When we talk about piping systems, the conversation usually revolves around drinking water and health and safety initiatives. The focus on protecting potable water is essential but means we sometimes forget our pipes carry much more. Different piping systems can also bring unique risks to a business: Process water piping systems or other systems that transport various fluids or gases present a risk of contamination. Medical gas or compressed air systems that don’t work properly or aren’t well documented can result in revenue loss and operational inefficiencies.
No matter what type of pipes we’re talking about, facility managers, maintenance personnel, and operational teams need to have clear visibility into the system’s structure and functionality. The impact of better insight into the pipes is often immediate and significant—on operations, planning, and revenue.
A Case Study in Piping Infrastructure
In 2024, HydroCorp worked with a multi-billion dollar electrical and power management business at one of their east coast facilities. The problem at hand? The customer needed a full-scale view of the entire 750,000 square foot facility’s compressed air piping system—by pipe diameter, by valve, and by purpose.
When we started working with them, they had no drawings, data, or information relating to the system. That meant they had serious gaps in their knowledge of strategic valve locations and how the system served equipment throughout their facility. Additionally, they suspected compressed air was leaking out of their system, but they didn’t know where.
The customer wanted piping schematics that allowed them to manage the system effectively, document existing pipe conditions, identify and inventory all shut-off valves, and identify leaks. And, with facility expansions on the horizon, they needed system information at the ready to inform plan development and materials purchases. Without express knowledge of the piping system, inaccurate or inefficient plans are created, resulting in excess material purchases and higher costs.
Finally, they needed to invest in labeling to make it easier to identify system elements and ensure compliance with regulations. Financial incentives aren’t the only reason beyond health and safety to take a good look at your pipes. Pipe labeling, which requires an on-site presence and knowledge of all pipes and system components, may be required in many industries and states. To be compliant, pipe labels may have to contain specific language and lettering, be of a certain color, and be installed at certain locations and intervals within the system.
More than Water
A wide variety of piping systems exist within any given facility. When HydroCorp comes on the scene, we start with the architectural background file of the facility to understand its size, the multitude and density of equipment in the building, and the scope of the project. Our surveys and schematics cover the entirety of the piping system—including potable water, process water, and systems like compressed air.
Compressed Air Systems
In a manufacturing plant, compressed air systems are often used to supply power tools and equipment used in the manufacturing process. Knowing what’s going on with your pipes means having visibility into how the tools and equipment that make your business money are functioning. In the case of compressed air systems, leaks can have serious financial and operational ramifications.
High levels of energy are needed to effectively run a compressed air system: If you have a leak, you’re losing air and money. Operational impacts are significant, too. With fluctuations in compressed air, machinery may not work as it’s supposed to, resulting in downtime and time-consuming repairs or an inconsistent product output.
Without a detailed, diligent effort, how can you know of any leaks? Maybe there’s a leak in a pipe located in the corner of a little-used room. Or maybe there are dead legs in the system that are leaking air. The only way to find these leaks is to conduct a comprehensive survey of the entire system.
Back to our customer: We completed a full-scale, in-depth survey at their facility and delivered comprehensive piping schematics—including for their compressed air system—within 60 days. By systematically tracing every inch of pipe within their facility, our team was able to identify areas of concern, and within a few months the customer was able to repair leaks and improve the operation of their system, saving the facility money.
To put the cost of compressed air leaks into perspective, it’s estimated that a significant quarter-inch diameter leak can cost a facility an average of more than $12,000 a year. Even smaller leaks can have big costs when not repaired, and leaks throughout the system can result in the loss of tens of thousands of dollars annually.
While on-site, we also evaluated the state of the customer’s pipe labeling. We noted where they had existing pipe labels and where new labels needed to be installed, ensuring they met regulatory requirements for their piping systems.
The Role of Piping Schematics
Piping schematics derived from a comprehensive, on-site survey pay dividends in the operations and productivity of any facility. The return on investment (ROI) is clear: Not only does a better understanding of the piping system help identify and repair leaks, saving money, but it also provides a clear roadmap for maintenance and expansion down the road—while keeping your facility compliant with regulations.
Interested in learning more about how HydroCorp can support your facility with on-site surveys and piping schematic development?
