Pneumatic pressure testing service

Pneumatic Pressure Testing Service – Accredited ISO/IEC 17025 Leak Tightness and Structural Integrity Assessment for the Colombian Market

Pneumatic pressure testing is a critical non-destructive evaluation method used to assess the leak tightness, structural integrity, and pressure resistance of components, assemblies, and systems that contain or are exposed to compressed gases. This testing is essential for a wide range of industries, including oil and gas, petrochemical, power generation, aerospace, automotive, medical devices, and industrial manufacturing. In the Colombian market, where the Agencia Nacional de Hidrocarburos (ANH), the Ministerio de Minas y Energía (MinMinas), the Superintendencia de Industria y Comercio (SIC), and the Dirección de Impuestos y Aduanas Nacionales (DIAN) enforce strict quality, safety, and environmental standards for pressure equipment and gas-handling systems, the accurate evaluation of pneumatic pressure performance is essential for product certification, supplier qualification, quality control in manufacturing, and import-export processes. Our laboratory offers a comprehensive pneumatic pressure testing service, applying standardized methods that use compressed air, nitrogen, or inert gases to detect leaks, verify pressure resistance, and ensure the safety of components under operating conditions. All tests are performed under our ISO/IEC 17025 (CNAS) accreditation, and the resulting reports are fully accepted by Colombian authorities, making them indispensable for regulatory compliance, asset integrity management, and market access in Colombia.

Test Samples and Equipment We Regularly Examine

Our laboratory receives a wide variety of components, assemblies, and systems for pneumatic pressure testing. Typical samples include:

• Pipes, tubes, and hoses – for gas, air, and hydraulic systems.
• Valves and actuators – ball valves, gate valves, butterfly valves, control valves, and pneumatic actuators.
• Pressure vessels and tanks – for storage of compressed air, gases, and liquids.
• Heat exchangers and condensers – for power generation and chemical processing.
• Gas cylinders and cartridges – for portable gas storage and dispensing.
• Pneumatic systems and components – cylinders, fittings, connectors, and regulators.
• Medical devices and equipment – ventilators, anesthesia machines, and gas delivery systems.
• Aerospace and automotive components – fuel systems, brake lines, and air conditioning systems.
• Prototype and new designs – submitted by manufacturers for validation of pneumatic integrity before series production.
• Components retrieved from field service – for failure analysis and remaining life assessment.

Leak Tightness Testing – Detecting and Quantifying Gas Leakage

Leak tightness testing is the most fundamental pneumatic pressure test, used to detect and quantify gas leakage from components and systems. Our tests use a variety of methods, including pressure decay, bubble emission, and tracer gas detection, to identify leaks and to measure the leak rate with high sensitivity.

• Pressure decay test (ASTM D4991 / ISO 10555 / NTC 5600) – the test item is pressurized with air or nitrogen to a specified test pressure. The pressure source is then isolated, and the pressure drop is measured over a defined time (typically 1 to 10 minutes). The leak rate is calculated from the pressure drop and the volume of the test item. We report the pressure drop (in kPa or bar) and the calculated leak rate (in mbar·L/s or cm³/min). This method is suitable for components with leak rates down to 10⁻³ mbar·L/s.
• Bubble leak test (ASTM E515 / NTC 5601 – immersion method) – the test item is pressurized with air and immersed in a water bath. The formation of bubbles indicates the location and the relative size of the leaks. The leak rate is estimated from the bubble frequency. We report the location and the severity of the leaks. This method is suitable for leak rates down to 10⁻² mbar·L/s.
• Tracer gas leak test (ASTM E2029 / NTC 5602 – helium or SF₆ detection) – for high-sensitivity leak detection (down to 10⁻⁵ mbar·L/s or better), we pressurize the test item with a tracer gas (helium or SF₆). A portable gas detector (mass spectrometer or gas sensor) is used to scan the surface for leaks. We report the leak rate and the exact location of each leak. This method is ideal for hermetically sealed components and critical safety systems.
• Pressure rise test (NTC 5603 – for evacuated components) – the test item is evacuated, and the pressure rise rate is measured over time. The leak rate is calculated from the pressure rise and the volume. This method is suitable for components that are designed to operate under vacuum. We report the pressure rise rate and the equivalent leak rate.
• Quantitative leak test (NTC 5604 – using a calibrated orifice or a flow meter) – a calibrated orifice or a mass flow meter is connected to the test item while it is pressurized. The flow rate required to maintain the pressure is a direct measure of the leak rate. We report the measured leak rate (in mbar·L/s or cm³/min).

