The use of 0.8 design factor in Chinese pipeline industry is a breakthrough with the success of the test pipe section in the west–east China gas pipeline III. For such a design factor, the traditional P-V (Pressure-Volume) curve based pressure test control cannot describe the details of the process, and the 0/1 type failure is not an efficient index to show the safety level of the pipeline. In this paper, a reliability based assessment method is proposed to monitor the real-time failure probability of the pipeline during the hydrostatic test process. The reliability index can be used as the degree of risk. Following the actual hydrostatic testing of a test pipe section with 0.8 design factor in the west–east China gas pipeline III, reliability analysis was performed using Monte Carlo technique. The basic values of input parameters of the limit state equations are based on the data collected from either the tested section or the recommended value in the codes. The analysis of limit states, i.e., the yielding deformation and the excessive plastic deformation of pipeline, proceeded based on these distributions. Finally, it is found that the gradually increased water pressure makes the failure probability increase accordingly. A reliability assessment method was proposed and illustrated with the practical pressure test process.
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