When it comes to hydraulic and pressure systems, safety isn’t optional, it’s essential. One small failure in a hose, cylinder, or pipeline can turn into a costly disaster. That’s where hydrotesting comes in: a controlled, precise way to ensure your equipment can handle the pressure before it faces the real world.
If you’re new to hydrotesting or looking to expand your knowledge, it helps to understand the different types of hydrotesters and equipment available. Here is a simple guide for understanding some of the equipment and components to a hydrotesting system.
1. Custom Test Benches
Custom test benches are stationary setups designed for testing specific equipment, such as hydraulic cylinders, valves, pumps, or tanks. Like buying a new car, what the show next to you needs may not be what you need and having the option for customization can help ensure the productivity and safety are not compromised.
Purpose: These benches allow operators to safely simulate real-world operating conditions while controlling pressure, temperature, and fluid flow.
Features: They often include pressure gauges, relief valves, and automated controls. Some benches can test multiple units simultaneously.
Benefits: Using a custom bench ensures accurate testing, repeatability, and safety, making them ideal for in-house testing of standard equipment or quality control purposes.
2. Custom Portable Hydrotesters
Portable hydrotesters bring the same precision as a test bench but with the flexibility to work on-site. Not everything can be down in a shop all the times and having the ability to bring your hydrotesters to site, can be a game changer.
Purpose: Perfect for field testing of pipelines, hoses, or hydraulic systems that cannot be moved to a shop.
Features: Lightweight frames, built-in pumps, adjustable pressure settings, and easy connections to hoses and fittings. Some portable units are battery-powered or equipped with electric motors for remote locations.
Benefits: They allow technicians to perform inspections and maintenance without disrupting operations or transporting heavy equipment.
3. Data Logger Systems
Modern hydrotesting isn’t just about pass or fail—it’s about capturing information. Now we are getting fancy.
Purpose: Data loggers record pressure, temperature, flow, and time during a hydrotest.
Features: Digital displays, automated logging, wireless connectivity, and integration with reporting software.
Benefits: These systems provide traceable records for compliance with safety regulations, help identify trends in equipment performance, and improve troubleshooting efficiency.
4. Electrical Hydrotesters
Electrical hydrotesters automate the pressurization process for precise and repeatable results.
Purpose: Designed for high-volume or highly-sensitive equipment testing.
Features: Programmable pressure profiles, automatic pressure ramp-up and release, and safety shutdown systems.
Benefits: They reduce human error, improve efficiency, and ensure that sensitive equipment is tested under exact conditions without risk.
5. Gas Boosters
Gas boosters are specialized hydrotesting units that use gas to pressurize equipment. Not all pressure systems are hydraulic and with that there needs to be someone that can accommodate.
Purpose: Ideal for pneumatic systems or applications where hydraulic fluid is unsuitable.
Features: Adjustable pressure control, compact design, and compatibility with different gases.
Benefits: They offer controlled, high-pressure testing while eliminating the need for hydraulic fluid, reducing contamination risk, and making certain leak detection tests easier.
6. Hoses and Fittings
Using the correct hose and fittings for your hydrotesting unit is equally as important as the unit itself. All of them are rated for certain working pressures, attachment sizes and types and these need to be appropriate for what you are testing.
Purpose: Safely transfer pressurized fluids or gases between the hydrotester and the equipment being tested.
Features: Rated for different PSI ranges, flexible or rigid options, corrosion-resistant materials, and quick-connect fittings.
Benefits: Correct hoses and fittings prevent leaks, bursts, and pressure drops, ensuring the accuracy of your tests and safety of personnel.
7. Understanding Different PSI Levels
Low pressure, medium pressure, high pressure and even ULTRA high pressure. PSI rating ranges from equipment and needs and understanding what the pressure is that you need is extremely important. With hydrotesting, different equipment requires testing at different pressures to ensure reliability.
Purpose: Determine the maximum operating pressure and safety limits of the equipment.
Guidance: Always test slightly above the normal operating pressure, following manufacturer recommendations and industry standards.
Benefits: Proper PSI testing ensures that the equipment will withstand real-world conditions without failure, helping prevent accidents and downtime.
What does it come down to?
Hydrotesting may not be flashy, but it is critical to industrial safety and operational reliability. Whether you’re using a custom test bench, a portable hydrotester, data logging systems, electrical hydrotesters, gas boosters, or the right hoses and fittings, understanding your options ensures you can test safely, accurately, and efficiently.
Whether you’re looking to design and build a brand-new custom hydrotesting unit or need support with your existing system, we’re here to work with you every step of the way. Our team can tailor solutions to meet your exact needs and ensure your equipment performs at its best.