This comparison highlights the advantages of Tube-Mac® non-welded flange systems over conventional welded piping systems in hydraulic applications. By evaluating key factors such as installation time, labour requirements, flushing processes, and overall project costs, it becomes evident that non-welded systems offer significant efficiency and cost benefits. Despite higher initial material costs, the reduction in labour, elimination of chemical flushing, and faster commissioning result in substantial overall savings, making Tube-Mac® a reliable and cost-effective alternative.The following is a cost comparison summary of a typical hydraulic piping project
Location: United States of America
Pipe Range: 1/2” through 6”
| TMI Non-Welded Piping System | Welded Piping System | |
|---|---|---|
|
Materials |
$75,793.07 |
$60,350.52 |
|
Labour |
$195,096.77 |
$220,612.90 |
|
Flushing |
$83,612.90 |
$225,754.83 |
|
TOTAL |
$354,502.74 |
$506,718.25 |
Overall cost savings, installed and flushed, using a Tube-Mac® non-welded piping system, equals approx. $152,215.51 USD or 30%.The Tube-Mac® non-welded piping system is also faster to install and flush, resulting in savings of approx 1,521 man hours.While not included in this example, contractors can also save time and money with reduced commissioning and start-up times.The Tube-Mac® system is guaranteed to be installed clean; the welded piping system can’t provide any cleanliness guarantees.
While material costs for the Tube-Mac® non-welded piping system are higher than a comparable welded system, labour and flushing cost savings more than compensate for the initial expense.
General Labour
No special skilled labour required to flare the pipe vs. qualified welder.
Time Savings
Actual flaring time is measured in seconds vs. hours for a welded joint.
No Permits
No special hot work permits or fire watch personnel required.
No Leaks
Tube-Mac® non-welded connections are stress free and leak free vs. added stresses from welding especially with misaligned fittings.
Stress fatigue in welds results in leaks.
Low Maintenance
Tube-Mac® non-welded flanged joints make it easy to add or change components vs. torch cutting and re-welding to add or modify a welded system.
Better Fittings
Field-bent pipe at 90 and 45 degrees reduces component cost. Field bending creates less pressure drop, which equals horsepower savings.
No X-Ray
Costly and time-consuming X-Rays are needed for high-pressure welds, but not for the Tube-Mac® non-welded piping system
Oil Flush ONLY
No acid flush chemicals and neutralizers are required, meaning no added cost or environmental issues related to chemical waste disposal. The system fluid is used in the flushing procedure and remains in the pipe for system operation, and is polished to the desired ISO cleanliness level. This also guarantees system cleanliness, which can’t be assured in a welded system. The flushing time is measured in hours vs. days to acid pickle and flush a welded system.
General Notes:
1. This price comparison is based our knowledge and experience with Tube-Mac® non-welded piping systems.
2. We have compiled information provided to us from general contractors to prepare this comparison. Tube-Mac® is not responsible for the accuracy of the information as provided.
3. This price comparison is based on a typical installation with pressure and return lines varying in size from 1/2” schedule 80 through 6” XXS pipe.
4. All pipe and material take-offs were done on an equal basis for both systems.
5. The Tube-Mac® non-welded piping system utilized field bent pipe versus welded elbow fittings.All cost figures were adjusted to reflect a contractor’s purchasing practices.
6. All labour rates were the same for both systems – the cost difference relates to the man-hours required to install each system.
7. The labour times used are based on industry standards. Welding man-hours were based on the standard GTAW (TIG) welding for the root and one pass.
8. Flushing a Tube-Mac® non-welded system requires no chemicals only the system oil. A welded system requires extensive cleaning with chemicals, followed by neutralizing and disposal of chemical waste.
9. Chemical cleaning companies refuse to offer a fixed price, as they have no idea of the amount of welding contamination inside the pipe they have to clean until they begin the process. An estimate was furnished to us for the purposes of this comparison with the note that the actual cost could very well be higher.
10. The installation tools and flushing equipment rentals were NOT factored into the cost of either system.
