Manufacturers running pressure test equipment don’t need to replace mechanically sound hardware to get modern testing capability. Upgrade & modernize existing test equipment with new control software – rather than the full cabinet – brings existing equipment up to current performance, connectivity, and cybersecurity standards at roughly a quarter of the cost of a new system.
Pressure test equipment is built to last. The mechanical core of a test cabinet the stations, the pneumatic and hydraulic hardware, is typically engineered for decades of service. What ages faster is the layer running on top of it: the controller and the software.
SIGMA is SCITEQ’s software platform for upgrading and modernizing existing pressure testing systems, developed to bring older equipment in line with current testing, connectivity, and cybersecurity requirements – without requiring a full system replacement.
Developing SIGMA, SCITEQ incorporates six decades of practical insight from working with pipe and fitting manufacturers running pressure test infrastructure across shifts, standards, and production environments.
The case of upgrade & modernize existing test equipment rather than replacing is straightforward. The majority of the cost and the environmental footprint of a pressure testing system sits in its mechanical hardware, not its software. Replacing a system that is mechanically sound simply because its controls have fallen behind means paying for, and manufacturing, the same steel and hydraulics twice.
SIGMA addresses this directly: the existing cabinet is upgraded onsite with new hardware and the latest controller software, while the mechanical core, the part that didn’t need replacing stays in service.
SIGMA is browser-based and controlled from PC, tablet, or phone, with an advanced yet intuitive test recipe system, real-time overview of test progress and system status, and dynamically adjusted real-time finish times. Instant report generation removes a step that has traditionally been manual and time-consuming.
The practical result is a pressure test system that is faster to set up, faster to run, and noticeably easier for operators to use day to day, without changing the underlying hardware they already know.
A test system that cannot communicate with the rest of a production line is, in practical terms, an isolated island of data. SIGMA supports OPC UA and SQL/Influx integration, allowing upgraded equipment to connect directly into a facility’s broader production and data infrastructure. Test results and system status become part of the same data environment as the rest of the plant, rather than something extracted and handled separately.
That connectivity is designed with cybersecurity built in, in line with the EU’s Cyber Resilience Act (CRA) and NIS2, which introduces new compliance requirements for connected industrial equipment toward 2027. Upgrading now addresses that requirement as part of a planned modernization, rather than as a separate, reactive project later.
Because the upgraded and modernized systems can be accessed online, SCITEQ’s technical support can connect remotely to help operators troubleshoot issues as they arise, rather than waiting for a scheduled site visit. Ongoing tests can also be monitored remotely by the operator’s own team, or together with SCITEQ support, making it possible to catch and respond to issues while a test is still running.
For facilities running test programs across multiple shifts, this reduces the time equipment spends waiting on diagnosis rather than producing results.
Because the majority of the existing hardware remains in service, upgrading avoids the material and manufacturing footprint of building an entirely new system from scratch. It extends the working life of equipment that is often still mechanically sound, and reduces the volume of industrial equipment retired prematurely for reasons that have nothing to do with its physical condition.
As a rule of thumb, a refurbishment to SIGMA costs around a quarter of what a comparable new system would cost. The result is comparable to installing an entirely new test system, modern regulation, a full set of current functions, and industrial connectivity, delivered through the hardware the customer already owns.
The transition follows three steps:
This structured approach keeps disruption to ongoing operations to a minimum, and gives facilities a scoped, predictable path to a modern test system.
Can old pressure test equipment be upgraded instead of replaced? Yes. If the majoority of the mechanical hardware of your existing pressure test cabinet is still sound, the controller and software can be upgraded onsite while the hardware stays in service, avoiding the cost and waste of a full replacement.
How much does it cost to upgrade a pressure test system compared to buying new? As a rule of thumb, upgrading existing equipment to SIGMA costs around a quarter of the price of a comparable new system.
Does upgraded test equipment support Cyber Resilience Act (CRA) compliance? Yes. SIGMA is designed with cybersecurity built in, in line with CRA and NIS2 requirements taking effect for connected industrial equipment toward 2027.
Can upgraded pressure test equipment connect to production systems? Yes. SIGMA supports OPC UA and SQL/Influx integration, allowing test data and system status to connect directly into a facility’s production and data infrastructure.
How long does a pressure test equipment upgrade take? The process follows three steps; Online meeting to determine the configuration of the upgrade – Onsite hardware and software installation and calibration – Operator training. Absolute minimal disruption to ongoing operations.
We install and upgrade test systems globally and across industries. Reach out to us to learn more about how we can help you modernize your existing pressure test equipment.
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Testing protocols evolve. The liteTANK is designed with this in mind. For applications requiring test temperatures below 20 °C, an optional chiller solution can be added to the test tank —either at initial installation or retrofitted later. This modular approach avoids premature over-investment while ensuring the system remains technically relevant as standards or product requirements change.
We install test systems globally and across industries. Reach out to us to learn more about how we can help you with a pragmatic and cost-efficient test setup.
Learn more about SCITEQ Hydrostatic test systems
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