\) "Tap (valve)") [Thermostatic mixing valve](https://en.wikipedia.org/wiki/Thermostatic_mixing_valve "Thermostatic mixing valve") [Trench drain](https://en.wikipedia.org/wiki/Trench_drain "Trench drain") [Vacuum breaker](https://en.wikipedia.org/wiki/Vacuum_breaker "Vacuum breaker") [Vacuum ejector](https://en.wikipedia.org/wiki/Vacuum_ejector "Vacuum ejector") [Valve](https://en.wikipedia.org/wiki/Valve "Valve") [Water tank](https://en.wikipedia.org/wiki/Water_tank "Water tank") [Zone valve](https://en.wikipedia.org/wiki/Zone_valve "Zone valve") |
| [Plumbing fixtures](https://en.wikipedia.org/wiki/Plumbing_fixture "Plumbing fixture") | [Accessible bathtub](https://en.wikipedia.org/wiki/Accessible_bathtub "Accessible bathtub") [Bathtub](https://en.wikipedia.org/wiki/Bathtub "Bathtub") [Bidet](https://en.wikipedia.org/wiki/Bidet "Bidet") [Dehumidifier](https://en.wikipedia.org/wiki/Dehumidifier "Dehumidifier") [Dishwasher](https://en.wikipedia.org/wiki/Dishwasher "Dishwasher") [Drinking fountain](https://en.wikipedia.org/wiki/Drinking_fountain "Drinking fountain") [Electric water boiler](https://en.wikipedia.org/wiki/Electric_water_boiler "Electric water boiler") [Evaporative cooler](https://en.wikipedia.org/wiki/Evaporative_cooler "Evaporative cooler") [Flush toilet](https://en.wikipedia.org/wiki/Flush_toilet "Flush toilet") [Garbage disposal unit](https://en.wikipedia.org/wiki/Garbage_disposal_unit "Garbage disposal unit") [Hot water storage tank](https://en.wikipedia.org/wiki/Hot_water_storage_tank "Hot water storage tank") [Humidifier](https://en.wikipedia.org/wiki/Humidifier "Humidifier") [Icemaker](https://en.wikipedia.org/wiki/Icemaker "Icemaker") [Instant hot water dispenser](https://en.wikipedia.org/wiki/Instant_hot_water_dispenser "Instant hot water dispenser") [Laundry tub](https://en.wikipedia.org/wiki/Laundry_room "Laundry room") [Shower](https://en.wikipedia.org/wiki/Shower "Shower") [water recycling shower](https://en.wikipedia.org/wiki/Water_recycling_shower "Water recycling shower") [Sink](https://en.wikipedia.org/wiki/Sink "Sink") [Storage water heater](https://en.wikipedia.org/wiki/Storage_water_heater "Storage water heater") [Sump pump](https://en.wikipedia.org/wiki/Sump_pump "Sump pump") [Tankless water heating](https://en.wikipedia.org/wiki/Tankless_water_heating "Tankless water heating") [Urinal](https://en.wikipedia.org/wiki/Urinal "Urinal") [Washing machine](https://en.wikipedia.org/wiki/Washing_machine "Washing machine") [Washlet](https://en.wikipedia.org/wiki/Washlet "Washlet") [Water dispenser](https://en.wikipedia.org/wiki/Water_dispenser "Water dispenser") [Water filter](https://en.wikipedia.org/wiki/Water_filter "Water filter") [Water heating](https://en.wikipedia.org/wiki/Water_heating "Water heating") [Water softening](https://en.wikipedia.org/wiki/Water_softening "Water softening") |
| Specialized tools | [Basin wrench](https://en.wikipedia.org/wiki/Basin_wrench "Basin wrench") [Blowtorch](https://en.wikipedia.org/wiki/Blowtorch "Blowtorch") [Borescope](https://en.wikipedia.org/wiki/Borescope "Borescope") [Core drill](https://en.wikipedia.org/wiki/Core_drill "Core drill") [Drain cleaner](https://en.wikipedia.org/wiki/Drain_cleaner "Drain cleaner") [Driving cap](https://en.wikipedia.org/wiki/Driving_cap "Driving cap") [Flare-nut wrench](https://en.wikipedia.org/wiki/Flare-nut_wrench "Flare-nut wrench") [Pipecutter](https://en.wikipedia.org/wiki/Pipecutter "Pipecutter") [Pipe wrench](https://en.wikipedia.org/wiki/Pipe_wrench "Pipe wrench") [Plumber's snake](https://en.wikipedia.org/wiki/Plumber%27s_snake "Plumber's snake") [Plumber wrench](https://en.wikipedia.org/wiki/Plumber_wrench "Plumber wrench") [Plunger](https://en.wikipedia.org/wiki/Plunger "Plunger") [Strap wrench](https://en.wikipedia.org/wiki/Strap_wrench "Strap wrench") [Tap and die](https://en.wikipedia.org/wiki/Tap_and_die "Tap and die") |
