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QUALITY REPORT

STATISTICAL PRESENTATION on TECHNICAL QUALITY DATA

for
CLIENT: ENTERPRISE-PRODUCTS OPERATING L.P. PROJECT: HAYNESVILLE-ACADIAN PIPE SIZE: 36”ODX0.625”(15.88 mm) WT GRADE: API5L X70M PSL2 STEEL SOURCE : POSCO, KOREA 22-01-2010

WELSPUN GUJARAT STAHL ROHREN LTD., ANJAR, INDIA
Strictly Private & Confidential

Index
1. General Terminology about Statistical Data Analysis 2. Project Summary 3. Coil to Pipe Mechanical Properties Variation 4. Mechanical Testing Status for Pipe
• •

Heat (YS < 540 MPa as per POSCO RMTC) Heat (YS ≥ 540 MPa as per POSCO RMTC)

5. Co-relation of Coil YS & Pipe YS for
• •

Heat (YS < 540 MPa as per POSCO RMTC) Heat (YS ≥ 540 MPa as per POSCO RMTC)

6. Dimensional Variation in Pipes 7. Pipe Outside Diameter Before & After Hydro-Testing (HT) 8. Conformance to Chemical Composition 9. Repair and Rejection Details with Reasons

Fish-bone diagrams
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Strictly Private & Confidential

General Terminology about Statistical Data Analysis
LSL = Lower specification Limit USL = Upper Specification Limit Mean = Average of data set in a sample StDev (Within) = Standard Deviation showing the variation within sub-groups/short time variation. StDev (Overall) = Standard Deviation showing the total variation within sub-groups + between the sub-groups/long time variation N = No. of data points in a sample CoV = Coefficient of Variation (Overall Standard deviation/mean*100). CoV < 3% indicates that the process is operation under good control (narrow range of Lower Control Limit (LCL) & Upper Control Limit (UCL). Range = Maximum – Minimum NOTE: It is assumed that data is continuous in nature and follow the Normal distribution.

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General Terminology about Statistical Data Analysis
Ppk = Performance Index = Minimum of [ { (USL-Mean)/(3x overall standard deviation)}, { (Mean – LSL)/(3x overall standard deviation)} ]. Ppk shows the actual performance of the process taking care of the shift in the process which occurs in long run. This is good for external view of the process performance as seen by the customer to meet the specified limits in the product. Cpk = Capability Index = Minimum of [ { (USL-Mean)/(3x within standard deviation)}, { (Mean – LSL)/(3x within standard deviation)} ]. Cpk shows the could be performance of the process not taking process in account. This is good for internal process control. If Cpk = 2, then process is operating at six sigma level. Cpk > 1 shows that the process is stable and well under control.
NOTE: It is assumed that data is continuous in nature and follow the Normal distribution.

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General Terminology about Statistical Data Analysis
Probability plots: The probability plot is a graphical display of the estimated probability regression equation. The middle line on the graph estimates the percent of units at a given level of stress. The upper and lower limits give an approximate 95% confidence interval for the percent of units at a given level of stress. The probability plot also assess how well the chosen distribution fits your data. The closer the points fall to the middle line the better the distribution fits the data. This is estimated by p-value (> 0.1) Anderson-Darling statistic: Measures how well the data follow a particular distribution. The better the distribution fits the data, the smaller this statistic will be. Anderson-Darling statistic compares the fit of several distributions to see which one is best or to test whether a sample of data comes from a population with a specified distribution. If the p-value for the Anderson-Darling test is lower than the chosen significance level (usually 0.05 or 0.10), conclude that the data do not follow the specified distribution. NOTE: It is assumed that data is continuous in nature and follow the Normal distribution.

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2 0.28 % 98.20 76048.8 - FEET 76014 36 76979.Project Summary RAW MATERIAL DETAILS TOTAL HEATS USED HEATS WITH YS < 540 MPa (COIL) HEATS WITH YS ≥ 540 MPa (COIL) COIL CONSUMED NUMBER 48 24 24 282 PRODUCTION SUMMARY TOTAL ORDER QUANTITY AVERAGE LENGTH AS PER ORDER (MINIMUM) TOTAL PIPE FORMING TOTAL PIPE TPI CLEARED AVERAGE LENGTH ACHIEVED PIPES REPAIRED PIPES REJECTED UT CALIBRATION NUMBER 2112 % 98.4 1.36 34.1 Strictly Private & Confidential 6 .73 38.06 1.34 852.04 1984 1960 47 23 1 2.80 42.79 0.11 0.

