Oil, Gas & Energy Equipment Manufacturing worked example

Hydrotest Capacity at 65% test bay uptime: a worked example in oil, gas & energy equipment manufacturing

Here is what the math looks like when conditions slip. We hold every other input steady and drop test bay uptime to 65%, then walk the calculation through step by step. Estimate how many vessels, spools, or assemblies your hydrostatic test bay can complete, from units per test cycle, available cycles, test bay uptime, and first-pass test yield, so teams can confirm test capacity covers demand before committing the schedule.

The inputs for this scenario

  • Units tested per cycle: 4 units / cycle (held at the documented default)
  • Available test cycles: 480 cycles (held at the documented default)
  • Test bay uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass test yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross hydrotest capacity = units tested per cycle × available test cycles.
  • Good hydrotest capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross hydrotest capacity works out to 1,920 units at these inputs.
  • Test bay downtime loss works out to 672 units at these inputs.
  • Retest and repair loss works out to 37.44 units at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where test bay uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 27.78% below the baseline at 1,211 units.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to test bay uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It treats uptime and yield as flat averages; a run of failed welds or a pump outage can cluster losses and starve shipping even when the average looks fine.

Results at a glance

  • Good hydrotest capacity: 1,211 units (headline result)
  • Gross hydrotest capacity: 1,920 units
  • Test bay downtime loss: 672 units
  • Retest and repair loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Hydrotest Capacity calculator, set test bay uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.