| Measurement and control | [Control valve](https://en.wikipedia.org/wiki/Control_valve "Control valve") [Flow sensor](https://en.wikipedia.org/wiki/Flow_measurement "Flow measurement") [Pressure sensor](https://en.wikipedia.org/wiki/Pressure_sensor "Pressure sensor") [Water detector](https://en.wikipedia.org/wiki/Water_detector "Water detector") [Water metering](https://en.wikipedia.org/wiki/Water_metering "Water metering") |
| Professions, trades, and services | [Hydronic balancing](https://en.wikipedia.org/wiki/Hydronic_balancing "Hydronic balancing") [Hydrostatic testing]() [Leak detection](https://en.wikipedia.org/wiki/Leak_detection "Leak detection") [Mechanical, electrical, and plumbing](https://en.wikipedia.org/wiki/Mechanical,_electrical,_and_plumbing "Mechanical, electrical, and plumbing") [Pipe marking](https://en.wikipedia.org/wiki/Pipe_marking "Pipe marking") [Pipefitter](https://en.wikipedia.org/wiki/Pipefitter "Pipefitter") [Pipelayer](https://en.wikipedia.org/wiki/Pipelayer "Pipelayer") [Plumber](https://en.wikipedia.org/wiki/Plumber "Plumber") |
| Industry organizations and standards | [International Association of Plumbing and Mechanical Officials (IAPMO)](https://en.wikipedia.org/wiki/IAPMO "IAPMO") [NSF International](https://en.wikipedia.org/wiki/NSF_International "NSF International") [Plumbing & Drainage Institute (PDI)](https://en.wikipedia.org/wiki/Plumbing_%26_Drainage_Institute "Plumbing & Drainage Institute") [Uniform Plumbing Code (UPC)](https://en.wikipedia.org/wiki/Uniform_Plumbing_Code "Uniform Plumbing Code") [World Plumbing Council (WPC)](https://en.wikipedia.org/wiki/World_Plumbing_Council "World Plumbing Council") |
| Health and safety | [Plumbing code](https://en.wikipedia.org/wiki/Plumbing_code "Plumbing code") [Scalding](https://en.wikipedia.org/wiki/Scalding "Scalding") [Waterborne disease](https://en.wikipedia.org/wiki/Waterborne_disease "Waterborne disease") |
| See also | [Fire sprinkler system](https://en.wikipedia.org/wiki/Fire_sprinkler_system "Fire sprinkler system") [Piping](https://en.wikipedia.org/wiki/Piping "Piping") [Template:HVAC](https://en.wikipedia.org/wiki/Template:HVAC "Template:HVAC") [Template:Public health](https://en.wikipedia.org/wiki/Template:Public_health "Template:Public health") [Template:Sewerage](https://en.wikipedia.org/wiki/Template:Sewerage "Template:Sewerage") [Template:Human waste elimination](https://en.wikipedia.org/wiki/Template:Human_waste_elimination "Template:Human waste elimination") [Template:Wastewater](https://en.wikipedia.org/wiki/Template:Wastewater "Template:Wastewater") |

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Hydrostatic test
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| Readable Markdown | From Wikipedia, the free encyclopedia
[](https://en.wikipedia.org/wiki/File:Hydrostatic_Tester.jpg)
Hydrostatic tester
A **hydrostatic test** is a way in which [pressure vessels](https://en.wikipedia.org/wiki/Pressure_vessel "Pressure vessel") such as [pipelines](https://en.wikipedia.org/wiki/Pipeline_transport "Pipeline transport"), [plumbing](https://en.wikipedia.org/wiki/Plumbing "Plumbing"), [gas cylinders](https://en.wikipedia.org/wiki/Gas_cylinder "Gas cylinder"), [boilers](https://en.wikipedia.org/wiki/Boiler "Boiler") and fuel tanks can be tested for strength and leaks. The test involves filling the vessel or pipe system with a liquid, usually water, which may be dyed to aid in visual [leak detection](https://en.wikipedia.org/wiki/Leak_detection "Leak detection"), and pressurization of the vessel to the specified test pressure. Pressure tightness can be tested by shutting off the supply valve and observing whether there is a pressure loss. The location of a leak can be visually identified more easily if the water contains a colorant. Strength is usually tested by measuring permanent deformation of the container.