Coil to Pipe Mechanical Properties Variation Strictly Private & Confidential .

8 2.08 90 95 6 0. Mean decrease in YS from Coil to pipe = 10 MPa (1.1 3.81 StDev 10 12 1 0. MPa Coil elongation. Different sample locations in coil & pipe 3.77 486 612 36 0.13 Observations: 1.14 2. CoV increase in YS from Coil to pipe = 0.88 Range 47 56 5 0. MPa Coil UTS.9 1.85%) 2. Flattening of samples for testing Total no.0 3.70% Reasons for observed changes are: 1. of heats = 48 Strictly Private & Confidential 8 . Unwinding of coils & forming strains resulting in reverse plasticity 2.02 CoefVar 1.80 532 660 40 0.2 2. MPa Pipe UTS.Statistics of Coil & Pipe Mechanical Properties Variable Coil YS.75 Maximum 568 704 41 0. % Coil YS/UTS Pipe YS.08 Minimum 521 648 36 0. MPa Pipe elongation.02 14 14 1 0. % Pipe YS/UTS Count 149 149 149 149 149 149 149 149 Mean 542 676 38 0.85 576 707 42 0.6 2.

of tests 30 20 14 29 36 36 27 21 17 10 0 2 0 1 0 0 6 3 3 1 1 0 490 500 510 520 530 540 550 560 570 580 590 600 YS. MPa Strictly Private & Confidential 9 .15 149 532.98 149 40 No.1 10.2 13. Pipe YS 60 50 43 LSL 485 MPa 58 USL 635 MPa Variable Coil YS Pipe YS Mean StDev N 542.YS Change from Coil to Pipe Histogram of Coil YS.

2 13.1 LSL 485 MPa Mean StDev N AD P-Value 532. MPa 560 580 1 0.784 99.98 149 0.1 Strictly Private & Confidential 10 .Probability Plot of Pipe YS Probability Plot of Pipe YS Normal .9 99 95 90 80 70 60 50 40 30 20 10 5 Percent 0.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.95% CI 99.1% probability for YS < 485 MPa at 95 % confidence level. 480 500 520 540 Pipe YS.237 0.

5 13.7 11. of tests 50 40 32 45 35 38 60 LSL 570 MPa 69 USL 760 MPa Variable C oil UTS Pipe UTS Mean StDev N 675.62 149 30 20 10 0 570 0 2 0 1 0 5 5 5 1 0 600 630 660 UTS. MPa 690 720 750 Strictly Private & Confidential 11 .95 149 659.UTS Change from Coil to Pipe Histogram of Coil UTS. Pipe UTS 80 70 60 No.

Pipe YS/UTS 70 62 USL 0.79 0.8024 0.02485 149 60 50 44 48 No.87 0.92 Variable Coil YS/UTS Pipe YS/UTS Mean 0.75 0.83 YS/UTS ratio 0.8071 StDev N 0.01714 149 0. of tests 40 34 31 30 20 10 0 18 17 23 10 6 0 2 3 0 0.91 Strictly Private & Confidential 12 .YS/UTS Change from Coil to Pipe Histogram of Coil YS/UTS.

176 149 79 48 38 39 28 24 0 27 30 33 36 39 Elongation (2"GL).70 1.97 0.Elongation Change from Coil to Pipe Histogram of Coil elongation.8378 149 39. of tests 50 40 30 20 10 2 4 17 11 4 2 LSL 25% Variable Coil elongation Pipe elongation Mean StDev N 37. % Strictly Private & Confidential 0 42 13 . Pipe elongation 80 70 60 No.

Mechanical Testing Status for Pipe Heat (YS < 540 MPa as per POSCO RMTC) Heat (YS ≥ 540 MPa as per POSCO RMTC) Strictly Private & Confidential .

