Cortec® Solves the Corrosion Conundrum of Hydrotesting
May 8, 2025
Hydrostatic testing or “hydrotesting” is a critical step in confirming the integrity of vessels that handle a variety of fluids—from water to crude oil. The irony is that the same water used to test for leaks or weak points also introduces the risk of corrosion into the vessel, potentially leading to other integrity issues or corrosion related problems in the future. Cortec’s simple solution? Add a corrosion inhibitor to the hydrotesting water.
An Easy, Versatile Solution for Hydrotesting
The Cortec® VpCI®-649 Series offers effective and versatile options for corrosion protection during and after hydrotesting. This corrosion inhibitor additive forms a protective corrosion inhibiting film on metal surfaces in direct contact with the treated hydrotesting fluid. It also vaporizes to leave behind a protective molecular layer on metals in void spaces that may be above the water level. A minimum dose of VpCI®-649 offers corrosion protection during hydrotesting, while increasing the dosage provides extended protection for six months to two years after hydrotesting. VpCI®-649 is available with a molybdate tracer or a PTSA tracer for easy detection to confirm proper concentration when recycling water for multiple hydrotesting rounds. It is also available as VpCI®-649 HP, a version that is certified to meet ANSI/NSF Standard 61 for drinking water system components.*
Hydrotesting with VpCI®-649: Do It Right or Not at All
It is important to remember that having a good corrosion inhibitor for hydrotesting is not the end of the story. For the corrosion inhibitor to be effective, it must be used in the right way. The first important step is to confirm the proper dosage. As implied, this can depend on the type of water used and the desired length of protection. For example, does a manufacturer want to protect a valve only during hydrotesting, or also during shipment to the end user? Will a new heat exchanger need to sit idle on the construction site for a year or two before it is installed? Each of these situations requires a different dose of VpCI®-649 for full effectiveness. After determining the right dosage, it is equally important to ensure proper mixing and “dwell time” to achieve full treatment of the system.
Get Your Hydrotesting Prescription
Hydrotesting is a vulnerable time for piping and other vessels containing fluids. The VpCI®-649 Series is an excellent way to alleviate corrosion fears and successfully navigate this stage with corrosion-free systems that are internally protected— even for potentially long periods. If you are facing a hydrotesting project, don’t let corrosion complicate the story. Contact Cortec® to get a custom prescription for hydrotesting your tubes, valves, or vessels with the VpCI®-649 Series.
*When used as a surface treatment at concentrations up to 3.0% and drained.
Keywords: Cortec, corrosion, hydrotesting, hydrostatic testing, corrosion protection, pressure testing, NSF Standard 61, corrosion protection for drinking water components, corrosion inhibitor, VpCI-649
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