Hydrostatic testing is the most common method employed for testing pipes and pressure vessels. Using this test helps maintain safety standards and durability of a vessel over time. Newly manufactured pieces are initially qualified using the hydrostatic test. They are then revalidated at regular intervals according to the relevant standard. In some cases where a hydrostatic test is not practicable a pneumatic pressure test may be an acceptable alternative.[\[1\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-Proof-1)
Testing of pressure vessels for transport and storage of gases is very important because such containers can explode if they fail under pressure.
Hydrostatic tests are conducted under the constraints of either the industry's or the customer's specifications, or may be required by law. The vessel is filled with a nearly incompressible liquid – usually [water](https://en.wikipedia.org/wiki/Water "Water") or [oil](https://en.wikipedia.org/wiki/Oil "Oil") – pressurised to test pressure, and examined for leaks or permanent changes in shape. [Red](https://en.wikipedia.org/wiki/Red "Red") or [fluorescent](https://en.wikipedia.org/wiki/Fluorescent "Fluorescent") [dyes](https://en.wikipedia.org/wiki/Dye "Dye") may be added to the water to make leaks easier to see. The test pressure is always considerably higher than the operating pressure to give a factor of safety. This factor of safety is typically 166.66%, 143% or 150% of the designed working pressure, depending on the regulations that apply. For example, if a cylinder was rated to DOT-2015 PSI (approximately 139 bar), it would be tested at around 3360 PSI (approximately 232 bar).
[Water](https://en.wikipedia.org/wiki/Water "Water") is commonly used because it is cheap and easily available, and is usually harmless to the system to be tested. Hydraulic fluids and oils may be specified where contamination with water could cause problems. These fluids are nearly incompressible, therefore requiring relatively little work to develop a high pressure, and is therefore also only able to release a small amount of energy in case of a failure - only a small volume will escape under high pressure if the container fails. If [high pressure](https://en.wikipedia.org/wiki/High_pressure "High pressure") [gas](https://en.wikipedia.org/wiki/Gas "Gas") were used, then the gas would expand to V=(nRT)/p with its compressed volume resulting in an explosion, with the attendant risk of damage or injury.
[](https://en.wikipedia.org/wiki/File:Water_jacket_test_diagram.jpg)
Water jacket test
Small pressure vessels are normally tested using a water jacket test. The vessel is visually examined for defects and then placed in a container filled with water, and in which the change in volume of the vessel can be measured, usually by monitoring the water level in a calibrated tube. The vessel is then pressurised for a specified period, usually 30 or more seconds, and if specified, the expansion will be measured by reading off the amount of liquid that has been forced into the measuring tube by the volume increase of the pressurised vessel. The vessel is then depressurised, and the permanent volume increase due to plastic deformation while under pressure (permanent set) is measured by comparing the final volume in the measuring tube with the volume before pressurisation.[\[2\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-Sauta_2010-2)
A leak will give a similar result to permanent set, but will be detectable by holding the volume in the pressurised vessel by closing the inlet valve for a period before depressurising, as the pressure will drop steadily during this period if there is a leak. In most cases a permanent set that exceeds the specified maximum will indicate failure. A leak may also be a failure criterion, but it may be that the leak is due to poor sealing of the test equipment. If the vessel fails, it will normally go through a condemning process marking the cylinder as unsafe.[\[2\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-Sauta_2010-2)[\[3\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-Hydro_Key_Largo-3)
The information needed to specify the test is stamped onto the cylinder. This includes the design standard, serial number, manufacturer, and manufacture date. After testing, the vessel or its nameplate will usually be stamp marked with the date of the successful test, and the test facility's identification mark.[\[3\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-Hydro_Key_Largo-3)
A simpler test, that is also considered a hydrostatic test but does not require pressure pumps, is to pressurise the vessel by filling it with water to a hydrostatic head by using a riser pipe connected to the tank and to physically examine the outside for leaks. This type of test is suitable for containers such as boat fuel tanks, which are not pressure vessels but must work under the hydrostatic pressure of the contents. A hydrostatic test head is usually specified as a height above the tank top. The tank is pressurised by filling water to the specified height through a temporary standpipe if necessary. It may be necessary to seal vents and other outlets during the test.[\[4\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-4)
Portable fire extinguishers are safety tools that are required in most public buildings. Fire extinguishers are also recommended in homes. Over time the conditions in which they are housed, and the manner in which they are handled affect the structural integrity of the extinguisher. A structurally weakened fire extinguisher can malfunction or even burst when it is needed the most. To maintain the quality and safety of this product, hydrostatic testing is utilized. All critical components of the fire extinguisher should be tested to ensure proper function.