Mechanical Testing Status as per YS in Heats (RMTC) Sr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Heat No. of pipes Formed 56 49 49 28 7 34 61 42 21 49 21 56 63 49 49 56 35 49 7 21 63 35 56 56 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Heat No. No. No. of tests 1 1 4 4 6 3 5 5 5 5 3 2 6 2 7 7 8 5 3 5 8 6 6 4 Test status for heats YS < 540 MPa Sr. of tests 2 2 3 1 1 1 2 1 1 1 1 2 2 1 1 2 1 2 1 1 4 1 2 2 Test status for heats YS ≥ 540 MPa 20 21 22 23 24 Strictly Private & Confidential 15 . SP40607 SP40611 SP40616 SP40643 SQ67864 SQ67869 SQ67888 SQ67963 SQ68017 SQ68098 SQ68111 SQ68174 SQ68181 SQ68183 SQ68235 SQ68241 SQ68288 SQ68294 SQ68298 SQ68332 SQ68341 SQ68344 SQ69043 SQ69052 No. SP40641 SQ67858 SQ67883 SQ67891 SQ67949 SQ67951 SQ67969 SQ67971 SQ67974 SQ68021 SQ68030 SQ68104 SQ68106 SQ68109 SQ68169 SQ68171 SQ68230 SQ68233 SQ68238 SQ68244 SQ68286 SQ68346 SQ69046 SQ69049 No. of pipes Formed 8 7 35 35 56 28 49 49 43 42 22 14 52 14 65 63 66 49 21 49 65 56 49 35 No.

Co-relation of Coil YS & Pipe YS for Heat (YS < 540 MPa as per POSCO RMTC) Heat (YS ≥ 540 MPa as per POSCO RMTC) Strictly Private & Confidential .

18 Minimum 521 648 36 0. % Pipe YS/UTS Count 111 111 111 111 111 111 111 111 Mean 539 674 38 0.81 StDev 9 12 1 0.7 2. Flattening of samples for testing Total no.13 2.Statistics of Coil YS & Pipe YS for . of heats (YS < 540 MPa) = 24 Strictly Private & Confidential 17 . Mean decrease in YS from Coil to pipe = 5 MPa (0.02 14 13 1 0.08 81 83 6 0.88 Range 41 55 5 0. % Coil YS/UTS Pipe YS. MPa Pipe elongation.Heats YS < 540 MPa (RMTC) Variable Coil YS.1 3. MPa Pipe UTS.85 567 695 42 0.6 1.03 CoefVar 1.0 3.75 Maximum 562 703 41 0.3 2.13 Observations: 1. MPa Coil elongation.77 486 612 36 0. MPa Coil UTS.6 2.80 532 659 40 0.93%) 2.0% Reasons for observed changes are: 1. Unwinding of coils & forming strains resulting in reverse plasticity 2. CoV increase in YS from Coil to pipe = 1. Different sample locations in coil & pipe 3.

Pipe YS 50 LSL 485 MPa 48 USL 635 MPa Variable C oil YS (< 540 MPa) Pipe YS 40 30 29 27 23 21 Mean StDev N 538. MPa 580 600 620 Strictly Private & Confidential 18 .98 111 No.Heats YS < 540 MPa (RMTC) Histogram of Coil YS.3%) 0 0 0 9 6 0 7 3 1 0 0 480 500 520 540 560 YS. of tests 30 20 16 10 2 (1.857 111 532.2 13.9 8.YS Change from Coil to Pipe .

480 500 520 540 Pipe YS.1% probability for YS < 485 MPa at 95 % confidence level. MPa 560 580 Strictly Private & Confidential 19 .98 111 0.794 Percent 0.233 0.95% CI 99.2 13.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.1 LSL 485 MPa Mean StDev N AD P-Value 532.Probability Plot of Pipe YS – Heats YS < 540 MPa (RMTC) Probability Plot of Pipe YS Normal .

