Pipe testing (leak and pressure testing)

Ensuring leak tightness and load-bearing capacity – reliably under operating pressure

Pipelines and pressure-bearing components are often exposed to high mechanical, thermal, or chemical stresses. Even the smallest leaks or material weaknesses can lead to malfunctions, loss of efficiency, or safety-critical damage.

Pipe testing verifies whether the component can withstand the intended operating pressure over the long term and does not exhibit any unacceptable leaks. Depending on the requirements, leak tests, pressure tests, or supplementary non-destructive testing methods are used.

What characteristics are examined?

The following properties, among others, can be evaluated during pipe testing:

• Tightness of piping, screw connections, and welded joints
• Pressure resistance under defined test conditions
• Material weaknesses or wall thickness deviations
• Surface or volumetric defects in pressure-bearing areas

The selection of the test method depends on the medium, operating pressure, material, and the respective safety requirements.

Testing methods used

Pipe testing may involve various methods depending on the testing objective:

• Pressure testing (hydrostatic or pneumatic) – to verify strength and leak tightness under defined test pressure
• Leak testing – to detect even the smallest leaks
• Ultrasonic testing (UT) – to determine wall thicknesses or detect internal defects
• Radiographic testing (RT) – for volumetric evaluation of welds
• Visual testing (VT) – for inspecting surfaces, joints, and assembly conditions

In safety-critical applications, these methods are often combined to verify both structural integrity and leak tightness.

Typical applications of pipe testing

Pipe inspection is used in particular:

• After the manufacture or installation of piping
• After welding work on pressure pipes
• As part of maintenance measures
• Before commissioning technical systems
• At recurring inspection intervals

Depending on requirements, the inspection is performed on a random basis, during production, or as a complete pressure acceptance test.

Industries and application areas of pipe inspection

Pipe inspection is required wherever media are transported or conveyed under pressure, including in:

• Energy and power plant sector
• Mechanical and plant engineering
• Chemical and process industry
• Aerospace
• Automotive and supplier industry
• Pipeline and pressure vessel construction

The specific design of the inspection depends on the component, accessibility, and the respective quality requirements.

Conducting pipe inspections at Technomix

Pipe inspections are performed based on clearly defined test parameters and agreed-upon specifications. Depending on the inspection objective, suitable pressure or leak testing methods are selected and, if necessary, supplemented by non-destructive testing methods.

The results are documented in a traceable manner and integrated into the existing quality process. Organizational integration takes place within the framework of our quality management system in accordance with DIN EN ISO 9001.