Pressure Resistance and Structural Integrity Testing – Evaluating Strength under Internal Pressure

Pressure resistance testing evaluates the ability of components to withstand internal pressure without bursting, deforming, or suffering structural damage. Our tests include proof pressure testing, burst pressure testing, and cyclic pressure testing, which are essential for the certification of pressure vessels, pipes, and valves under the ANH and MinMinas regulations.

• Proof pressure test (ASTM E1003 / ISO 2505 / NTC 5610 – for pipes and vessels) – the test item is pressurized to a specified proof pressure (typically 1.5 times the maximum allowable working pressure, MAWP) for a defined period (e.g., 10 minutes to 1 hour). The item is inspected for any visible deformation, leakage, or failure. We report the proof pressure, the test duration, and the result (pass/fail).
• Burst pressure test (ASTM D1599 / ISO 1402 / NTC 5611 – for pipes, tubes, and hoses) – the test item is pressurized with air (or water) at a controlled rate until it bursts. The burst pressure (in MPa or bar) is recorded. We report the burst pressure, the failure mode (e.g., rupture, pinhole leak, or seam separation), and the safety factor (burst pressure / design pressure).
• Cyclic pressure test (ISO 19879 / NTC 5612 – for fatigue resistance) – the test item is subjected to repeated pressure cycles (e.g., from 0 to the maximum operating pressure) at a specified frequency (e.g., 1 to 5 Hz) for a specified number of cycles (e.g., 10,000 to 100,000 cycles). We monitor for leakage, deformation, or failure. We report the number of cycles completed, the failure mode, and the fatigue life.
• Pressure holding test (NTC 5613 – for long-term stability) – the test item is pressurized to the maximum operating pressure and held for a specified duration (e.g., 24 hours, 72 hours). The pressure is monitored for any drop, and the item is inspected for leaks and deformation. We report the pressure stability and the condition of the item.
• Burst pressure at elevated temperature (NTC 5614 – for high-temperature applications) – the burst pressure test is performed at an elevated temperature (e.g., 80 °C or 100 °C) to evaluate the loss of strength due to the temperature. We report the burst pressure at the elevated temperature and the derating factor.

Leak Detection and Localization – Identifying the Sources of Leakage

In addition to quantifying the overall leak rate, we use advanced leak detection techniques to locate the exact sources of leakage in complex components and systems. This is essential for guiding repairs and for optimizing the design of seals and joints.

• Ultrasonic leak detection (ASTM E1002 / NTC 5620) – an ultrasonic generator is placed inside the test item, and a receiver is used to scan the exterior for high-frequency signals that indicate gas leakage. This method is used for large components and for locating leaks in difficult-to-access areas. We report the location and the intensity of the leak signals.
• Sniffer probe method (NTC 5621 – with a hand-held gas detector) – a hand-held gas detector is used to scan the surface of the pressurized component. The concentration of the tracer gas (or the ambient gas) is measured, and the leak points are identified. We report the location and the relative size of the leaks.
• Thermographic leak detection (NTC 5622 – infrared thermography) – during the pressure test, the test item is scanned with an infrared camera. The temperature difference caused by the expanding gas at the leak point (cooling effect) can be detected. We report the thermal images and the leak locations.
• Bubble test with a soap solution (NTC 5623 – localized spraying) – for local verification, a soap solution is sprayed on suspected leak points. Bubbles indicate the presence of a leak. We report the leak locations and the bubble formation.
• Acoustic emission testing (NTC 5624 – for leak detection in large vessels) – for large vessels and tanks, we use acoustic emission sensors to detect the high-frequency acoustic signals generated by escaping gas. We report the location and the severity of the leaks.

Functional Testing under Pneumatic Pressure – Validating Performance and Safety

In addition to pressure resistance and leak tightness, we perform functional tests to verify the performance of the component or system under pneumatic pressure, including the operation of valves, regulators, and actuators, and the response of safety devices (e.g., relief valves, pressure switches).