27%) 2.86 Range 28 51 3 0.81 532 662 40 0.Statistics of Coil YS & Pipe YS – Heats YS ≥ 540 MPa (RMTC) Variable Coil YS. Unwinding of coils & forming strains resulting in reverse plasticity 2. Flattening of samples for testing Total no. MPa Coil elongation. MPa Coil UTS. % Pipe YS/UTS Count 38 38 38 38 38 38 38 38 Mean 552 680 38 0.76 Maximum 568 704 39 0.02 CoefVar 1.78 503 638 38 0.10 Observations: 1.7 1. of heats (YS ≥ 540 MPa) = 24 Strictly Private & Confidential 20 . Different sample locations in coil & pipe 3.01 14 15 1 0.7 2.5 2.3% Reasons for observed changes are: 1. MPa Pipe UTS.2 2. CoV increase in YS from Coil to pipe = 1.84 576 707 42 0. Mean decrease in YS from Coil to pipe = 7 MPa (1.06 73 69 3 0. MPa Pipe elongation.7 1.4 1.80 StDev 7 12 1 0.76 Minimum 540 653 36 0.72 2. % Coil YS/UTS Pipe YS.

YS Change from Coil to Pipe – Heats YS ≥ 540 MPa (RMTC) Histogram of Coil YS.6 7. Pipe YS 25 LSL 485 MPa USL 635 MPa Variable Coil YS (≥ 540 MPa) Pipe YS 20 15 13 10 9 10 Mean StDev N 551. MPa 580 600 620 Strictly Private & Confidential 21 .2 14. of tests 15 10 5 4 5 1 0 5 3 0 0 0 0 0 0 1 0 500 520 540 560 YS.17 38 No.478 38 532.

381 0.Probability Plot of Pipe YS – Heats YS ≥ 540 MPa (RMTC) Probability Plot of Pipe YS Normal . 480 500 520 540 560 580 1 Pipe YS. 0.1% probability for YS < 485 MPa at 95 % confidence level. MPa Strictly Private & Confidential 22 .17 38 0.384 95 90 80 Percent 70 60 50 40 30 20 10 5 1% probability for YS < 490 MPa at 95 % confidence level.95% CI 99 LSL 485 MPa Mean StDev N AD P-Value 532.2 14.

Dimensional Variation in Pipes Strictly Private & Confidential .

39 C pk 1.875 S ample N 1960 S tD ev (Within) 0.510917 S tD ev (O v erall) 0.19 1.19 W ithin Ov erall 2 Strictly Private & Confidential 3 4 5 24 .Pipe Dimensions – Out of Roundness (mm) SPECIFICATION LIMITS: USL = 5.0 mm OUT OF ROUNDNESS BODY USL P rocess D ata LS L * Target * USL 5 S ample M ean 2.39 O v erall C apability Pp PPL PPU P pk * * 1.597073 P otential (Within) C apability Cp * C PL * C P U 1.

82 C pk 1.440773 S tD ev (O v erall) 0.520771 P otential (Within) C apability Cp * C PL * C P U 1.Pipe Dimensions – Out of Roundness (mm) SPECIFICATION LIMITS: USL = 5.54 W ithin Ov erall 1 2 3 4 5 Strictly Private & Confidential 25 .59235 S ample N 1960 S tD ev (Within) 0.0 mm F END OUT OF ROUNDNESS USL P rocess D ata LS L * Target * USL 5 S ample M ean 2.82 O v erall C apability Pp PPL PPU P pk * * 1.54 1.

52245 S ample N 1960 S tD ev (Within) 0.77 O v erall C apability Pp PPL PPU P pk * * 1.56 1.467473 S tD ev (O v erall) 0.Pipe Dimensions – Out of Roundness (mm) SPECIFICATION LIMITS: USL = 5.77 C pk 1.0 mm T END OUT OF ROUNDNESS USL P rocess D ata LS L * Target * USL 5 S ample M ean 2.530351 P otential (Within) C apability Cp * C PL * C P U 1.56 W ithin Ov erall 1 2 3 4 5 Strictly Private & Confidential 26 .

