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Cut Pre-Startup Leak Testing From Days to Hours

Hydrus Works provides ultrasonic leak testing services that compress the pre-startup testing phase of turnarounds, reducing nitrogen consumption, lowering test pressures, finding more leaks, and getting your facility back online faster.

Every Hour of Restart Delay Has a Price. Most Teams Accept It.

Before a facility can restart after a turnaround, every flange and connection has to be tested for leaks. Conventionally, that means pressurizing the system with nitrogen and sending a crew through with soapy water, snoop testing every joint by hand. It works. It’s also slow, pressure-intensive, nitrogen-heavy, and prone to missing leaks in hard-to-reach locations.

Hydrus Works uses ultrasonic leak detection to do the same job faster and more thoroughly. Lower test pressures, significantly less nitrogen, and the ability to find leaks that conventional snooping routinely misses. In large facilities, the difference between these two approaches can be measured in days, and the cost of a delayed restart can run into the millions.

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Faster Testing. Fewer Leaks. Earlier Restart.

Hours Saved, Not Hours Spent

Ultrasonic testing is significantly faster than conventional snooping. In large facilities with thousands of flanges and connections, we routinely compress multi-day testing programs into hours, directly reducing the time between end of TAR work and first startup.

Finds Leaks Conventional Methods Miss

Soap-and-bubble testing misses small leaks, leaks in awkward locations, and leaks that only appear under certain conditions. Ultrasonic detection is more sensitive and more consistent, so you find more before startup, not after.

Lower Pressures, Less Nitrogen

Ultrasonic testing works at lower system pressures than conventional snooping requires, which means less nitrogen consumption and less stress on equipment and connections during the testing phase itself.

Real Cost Impact

For facilities where every day of delayed restart carries a significant cost (refinery units, chemical plants, power generation), the savings from a faster, more thorough testing program can easily reach seven figures. The testing cost is a small fraction of that.

Our Turnaround & Startup Services

Ultrasonic Leak Testing

Field crews equipped with ultrasonic detection equipment survey flanges, connections, valves, and fittings during the pre-startup phase, finding leaks faster and more thoroughly than conventional snooping methods.

Pre-Startup Testing Programs

We work with TAR coordinators and operations teams to plan and execute testing programs that fit the restart schedule, prioritize critical systems, and minimize time between end of TAR work and safe startup.

Leak Survey & Documentation

Every identified leak is documented with location, severity, and priority, giving your team a clear, actionable list to work through before pressurization and startup.

TAR Planning Support

We can engage early in the TAR planning process to scope the testing program, estimate time savings, and integrate ultrasonic testing into the restart schedule from the start.

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Let’s Talk Turnaround & Startup 

If you have a TAR coming up and want to understand what ultrasonic leak testing could save you in time and restart cost, we’re happy to walk through the numbers. The earlier we’re involved in the planning, the more we can help.