Hydrostatic Testing Services

ASME Hydrostatic Test Requirements

Our ASME hydrostatic test services use ISO 17025 accredited, ISTA certified, ANAB accredited, CSA approved laboratories. We are no strangers to highly customized as well as routine testing and test system development based on decades of engineering experience.

We are no ordinary test laboratory service because we strive to work with our clients to maximize the desired test output cost-effectively, and in a timely manner.

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Pressure Testing

Right to left: High temp. steam, large safety chamber, high temp. pressure chamber

ASME Hydrostatic Test Requirements – Titan Research Group’s hydrostatic pressure testing services utilizes state-of-the-art precision servo hydraulic pressure generators, which when compared to standard air-to-fluid pressure boosters, eliminates pressure fluctuation and produces linear ramp rates.

Our hydro performance test lab features test equipment that can utilize pressure transducers that are NIST traceable with ISO 17025 calibration certificates. The following ASME B31.3 pressure testing solutions are provided:

Pressure burst, leak and proof testing to CSA, ASTM, AWWA, ISO, and ASME standards
TSSA witnessed proof testing service
Advanced high pressure impulse cycle testing between 50 and 100,000 psi at rates up to 20 Hz. High tolerance trapezoid, square and sine waveforms can be controlled in very tight tolerance. Automatic sample failure detection.
Combined pressure, load and temperature testing to apply mechanical load and extreme temperature conditions in a load range up to 110,000 lb from -70 to 600ºC
Test mediums: water, steam, oil, calibration fluids, nitrogen & air
Test pressure up to 100,000 psi

Industry Applications of Hydrostatic Testing

Oil and Gas Pipelines and Equipment

Hydrostatic testing makes sure that pipelines, pressure vessels, and storage tanks in the oil and gas industry can safely handle high pressures. Testing before commissioning helps identify leaks, weak joints, or potential rupture points that could cause environmental damage or operational downtime. It’s particularly critical for offshore platforms, refineries, and distribution networks where safety and containment are paramount.

Chemical and Process Industries

Reactors, storage tanks, and pressure vessels used in chemical processing are subjected to rigorous hydrostatic tests to guarantee containment of hazardous or volatile substances. By simulating operating pressures beyond normal conditions, hydrostatic testing guarantees that the equipment can withstand stress without leaks or failures, protecting both employees and surrounding facilities.

Water and Wastewater Systems

Municipal water distribution and wastewater treatment rely on hydrostatic testing to confirm that pipelines, pumps, and storage tanks function correctly under full operational pressure. Testing helps prevent leaks and contamination, verifies reliability, and confirms that infrastructure meets regulatory standards for safe water delivery and environmental protection.

Energy and Power Generation

Boilers, steam lines, and high-pressure turbines in power plants are subjected to hydrostatic testing to validate structural integrity and safe operation under extreme pressure and temperature conditions. This testing reduces the risk of catastrophic failures, supports regulatory compliance, and helps optimise energy system performance.

Manufacturing and Industrial Equipment

Pressure vessels, piping systems, and high-pressure equipment used in manufacturing industries such as metals, pharmaceuticals, and food processing undergo hydrostatic testing to verify durability and consistent performance. Proper testing minimises downtime, prevents accidents, and guarantees that equipment meets both safety and quality standards.

The Importance of Pressure Testing

Pressure testing is a critical step in verifying the integrity and safety of piping systems and pressure vessels. Tests are conducted at pressures exceeding the expected operating levels to confirm that the system can withstand normal service conditions without failure.

Equipped with advanced technology and extensive experience, Titan Research Group provides comprehensive pressure testing services for both liquid and gas applications. Our team can conduct tests at pressures up to 100,000 psi, ensuring all systems meet regulatory standards and are safe for commissioning and continued operation.

Structural and Mechanical Testing

✔ Cyclic and dynamic loading

✔ Load capacity up to 110,000 lb

✔ Servo-hydraulic test rigs

Pressure Testing Equipment For Pipes

Pressure Testing Equipment For Pipes is a test that is carried out at any under-construction site after the installation of the pipes before we put them into use. This is done to evaluate the certain limits of pipelines in terms of reliability, maximum capacity, leaks, joint fittings, and pressure. Without testing the installed pipelines, one cannot ensure if pipes meet the standard installation requirements. While the non-technical basic purpose of developing the system for pipelines is to ensure the safety of labor working on the construction site and outline the safety practices that must be carried out while testing pipes.

The main responsibility of Pressure Testing Equipment for Pipes lies with two personnel, the plumbing foreman and the project engineer. They perform the hydrostatic test to find out leakages or damages in the pipelines. The information received from the test helps construction personnel to maintain the safety standards and keep the pipelines in good working condition. This information is documented and signed by the assigned personnel.

The system uses two methods: Hydrostatic Pressure Testing Equipment For Pipes and Pneumatic Pressure. These test methods use the quick couplings and air compressors as the testing equipment.