Pipe Dimensions – Body Diameter (mm) SPECIFICATION LIMITS: LSL = 910 mm. USL = 918 mm BODY DIAMETER ( B .2 916.48 C ov 0.82 P P L 3.16 P P U 2.9 913.63 C P U 2.24 C P L 3.0 914.8 Strictly Private & Confidential 911.48 P pk 2.472412 P otential (Within) C apability Cp 3.1) LSL P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.1 915.411585 S tD ev (O v erall) 0.4 27 .85 C pk 2.482 S ample N 1960 S tD ev (Within) 0.3 917.85 O v erall C apability Pp 2.1% USL W ithin O v erall 910.

3 917.29 C P L 3.404797 S tD ev (O v erall) 0. USL = 918 mm BODY DIAMETER ( B .60 P pk 2.454726 P otential (Within) C apability Cp 3.2) LSL P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.60 C ov 0.9 913.2 916.1 915.92 O v erall C apability Pp 2.1% USL W ithin O v erall 910.Pipe Dimensions – Body Diameter (mm) SPECIFICATION LIMITS: LSL = 910 mm.93 P P L 3.26 P P U 2.92 C pk 2.67 C P U 2.452 S ample N 1960 S tD ev (Within) 0.0 914.8 Strictly Private & Confidential 911.4 28 .

9 913.4 29 .2 916.68 C pk 2.72 3.00 2.68 O v erall C apability Pp PPL PPU P pk C ov 2. USL = 918 mm BODY DIAMETER ( B .3) LSL P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.31 C P U 2.Pipe Dimensions – Body Diameter (mm) SPECIFICATION LIMITS: LSL = 910 mm.1 915.44 2.416 S ample N 1960 S tD ev (Within) 0.00 C P L 3.44 0.490112 P otential (Within) C apability Cp 3.444973 S tD ev (O v erall) 0.3 917.8 Strictly Private & Confidential 911.0 914.1% USL W ithin Ov erall 910.

00 O v erall C apability Pp PPL PPU P pk C ov 2.9 913.2 916.94 3.4) LSL P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.24 2. USL = 918 mm BODY DIAMETER ( B .67 C P U 3.1% USL W ithin Ov erall 910.3 917.00 C pk 3.65 0.0 914.4 30 .Pipe Dimensions – Body Diameter (mm) SPECIFICATION LIMITS: LSL = 910 mm.1 915.452829 P otential (Within) C apability Cp 3.34 C P L 3.8 Strictly Private & Confidential 911.65 2.401 S ample N 1960 S tD ev (Within) 0.399276 S tD ev (O v erall) 0.

403475 S tD ev (O v erall) 0. USL = 915.0 914.41 Target * USL 915.5 913.41 mm.5 915.03 1.173 S ample N 1960 S tD ev (Within) 0.5 Strictly Private & Confidential 31 .28 1.1% USL W ithin O v erall 912.Pipe Dimensions – End Diameter (mm) SPECIFICATION LIMITS: LSL = 912.5 914.17 O v erall C apability Pp PPL PPU P pk C ov 1.46 C P U 1.31 C P L 1.0 913.59 mm F END DIA METER LSL P rocess D ata LS L 912.457802 P otential (Within) C apability Cp 1.17 C pk 1.59 S ample M ean 914.16 1.03 0.0 915.

0 913.5 32 .41 mm.432718 S tD ev (O v erall) 0.1% USL W ithin Ov erall 912.5 914. USL = 915.41 Target * USL 915.05 O v erall C apability Pp PPL PPU P pk C ov 1.05 C P U 1.59 mm T END DIA METER LSL P rocess D ata LS L 912.25 0.5 915.09 0.94 0.59 S ample M ean 913.94 1.0 914.22 C P L 1.40 C pk 1.485496 P otential (Within) C apability Cp 1.0 915.773 S ample N 1960 S tD ev (Within) 0.5 Strictly Private & Confidential 913.Pipe Dimensions – End Diameter (mm) SPECIFICATION LIMITS: LSL = 912.

0676287 P otential (Within) C apability Cp 6.46 mm F END WALL THICKNESS LSL P rocess D ata LS L 15.48 7.3 Strictly Private & Confidential 15.6 15.8 17.4% USL W ithin Ov erall 15.Pipe Dimensions – Wall Thickness (mm) SPECIFICATION LIMITS: LSL = 15. USL = 17.4 mm.48 0.47 3.2 16.44 C P U 9.0530829 S tD ev (O v erall) 0.50 C pk 4.9 16.44 O v erall C apability Pp PPL PPU P pk C ov 5.24 Target * USL 17.4 33 .46 3.9468 S ample N 1960 S tD ev (Within) 0.97 C P L 4.1 17.46 S ample M ean 15.5 16.