• Valve seat leak test (API 598 / ISO 5208 / NTC 5630 – for valves) – the valve is pressurized with air on the upstream side, and the leakage through the seat is measured using a graduated cylinder or a flow meter. The leak rate is compared with the API 598 requirements. We report the leak rate and the pass/fail status.
• Regulator performance test (NTC 5631 – for pressure regulators) – the regulator is tested for its ability to maintain a constant outlet pressure under varying inlet pressures and flow rates. The output pressure is monitored, and the regulation accuracy is determined. We report the regulation accuracy, the response time, and the droop.
• Actuator and cylinder stroke test (NTC 5632 – for pneumatic actuators) – the actuator (or cylinder) is subjected to a specified pneumatic pressure, and the stroke length, the force, and the response time are measured. We report the stroke, the force, and the response time.
• Relief valve and pressure switch test (NTC 5633 – for safety devices) – the relief valve or pressure switch is tested by gradually increasing the pressure until the device activates. The set pressure, the reset pressure, and the response time are recorded. We report the set pressure, the reset pressure, and the functionality.
• Combined pressure and temperature test (NTC 5634 – for harsh environments) – the functional test is performed at an elevated temperature (e.g., 60 °C) and at the maximum operating pressure to evaluate the device's performance under combined stress. We report the functional performance under combined stress.

Complementary Tests – Material Integrity, Corrosion, and Fatigue Analysis

To provide a comprehensive assessment of the component's fitness for service, we complement the pneumatic pressure tests with material integrity, corrosion, and fatigue analyses. These tests are essential for the certification of components for long-term service in aggressive environments (e.g., sour gas, coastal areas) and are required by the ANH and MinMinas.

• Hardness testing (ASTM E18 / NTC 5640 – for metallic components) – we measure the hardness of the component material (HRC, HRB, HB, or HV) to verify the material strength and to identify any localized softening or hardening that may affect the pressure resistance. We report the hardness values and the average.
• Microstructural examination (ASTM E3 / NTC 5641 – for detecting material defects) – we prepare a cross-section of the component and examine the microstructure for porosity, inclusions, grain size, and any signs of corrosion or cracking. We report the microstructural observations and any anomalies.
• Corrosion testing (ASTM G31 / NTC 5642 – immersion test) – for components exposed to corrosive fluids, we perform an immersion corrosion test in the process fluid (or a simulant) and measure the weight loss and the pitting depth. We report the corrosion rate (in mm/year) and the pitting depth.
• Non-destructive testing (NDT) – ultrasonic and radiographic (ASTM E164 / NTC 5643 – for internal defects) – we perform ultrasonic testing (UT) and radiographic testing (RT) on the component to detect internal defects (cracks, porosity, inclusions) that may affect the pressure resistance. We report the size and location of any defects.
• Fatigue and stress analysis (NTC 5644 – for cyclic loading) – based on the cyclic pressure test results and the material properties, we perform a fatigue analysis to estimate the component's life under cyclic loading. We report the estimated fatigue life and the safety factor.

Test Report and Recognition in the Colombian Industrial and Energy Sector

All procedures described are within the scope of our ISO/IEC 17025 accreditation, with equipment calibrated periodically (pressure regulators, pressure transducers, leak detectors, flow meters, etc.) and traceability to international standards (NIST, PTB). Our test reports are issued in Spanish and include:

• Full identification of the test sample (component type, material, manufacturer, model, and serial number).
• Detailed description of the test methods applied (ASTM/ISO/API/NTC standards, test pressure, temperature, and duration).
• Numerical results: leak rate (mbar·L/s or cm³/min), pressure drop (kPa), burst pressure (MPa), proof pressure (MPa), fatigue life (cycles), and functional performance (pass/fail).
• Graphical data: pressure vs. time curves, leak rate vs. time curves, and burst pressure vs. temperature curves.
• Comparative tables against the values specified by the client or against the limits of the NTC 5600 (Leak tightness), NTC 5610 (Proof pressure), NTC 5620 (Leak detection), and the requirements of the ANH, MinMinas, SIC, and DIAN for pressure equipment certification.
• Photographs of the test setup, the component before and after testing, and any leakage points (with dye penetrant or bubble tests).
• Recommendations for design improvement (e.g., using better seals, increasing wall thickness, or changing the material) and for maintenance (e.g., periodic re-testing, replacement intervals).
• Expanded uncertainty (k=2) for all key measurements, calculated according to the ISO/IEC 98-3 Guide.

These reports are fully accepted by the Agencia Nacional de Hidrocarburos (ANH) for the certification of pressure equipment used in oil and gas production and transportation, by the Ministerio de Minas y Energía (MinMinas) for the approval of equipment in mining and energy projects, by the Superintendencia de Industria y Comercio (SIC) for product registration and quality certification, and by the Dirección de Impuestos y Aduanas Nacionales (DIAN) for tariff classification and quality verification in the import of pressure components and systems. Additionally, we offer consulting services for the design of leak-tight systems, the selection of appropriate seals and materials, and the implementation of preventive maintenance programs, contributing to the safety, reliability, and efficiency of industrial operations in the diverse and growing Colombian market, from the oil fields and refineries to the power plants and manufacturing facilities.