Federal regulators have ordered Plains All American Pipeline LP to conduct a battery of tests and analyses to determine how the failure of its pipeline caused a spill of crude oil off Santa Barbara County, Calif., estimated at as much as 2,500 barrels, or 105,000 gallons.

Officials at the U.S. Transportation Department's Pipeline and Hazardous Materials Safety Administration, the agency responsible for oversight of the line, said Friday the company must fulfill all of the requirements of the corrective order, issued Thursday, before the line can restart pumping oil.

The order requires the company to determine the cause of the spill, and test the entire line for any conditions similar to the cause of the rupture. To do so, Plains All American must empty and purge the pipeline, and conduct a physical and analytical review that includes inspections of various engineering records and company data, among other materials.

The order sets out specific deadlines—from 45 to 90 days—by which these tests and analyses must be conducted. No fine was issued in the order.

While a cause of the spill wasn't determined, PHMSA said, in its order, previous in-line inspections had occurred on the ruptured line in 2007 and 2012, finding anomalies mostly because of external corrosion at the site of some welds. On Tuesday, the day of the spill, the controller of the ruptured line noticed anomalies in the line's operating pressure and shut it down. The spill was determined hours later.

Once the root cause of the spill is determined, the company must submit a restart plan that includes modifications to the company's operations and maintenance procedures that have to be approved by the administration.

The federal order comes as the cleanup response to the spill carries on as a 24-hour-a-day operation. Democratic Gov. Jerry Brown declared a state of emergency in the county Wednesday evening, freeing up emergency state funding and resources to help in the cleanup.

State wildlife officials said they had rescued five brown pelicans that had been coated with oil. They are being kept at a local wildlife care facility. A juvenile seal partially covered in oil had also been taken to SeaWorld for treatment.

The spill is also being investigated by the Environmental Protection Agency. Santa Barbara County District Attorney Joyce Dudley and state Attorney General Kamala Harris have also said they are looking into the spill for possible criminal prosecution or civil liability.

Write to Alejandro Lazo at alejandro.lazo@wsj.com and Erin Ailworth at Erin.Ailworth@wsj.com

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