942 S ample N 1960 S tD ev (Within) 0.0604384 P otential (Within) C apability Cp 7. USL = 17.9 16.45 O v erall C apability Pp PPL PPU P pk C ov 6.46 S ample M ean 15.37 3.87 0.0525398 S tD ev (O v erall) 0.4% USL W ithin Ov erall 15.87 8.1 17.4 mm.24 Target * USL 17.3 Strictly Private & Confidential 15.Pipe Dimensions – Wall Thickness (mm) SPECIFICATION LIMITS: LSL = 15.45 C P U 9.63 C pk 4.04 C P L 4.12 3.4 34 .2 16.5 16.46 mm T END WALL THICKNESS LSL P rocess D ata LS L 15.8 17.6 15.

42 C P L 2.93 C pk 1.93 O v erall C apability Pp PPL PPU P pk 2.4 S ample M ean 1.8 mm.91 C P U 1.120949 P otential (Within) C apability Cp 2.110239 S tD ev (O v erall) 0.5 1.20 2.1 2.76321 S ample N 1960 S tD ev (Within) 0.75 1. USL = 2.4 mm F END ROOT FACE LSL P rocess D ata LS L 0.75 USL W ithin Ov erall 0.9 Strictly Private & Confidential 1.8 2.65 1.2 1.Pipe Dimensions – Root Face (mm) SPECIFICATION LIMITS: LSL = 0.4 35 .8 Target * USL 2.

57 C P L 3.1 2.4 mm T END ROOT FACE LSL P rocess D ata LS L 0.31 2.84 1.15 C P U 1.4 S ample M ean 1.78 1.78 USL W ithin Ov erall 0.8 2.2 1.Pipe Dimensions – Root Face (mm) SPECIFICATION LIMITS: LSL = 0.98 C pk 1.8 Target * USL 2.115568 P otential (Within) C apability Cp 2.9 Strictly Private & Confidential 1.4 36 . USL = 2.103903 S tD ev (O v erall) 0.98 O v erall C apability Pp PPL PPU P pk 2.78332 S ample N 1960 S tD ev (Within) 0.8 mm.5 1.

09 C pk 2.94836 P otential (Within) C apability Cp * C PL * C P U 2.0 mm STRAIGHTNESS USL P rocess D ata LS L * Target * USL 10 S ample M ean 4.Pipe Dimensions – Straightness (mm) SPECIFICATION LIMITS: USL = 10.09 O v erall C apability Pp PPL PPU P pk * * 1.854847 S tD ev (O v erall) 0.89 1.63571 S ample N 1960 S tD ev (Within) 0.89 W ithin Ov erall 2 4 6 8 10 Strictly Private & Confidential 37 .

8 1.73 3.4 0.73 * W ithin Ov erall 0.0 1.6 38 .484643 S ample N 1960 S tD ev (Within) 0.6 mm F END SQUARENESS USL P rocess D ata LS L * Target * USL 1.4 1.6 0.06 C pk 4.6 S ample M ean 0.Pipe Dimensions – Squareness (mm) SPECIFICATION LIMITS: USL = 1.0997387 P otential (Within) C apability Cp * C PL * C P U 4.0915487 S tD ev (O v erall) 0.2 1.2 Strictly Private & Confidential 0.06 O v erall C apability Pp PPL PPU P pk C pm * * 3.

2 Strictly Private & Confidential 0.0997387 P otential (Within) C apability Cp * C PL * C P U 4.8 1.06 C pk 4.4 1.0915487 S tD ev (O v erall) 0.2 1.4 0.6 39 .6 S ample M ean 0.0 1.484643 S ample N 1960 S tD ev (Within) 0.73 W ithin Ov erall 0.06 O v erall C apability Pp PPL PPU P pk * * 3.Pipe Dimensions – Squareness (mm) SPECIFICATION LIMITS: USL = 1.6 mm F END SQUARENESS USL P rocess D ata LS L * Target * USL 1.73 3.6 0.

