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Service · Pressure Testing

500 bar hydrostatic. Helium leak detection. Pressure verified.

Q: What pressure for hydraulic components?

Standard hydraulic proof test: 1.5× design pressure for 5-15 minutes. For 200 bar working pressure → 300 bar proof. For 350 bar working pressure → 525 bar proof. Test duration per ASME or customer specification. After proof: visual inspection for permanent deformation, leak check at working pressure. Hardware passes if no leaks at working pressure and no permanent deformation.

Q: When is helium leak testing needed?

Helium leak required when leak rate must be very low: vacuum chambers (sub-10⁻⁸ atm·cc/sec), semiconductor process equipment, refrigerant systems, aerospace fuel/oxidizer, medical gas systems, scientific instruments. Standard pressure test (bubble or pressure decay) only detects gross leaks. For "no detectable leakage", helium method required. Sensitivity 10⁻⁹ atm·cc/sec ≈ 0.001 cc per year leakage at atmospheric pressure differential.

Q: API 6A pressure test specifics?

API 6A: oilfield equipment standard. Hydrostatic test 1.5× rated working pressure for 5 minutes minimum, 15 minutes for high-pressure equipment. Witnessed testing required for API 6A monogrammed equipment (we work with monogrammed customer manufacturers). Documentation: test certificate, pressure vs time chart, leak check results.

Q: Pressure vs leak distinction?

Pressure test: verify the part can withstand pressure without permanent deformation or rupture. Leak test: verify no fluid escapes through joints, seals, welds. Often combined — pressurize and check for leaks simultaneously. For critical applications, both tested separately at different pressures and durations.

Q: Test before final assembly?

Often. Test individual components or sub-assemblies before final assembly — easier to identify and fix leak source. After final assembly, system test verifies overall integrity. For complex hydraulic systems, multi-stage testing common: component test, sub-assembly test, system test.

Q: What documentation accompanies tests?

Test certificates include: test method, test pressure and duration, results (pass/fail with leak rates if applicable), pressure vs time chart, calibrated equipment IDs with last calibration date, operator signature, witnessed signature if applicable, photos of test setup if required. Format per customer specification.

Pressure and leak testing services for hydraulic components, pressure vessels, fluid handling systems. Hydrostatic to 500 bar (7250 psi), pneumatic, helium mass spectrometer leak detection. API/ASME-compatible documentation.

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Inspection & testingWuxi, ChinaMOQ 1 partDFM review included

Technical plate for 500 bar hydrostatic. Helium leak detection. Pressure verifie

How we run it

Pressure leak testing

Different pressure tests for different applications. Method selection depends on pressure level, fluid compatibility, leak detection sensitivity, and customer specification.

3-7 daysTypical lead time

MOQ 1No minimum quantity

<4 hQuote response

ISO 9001Quality system

01 · Test methods

Pressure test methods.

Hydrostatic test

Water-based pressure test. Typical proof test 1.5× design pressure for 5-15 minutes per ASME or API 6A. Standard for hydraulic and pressure vessels.

Pneumatic test

Air or nitrogen pressure test. Required when liquid contamination unacceptable. Higher safety risk — protective barriers used.

Helium leak detection

Mass spectrometer detects helium leakage. Most sensitive leak test. Standard for vacuum chambers, semiconductor, aerospace fuel.

Bubble leak test

Visual bubble detection in soap solution. Simple, no special equipment. Sensitivity 10⁻⁴ atm·cc/sec — adequate for most plumbing.

Pressure decay test

Pressurize, isolate, monitor pressure over time. Rate of decay indicates leakage. Common for production line testing.

Mass flow test

Measure flow into pressurized system to maintain pressure. Indicates leakage rate. Production-line capable.

Burst pressure test

Increase pressure until part fails. Verify margin to design pressure. Destructive test for design qualification.

Cycle pressure test

Repeated pressurization cycles to verify fatigue life. Critical for hydraulic components in cyclic service.

Witnessed testing

Customer or inspection agency witnesses test. Required for API 6A, some pressure vessel applications, acceptance.

Different pressure tests for different applications. Method selection depends on pressure level, fluid compatibility, leak detection sensitivity, and customer specification.

02 · Test capabilities

Test bay specifications.

Hydrostatic to 500 bar

7250 psi capability for typical hydraulic components

Pneumatic to 100 bar

1450 psi air/nitrogen capability

Helium leak to 10⁻⁹ atm·cc/sec

Mass spectrometer for vacuum-grade leak detection

Calibrated pressure transducers

NIST-traceable pressure measurement

Test fixtures

Standard and custom fixtures for component testing

Recording equipment

Pressure vs time recorded for each test

Witnessed test capability

Customer or 3rd-party inspection accommodated

Documentation

Test certificates with calibrated equipment IDs

Higher pressure routing

Pressures above 500 bar via partner facilities

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FAQ

500 bar hydrostatic — questions

What pressure for hydraulic components?

Standard hydraulic proof test: 1.5× design pressure for 5-15 minutes. For 200 bar working pressure → 300 bar proof. For 350 bar working pressure → 525 bar proof. Test duration per ASME or customer specification. After proof: visual inspection for permanent deformation, leak check at working pressure. Hardware passes if no leaks at working pressure and no permanent deformation.

When is helium leak testing needed?

Helium leak required when leak rate must be very low: vacuum chambers (sub-10⁻⁸ atm·cc/sec), semiconductor process equipment, refrigerant systems, aerospace fuel/oxidizer, medical gas systems, scientific instruments. Standard pressure test (bubble or pressure decay) only detects gross leaks. For "no detectable leakage", helium method required. Sensitivity 10⁻⁹ atm·cc/sec ≈ 0.001 cc per year leakage at atmospheric pressure differential.

API 6A pressure test specifics?

API 6A: oilfield equipment standard. Hydrostatic test 1.5× rated working pressure for 5 minutes minimum, 15 minutes for high-pressure equipment. Witnessed testing required for API 6A monogrammed equipment (we work with monogrammed customer manufacturers). Documentation: test certificate, pressure vs time chart, leak check results.

Pressure vs leak distinction?

Pressure test: verify the part can withstand pressure without permanent deformation or rupture. Leak test: verify no fluid escapes through joints, seals, welds. Often combined — pressurize and check for leaks simultaneously. For critical applications, both tested separately at different pressures and durations.

Test before final assembly?

Often. Test individual components or sub-assemblies before final assembly — easier to identify and fix leak source. After final assembly, system test verifies overall integrity. For complex hydraulic systems, multi-stage testing common: component test, sub-assembly test, system test.

What documentation accompanies tests?

Test certificates include: test method, test pressure and duration, results (pass/fail with leak rates if applicable), pressure vs time chart, calibrated equipment IDs with last calibration date, operator signature, witnessed signature if applicable, photos of test setup if required. Format per customer specification.

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