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Safety Protocols and Risk Management

Safety is critical during hydrostatic testing because pressurised systems can be hazardous if not managed correctly. Before testing begins, a thorough risk assessment is performed to identify potential hazards. All personnel follow strict personal protective equipment (PPE) requirements and safe work procedures. Equipment is inspected for integrity, and fail-safe pressure relief systems are in place to prevent accidental over-pressurisation.

Test plans include emergency shutoff procedures, monitoring protocols, and contingency steps for unexpected failures. By following these strict safety measures, hydrostatic testing not only verifies system integrity but also protects personnel, property, and the surrounding environment.

Pressure-Temperature Curves for Process Instrumentation

Establishing reliable temperature de-rating curves for products not covered by published North American standards is becoming an industry norm and expectation. Not only is it prudent to provide de-rating guidelines, but it is essential to the safety of instrumentation operation to understand the pressure-temperature behaviour of the product under various conditions such as: inlet temperature, working fluid type, ambient temperature, and pressure.

Canadian Registration Number Pressure Testing

When applying for a Canadian Registration Number (CRN), the CSA B51 referenced code, or a particular Canadian review engineer at any one of the review authorities, may require witnessed pressure testing to ASME code, or other accepted code.

Advanced Testing Techniques and Innovations

Modern hydrostatic testing has evolved beyond basic pressure checks. Today, advanced techniques allow for precise, repeatable, and data-driven testing. Digital pressure monitoring systems provide real-time feedback on pressure changes, while automated data logging creates detailed test reports that support regulatory audits. High-frequency impulse testing simulates rapid pressure fluctuations to uncover potential failure points before equipment is put into service.

Moreover, some labs integrate non-destructive evaluation (NDE) methods alongside hydrostatic testing to detect micro-cracks or weak welds without damaging equipment. These innovations guarantee more accurate results, minimise retesting, and reduce overall downtime for clients.

Package Testing

✔ ISTA standard package testing

✔ Shipping container testing up to 8’x5′

✔ Mechanical and environmental simulation

CLIENTS WE’VE HELPED WITH OUR TESTING SERVICES

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FAQs About Hydrostatic Pressure Testing

What is pressure testing?

Pressure testing is a method used to verify the integrity and safety of pressure vessels, pipelines, and other pressurized systems. It involves applying a controlled pressure test to make sure the system can operate safely under expected conditions. Companies looking for hydrostatic pressure testing services can find professionals to carry out these tests safely and accurately.

What is the difference between a hydrostatic test and a hydrotest?

Hydrostatic test and hydrotest are often used interchangeably. Both involve filling a system with water and applying pressure to check for leaks or weaknesses. An ASME pressure vessel hydrostatic test is a common type of hydrotest used for certified vessels and piping systems.

What is the typical hydrostatic test pressure?

The typical hydrostatic test pressure is usually 1.3 to 1.5 times the system’s design pressure, depending on regulations and equipment standards. Pressure testing companies will determine the exact pressure based on the design code and safety requirements.

What is a hydrostatic test for HST?

A hydrostatic test for HST (High-Pressure Steam Turbines or High-Pressure Systems) ensures that equipment can withstand operational pressures without leaking or failing. Professionals offering hydrostatic pressure testing services can conduct this test safely.

How long does a hydrostatic test last?

A hydrostatic test typically lasts from 15 minutes to a few hours, depending on system size, design pressure, and regulatory requirements.

How many types of hydrostatic tests are there?

The most common types are:

ASME pressure vessel hydrostatic test – for ASME-certified vessels.
Pneumatic tests – using air or gas instead of water.
Hydrostatic tests are preferred for safety because water is incompressible.

What are the rules for hydrostatic testing?

Hydrostatic testing must comply with standards like ASME, CSA, and local regulatory codes. Companies offering hydrostatic pressure testing services must follow strict procedures for test pressure, duration, and safety.

What are the risks of hydrostatic testing?

Risks include leaks, ruptures, or sudden releases of pressure. Using qualified pressure testing companies ensures the test is conducted safely.

What is the safest type of pressure testing?

Hydrostatic testing is considered the safest because water is incompressible. This reduces the stored energy in the system during testing, minimizing the risk of explosive failure if a leak or rupture occurs.

What happens when a hydrostatic test fails?

If a hydrostatic test fails, the system is depressurized and inspected to identify leaks or weak points. Necessary repairs or redesigns must be made before retesting.

How is hydrostatic test data interpreted?

Data from pressure transducers and monitoring equipment is analysed to verify that the system meets design pressures and shows no leakage. Deviations are investigated and documented for corrective action.

How often should hydrostatic tests be performed?

Testing frequency depends on regulations, equipment type, and operational conditions. Many industrial pipelines and pressure vessels are tested at initial commissioning and after major maintenance or modification.

Can testing be done on-site or only in a lab?

Both options are available. On-site testing is ideal for large pipelines or installed systems, while lab-based testing allows controlled conditions and precise instrumentation.

What best practices improve hydrostatic test results?

Maintain proper system preparation, accurate calibration of test equipment, controlled ramp rates, clear communication among testing personnel, and detailed documentation. Following these practices minimises errors and provides reliable, actionable results.