Hydrostatic Testing and the ZERUST® ZerioGuard™ Advantage

Why hydrostatic testing matters

Hydrostatic testing is a proven method to verify the integrity of pipelines, heat exchangers, storage tanks, and ship voids. By filling systems with water and applying pressure, operators can identify leaks and confirm structural reliability [1].

However, untreated water often introduces risks. Dissolved oxygen, salts, and minerals accelerate corrosion. Hardness leads to scaling. Residual moisture promotes long-term degradation, and improper discharge can create compliance challenges [2], [3]. Without the right chemical program, hydrotesting can unintentionally reduce asset life.

the role of additives in hydrotesting

Research confirms that untreated hydrotest water significantly increases corrosion risk, leading to flash rusting, pitting, and surface degradation [4].

• Inhibitors reduce corrosion rates dramatically compared to untreated water.
• Additives help control scaling by conditioning hardness and neutralizing acidic species.
• Industry guidance recommends corrosion inhibitors and oxygen scavengers where water may remain in the system before commissioning [1].

The right additives are therefore essential to maintain asset reliability during and after hydrotesting.

The ZerioGuard^™ Solution

Zerust Integrity Solutions developed the ZerioGuard^™ series to align with hydrotest best practices: 

ZerioGuard^™ 5

• Flash corrosion protection during and after testing
• SCI-based chemistry neutralizes acidic species
• Effective at low concentrations
• Suitable for short-term layup

ZerioGuard^™ 8

• Strong corrosion protection for projects under regulatory oversight
• Meets pH discharge compliance requirements
• Designed for hydrotests where environmental permitting is critical

ZerioGuard^™ 12

• Combines VCI and SCI chemistries for extended wet layup
• Protects systems awaiting commissioning, in transit, or in idle storage
• Provides durable rust prevention beyond the hydrotest phase

why choose ZerioGuard^™?

Compared to generic additive programs, ZerioGuard^™ offers:

• Operational efficiency: Low dosing volumes, easy application, and simple removal
• Regulatory alignment: Formulations developed to meet discharge requirements
• Extended protection: SCI and VCI chemistry safeguard assets both during hydrotesting and in subsequent layup

Hydrostatic testing is not just about validation; it is also an opportunity for preservation. ZerioGuard™ ensures both.

How to get started

Protect your assets before, during, and after hydrotesting. Contact ZERUST^® Integrity Solutions today to discuss which ZerioGuard^™ solution best fits your project.

references

[1] GATE Energy, Pre-Startup Corrosion Prevention and Hydrotesting, 2011. [Online]. Available: https://www.gate.energy/the-brainery/gat2004-gkp-2011-10/pre-startup-corrosion-prevention-hydrotesting

[2] U.S. Environmental Protection Agency (EPA), Effluent Guidelines for the Oil and Gas Extraction Category, 2023. [Online]. Available: https://www.epa.gov/eg/oil-and-gas-extraction-effluent-guidelines

[3] Zerust Excor, Hydrostatic Test Additives for Ultimate Protection, Zerust Blog, Aug. 2025. [Online]. Available: https://www.zerust.com/blog/2025/08/20/hydrostatic-test-additives-for-ultimate-protection/

[4] R. Winston Revie and H. H. Uhlig, Corrosion and Corrosion Control: An Introduction to Corrosion Science and Engineering, 4th ed. Hoboken, NJ: Wiley-Interscience, 2008.