This comparison demonstrates the potential advantages of Tube-Mac® non-welded flange systems over conventional welded piping in hydraulic applications. By assessing factors such as installation time, labour requirements, flushing procedures and overall project costs, non-welded systems can deliver improved efficiency and cost savings. Although the initial material costs may be higher, reduced labour requirements, simplified flushing processes and potentially faster commissioning can lower total project costs, making Tube-Mac® a practical and cost-effective alternative.
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 |
Using a Tube-Mac® non-welded piping system can deliver estimated overall savings of approximately US$152,215.51, or 30%, including installation and flushing costs. The system can also reduce installation and flushing time by approximately 1,521 labour hours. Although not included in this comparison, contractors may achieve further savings through shorter commissioning and start-up periods.
Tube-Mac® systems are designed to be installed clean, helping ensure the required cleanliness level is achieved. Conventional welded piping systems cannot offer the same cleanliness assurance without additional cleaning and verification procedures.
While the initial material cost of a Tube-Mac® non-welded piping system may be higher than that of a comparable welded system, savings in labour, flushing and installation time can more than offset the initial investment.
Key Advantages of Tube-Mac® Non-Welded Piping Systems
Reduced Labour Requirements
Pipe flaring can be performed without the need for qualified welders, reducing reliance on specialised welding labour.
Faster Installation
Pipe flaring typically takes seconds, compared with the significantly longer time required to complete a welded joint.
No Hot Work Permits
Installation does not require hot work permits or dedicated fire-watch personnel for welding operations, helping simplify site procedures.
Reliable, Leak-Resistant Connections
Tube-Mac® non-welded connections are designed to minimise installation-related stresses and provide reliable sealing. Welded joints may be affected by residual stresses, particularly where components are misaligned, potentially increasing the risk of fatigue-related leaks.
Simplified Maintenance and Modifications
Flanged connections make it easier to add, replace or modify system components. In contrast, changes to welded piping may require cutting, re-welding and additional inspection.
Reduced Fittings and Pressure Losses
Where permitted by the design and applicable piping requirements, field-bent pipe sections can replace certain 45° and 90° fittings. This can reduce component costs and pressure losses, potentially lowering the pumping power required.
No Weld Radiography for Non-Welded Joints
High-pressure welded piping may require radiographic inspection, depending on the applicable code and project specifications. Tube-Mac® non-welded joints avoid weld-related radiography requirements, reducing associated inspection time and costs.
Oil Flushing Only
Tube-Mac® systems can be flushed using the system fluid, eliminating the need for acid pickling, chemical neutralisers and the associated chemical-waste disposal in applications where this procedure is suitable. The flushing process can also be faster, typically taking hours rather than the days that may be required for acid pickling and flushing conventional welded piping. The fluid can remain in the system for operation and be filtered to achieve the specified ISO cleanliness level, supporting a cleaner commissioning process.
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.
