Pipeline Integrity Testing
Each year thousands of pipelines break across all industries, from energy to municipal, causing millions of dollars in damage and downtime. The best way to avoid this problem is to take a proactive approach through pipeline integrity testing. Integrity testing is used to examine the structural integrity of a pipeline system. This type of testing is a universal method that can apply to almost any pipeline.
One of the main types of pipeline integrity testing is hydrostatic testing. Typically, hydrostatic testing is required to install a new pipeline system. Using this type of testing, you can ensure that your new pipeline systems will operate at maximum fitness.
American Pipeline Solutions offers efficient and low-cost pipeline integrity testing solutions to our clients through hydrostatic testing. Keep reading to learn more about our pipeline integrity testing processes, who benefits from it and more.
American Pipeline Solutions’ Pipeline Integrity Testing Process: Hydrostatic Testing
The first step that APS takes when performing hydrostatic testing is to fill your pipeline. Our team uses high flow pumps during this filling process. Once the pipeline has been filled, the pipeline’s pressure is brought to the appropriate pressure level for testing. APS does this by using what is called a “squeeze” pump.
When the pipeline reaches a good line fill, our APS technicians monitor your pipeline’s pressure. This is achieved through the use of monitoring equipment, including calibrated deadweights, digital gauges and recorders.
After testing has been completed to industry standards, APS begins the process of depressurizing your pipelines. The depressuring process is carefully done to ensure the safety of the pipeline. In addition, this process is necessary to maintain compliance with industry code and standards.
What is Pipeline Integrity Testing?
Pipeline integrity testing refers to various processes, hydrostatic testing, used to test the structural integrity of a pipe.
Hydrostatic testing is used to test certain pressure vessels, such as plumbing systems or pipelines. This test aims to examine the strength of a vessel, which is a pipeline in this context. Through hydrostatic testing, you can determine the overall operational fitness of your pipeline. In addition, hydrostatic testing allows you to identify leaks in your pipeline. Because of this leak detection capability, hydrostatic testing is an important process to utilize when testing your pipes.
One scenario where hydrostatic testing is necessary is when you install a new pipeline. Once you’ve installed a new pipeline, you are sometimes required to undergo hydrostatic testing to test your pipe’s integrity.
When it comes to the testing of existing pipelines, integrity testing is required for certain asset owners. Let’s say you’re the owner of a natural gas company, and you transport your gas through pipeline systems. In this scenario, you would be required to test your pipelines every 3-5 years. The frequency of this testing depends on where your pipes are located.
Why Pipeline Integrity Testing Matters
Pipeline integrity testing plays a critical role in ensuring the safe and efficient operation of pipeline systems across various industries. From water and wastewater systems to high-pressure energy pipelines, proactive testing helps detect weaknesses or defects before they lead to costly failures. By simulating operational pressures or flow conditions, integrity testing allows operators to validate the pipeline’s structural strength and identify vulnerabilities early.
The main purpose of this testing is fourfold: to ensure safety, maintain operational efficiency, meet regulatory compliance, and extend the service life of assets. Preventing pipeline ruptures or leaks safeguards people, the environment, and property. At the same time, consistent testing reduces the likelihood of unexpected downtime and maintains optimal flow. In many industries, testing is also required to comply with safety standards and regulatory frameworks. Over time, routine integrity testing helps asset managers make informed maintenance decisions and preserve the long-term health of pipeline infrastructure.
Common Signs Your Pipeline Needs Integrity Testing
Even if your pipeline is functioning now, certain warning signs indicate that integrity testing is overdue. Ignoring these early indicators can lead to costly breakdowns, non-compliance, and safety hazards. If you’ve noticed any of the following, it’s time to schedule an inspection:
Unexplained pressure drops or reduced flow rates: These could point to hidden leaks or internal damage.
Visible signs of wear or corrosion: Joint leaks, rust, or degradation on the exterior of the pipeline may suggest internal weakness.
Environmental or structural disturbances: Ground shifts from nearby construction, floods, or earthquakes can compromise pipeline stability.
Missed testing deadlines: If it’s been more than 3–5 years since your last integrity test, you may be out of compliance with industry regulations.
Regular testing helps catch minor issues before they escalate — and ensures your operation stays efficient, safe, and compliant.
Other Pipeline Integrity Testing Methods
While hydrostatic testing is one of the most widely used methods for assessing pipeline integrity—especially for newly installed or pressurized systems—there are other industry-standard techniques used to detect flaws, prevent failures, and maintain compliance.
1. Inline Inspection (ILI):
Also known as smart pigging, this method involves running a tool (called a pig) through the pipeline to collect data about its internal condition. ILI tools can detect corrosion, metal loss, cracks, and geometric defects. This method is non-destructive and ideal for pipelines that are in service.
2. Direct Assessment:
Direct Assessment is a four-step process used to evaluate pipeline threats without inserting tools inside the pipe. It includes pre-assessment, indirect inspection (like cathodic protection readings), direct examination of areas of concern, and post-assessment. It's commonly used for pipelines that can't accommodate ILI tools.
3. Ultrasonic Testing (UT):
This non-destructive technique uses high-frequency sound waves to detect flaws or measure wall thickness. UT can be applied internally (with inline tools) or externally on exposed sections of pipeline. It’s especially useful in identifying localized corrosion or weld defects.
4. Magnetic Flux Leakage (MFL):
MFL uses magnetic fields to detect metal loss or pitting corrosion in pipelines. The method is commonly used for inline inspection and tank floor evaluations, providing detailed data on pipeline anomalies.
5. Acoustic Emission Testing:
This method detects transient elastic waves generated by crack formation or corrosion inside the pipe. It is often used in real-time monitoring and can help pinpoint active defects while the pipeline is under stress.
What Pipelines Can be Tested?
Pipeline integrity testing can be performed in any type of pipeline. Examples of these types of pipelines include:
PVC
Cast iron
Ductile iron
PVC
Steel
HDPE
APS has experience performing integrity testing in numerous types of pipeline systems. These pipeline systems include:
New gas pipeline systems
New water pipeline systems
Natural gas pipelines
Water or wastewater lines
This is by no means an exhaustive list. Customers are welcome to contact the APS team to find an appropriate integrity testing solution for their pipelines.
Want to learn how pipeline integrity testing can benefit your pipeline systems?
Contact the team at American Pipeline Solutions today to find the best solution for your needs.