Hydrotesting of pipes, pipelines and vessels is performed to expose defective materials that have missed prior detection, ensure that any remaining defects are insignificant enough to allow operation at design pressures, expose possible leaks and serve as a final validation of the integrity of the constructed system. ASME B31.3 requires this testing to ensure tightness and strength.
Buried high pressure oil and gas pipelines are tested for strength by pressurising them to at least 125% of their [maximum allowable working pressure](https://en.wikipedia.org/wiki/Maximum_allowable_working_pressure "Maximum allowable working pressure") (MAWP) at any point along their length. Since many long distance transmission pipelines are designed to have a steel hoop stress of 80% of [specified minimum yield strength](https://en.wikipedia.org/wiki/Specified_minimum_yield_strength "Specified minimum yield strength") (SMYS) at [Maximum allowable operating pressure](https://en.wikipedia.org/wiki/Maximum_allowable_operating_pressure "Maximum allowable operating pressure") MAOP, this means that the steel is stressed to SMYS and above during the testing, and test sections must be selected to ensure that excessive plastic deformation does not occur.\[*[citation needed](https://en.wikipedia.org/wiki/Wikipedia:Citation_needed "Wikipedia:Citation needed")*\]
For piping built to ASME B31.3, if the design temperature is greater than the test temperature, then the test pressure must be adjusted for the related allowable stress at the design temperature. This is done by multiplying 1.5 MAWP by the ratio of the allowable stress at the test temperature to allowable stress at the design temperature per ASME B31.3 Section 345.4.2 Equation 24. Test pressures need not exceed a value that would produce a stress higher than yield stress at test temperature. ASME B31.3 section 345.4.2 (c)
Other codes require a more onerous approach. BS PD 8010-2 requires testing to 150% of the *design* pressure – which should not be less than the MAOP plus surge and other incidental effects that will occur during normal operation.\[*[citation needed](https://en.wikipedia.org/wiki/Wikipedia:Citation_needed "Wikipedia:Citation needed")*\]
Leak testing is performed by balancing changes in the measured pressure in the test section against the theoretical pressure changes calculated from changes in the measured temperature of the test section.
Australian standard AS2885.5 "Pipelines – Gas and liquid petroleum: Part 5: Field pressure testing" gives an excellent explanation of the factors involved.\[*[clarification needed](https://en.wikipedia.org/wiki/Wikipedia:Please_clarify "Wikipedia:Please clarify")*\]
In the aerospace industry, depending on the airline, company or customer, certain codes will need to be followed. For example, Bell Helicopter has a certain specification that will have to be followed for any parts that will be used in their helicopters.\[*[citation needed](https://en.wikipedia.org/wiki/Wikipedia:Citation_needed "Wikipedia:Citation needed")*\]
Most countries have legislation or pressure vessel codes which requires vessels to be regularly tested, for example every two years (with a visual inspection annually) for high pressure gas cylinders and every five or ten years for lower pressure ones such as used in [fire extinguishers](https://en.wikipedia.org/wiki/Fire_extinguisher "Fire extinguisher").[\[5\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-5) \[*[clarification needed](https://en.wikipedia.org/wiki/Wikipedia:Please_clarify "Wikipedia:Please clarify")*\] Gas cylinders which fail are normally destroyed as part of the testing protocol to avoid the dangers inherent in them being subsequently used.[\[6\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-6)
These common US standard gas cylinders have the following requirements:[\[7\]](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_note-7)
- DOT-3AL gas cylinders must be tested every 5 years and have an unlimited life.
- DOT-3HT gas cylinders must be tested every 3 years and have a 24-year life.
- DOT-3AA gas cylinders must be tested every 5 years and have an unlimited life. (Unless stamped with a star (\*) in which case the cylinder meets certain specifications and can have a 10-year hydrostatic test life).
Typically organizations such as DOT [PHMSA](https://en.wikipedia.org/wiki/PHMSA "PHMSA"), [ISO](https://en.wikipedia.org/wiki/ISO "ISO"), [ASTM](https://en.wikipedia.org/wiki/ASTM "ASTM") and [ASME](https://en.wikipedia.org/wiki/ASME "ASME") specify the guidelines for the different types of pressure vessels.
Hydraulic testing is a hazardous process and should be performed with caution by competent personnel. Adhering to prescribed procedures defined in relevant [technical standards](https://en.wikipedia.org/wiki/Technical_standards "Technical standards") appropriate to the specific application and jurisdiction will usually reduce these risks to an acceptable level.
- A leak of high pressure liquid can cut or penetrate the skin and inject itself into body tissues. This can cause serious direct injury to the operator, and if the fluid is toxic or contaminated there will be additional adverse effects.
- A pressurised hose that is not securely attached or which fails under pressure may whip around spraying water or oil and could hit someone and cause injuries. A [whiplash arrestor](https://en.wikipedia.org/wiki/Glossary_of_underwater_diving_terminology:_T%E2%80%93Z#whiplash_arrestor "Glossary of underwater diving terminology: T–Z") can be used to restrain such hoses.
- Enclosing the components to be tested, hazard signage, use of appropriate [personal protective equipment](https://en.wikipedia.org/wiki/Personal_protective_equipment "Personal protective equipment") and providing barriers to access for non-essential personnel are common precautions.
- [Nondestructive testing](https://en.wikipedia.org/wiki/Nondestructive_testing "Nondestructive testing") – Type of analysis technique
- [Testing and inspection of diving cylinders](https://en.wikipedia.org/wiki/Testing_and_inspection_of_diving_cylinders "Testing and inspection of diving cylinders") – Periodical inspection and testing to revalidate fitness for service
1. **[^](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-Proof_1-0)**
["Proof-Pressure Test and Leak Detection Test in Metal Expansion Joints"](https://www.macoga.com/documents/en/metal-expansion-joints/proof-pressure-test-leak-detection-test.pdf) (PDF). *www.macoga.com*. Macoga SA. Retrieved 24 September 2021.
2. ^ [***a***](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-Sauta_2010_2-0) [***b***](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-Sauta_2010_2-1)
Sauta, Tom (1 Oct 2010). ["Hydro-Test Water Jacket Cylinder Test System Setup.wmv"](https://www.youtube.com/watch?v=KLrV0vGBZEk). www.hydrotest.com. Retrieved 29 July 2025 – via YouTube.
3. ^ [***a***](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-Hydro_Key_Largo_3-0) [***b***](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-Hydro_Key_Largo_3-1)
Angel (17 May 2022). ["How to Hydro Test a scuba tank"](https://www.youtube.com/watch?v=Bwd-GFCtLl8). Scuba Tech Key Largo. Retrieved 29 July 2025 – via YouTube.
4. **[^](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-4)**
Kim; An, Tae-Hyun; Lee, Tak-Kee (April 2022). ["Preliminary Study on Deformation During Hydrostatic Testing in a Deep Tank }first1=Geun-Gon"](https://doi.org/10.26748%2FKSOE.2021.075). *J. Ocean Eng. Technol*. **36** (2): 115–124\. [doi](https://en.wikipedia.org/wiki/Doi_\(identifier\) "Doi (identifier)"):[10\.26748/KSOE.2021.075](https://doi.org/10.26748%2FKSOE.2021.075).
5. **[^](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-5)**
["Federal Register :: Request Access"](https://www.ecfr.gov/current/title-49/subtitle-B/chapter-I/subchapter-C/part-180#p-180.209\(j\)).
6. **[^](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-6)**
["Federal Register :: Request Access"](https://www.ecfr.gov/current/title-49/subtitle-B/chapter-I/subchapter-C/part-180#p-180.205\(i\)).
7. **[^](https://en.wikipedia.org/wiki/Hydrostatic_test#cite_ref-7)**
["Federal Register :: Request Access"](https://www.ecfr.gov/current/title-49/section-180.209).
- ["OSHA"](https://www.osha.gov/SLTC/etools/evacuation/portable_hydro.html). Retrieved 2006-10-05. |
| Shard | 152 (laksa) |
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