615102 S ample N 1960 S tD ev (Within) 0.6 S ample M ean 0.6 mm F END PEAKING USL P rocess D ata LS L * Target * USL 1.Pipe Dimensions – Peaking (mm) SPECIFICATION LIMITS: USL = 1.142278 S tD ev (O v erall) 0.6 0.8 1.2 1.0 1.31 O v erall C apability Pp PPL PPU P pk * * 2.4 0.2 Strictly Private & Confidential 0.6 40 .14 2.31 C pk 2.14 W ithin O v erall 0.4 1.153191 P otential (Within) C apability Cp * C PL * C P U 2.

4 0.Pipe Dimensions – Peaking (mm) SPECIFICATION LIMITS: USL = 1.93 * W ithin O v erall 0.4 1.151193 S tD ev (O v erall) 0.643367 S ample N 1960 S tD ev (Within) 0.11 O v erall C apability Pp PPL PPU P pk C pm * * 1.11 C pk 2.0 1.6 41 .2 1.6 0.6 mm T END PEAKING USL P rocess D ata LS L * Target * USL 1.165155 P otential (Within) C apability Cp * C PL * C P U 2.2 Strictly Private & Confidential 0.93 1.6 S ample M ean 0.8 1.

0902816 S tD ev (O v erall) 0.31 * W ithin O v erall 0.31 8.Pipe Dimensions – Peaking (mm) SPECIFICATION LIMITS: USL = 3.57 C pk 9.2 mm PEAKING BODY USL P rocess D ata LS L * Target * USL 3.4 0.8 1.608316 S ample N 1960 S tD ev (Within) 0.6 2.2 1.8 3.0 2.4 2.2 S ample M ean 0.57 O v erall C apability Pp PPL PPU P pk C pm * * 8.104014 P otential (Within) C apability Cp * C PL * C P U 9.2 Strictly Private & Confidential 42 .

Pipe Outside Diameter Before & After Hydro-Testing (HT) Strictly Private & Confidential .

5 138 0 912.7 0.5 917.4898 1960 914.Increase in Pipe OD After Hydro-testing – Body Histogram of BODY (Before HT).4156 1960 1326 1390 1000 500 0 4 910.5 911. of pipes Mean StDev N 913.0 mm 1500 No. mm Strictly Private & Confidential 44 .5 27 0 916.5 914.5 Outside diameter.5 0 5 915. shift after hydro-testing = 2.5 487 494 49 913. BODY (After HT) 2000 LSL 910 mm Variable BODY (Before HT) BODY (A fter HT) USL 918 mm Mean shift after hydrotesting = 1.8 0.1 mm Max.

0 915.4807 1960 0.6 913.5 mm Max.41 mm Variable T-END (Before HT) T-END (A fter HT) Mean 913.0 912.Increase in Pipe OD After Hydro-testing – T-End Histogram of T-END (Before HT). of pipes 200 150 100 50 0 2 46 0 1 0 4 0 6 25 0 9 33 18 13 11 18 1 10 0 3 0 145 130 98 65 100 LSL 912.0 mm 230 287 229 222 142 0 912.4 915.59 mm Mean shift after hydrotesting = 0. T-END (After HT) 350 300 250 No.3 913. mm Strictly Private & Confidential 45 .6 Outside diameter.8 914.8 StDev N 0.2 913. shift after hydro-testing = 2.4855 1960 205 190 150 294 305 294 315 319 USL 915.

41 mm Variable F-END (Before HT) F-END (After HT) Mean StDev N 913. of pipes 200 Mean shift after hydrotesting = 0.2 0.0 915. shift after hydro-testing = 2.2 913.8 0. F-END (After HT) 400 LSL 912. mm Strictly Private & Confidential 46 .4987 1960 914.6 913.0 912.Increase in Pipe OD After Hydro-testing – F-end Histogram of F-END (Before HT).59 mm 300 No.4577 1960 292 269 252 353 347 315 313 297 USL 915.0 mm 107 171 132 116 181 163 134 103 75 53 29 5 0 16 0 100 44 0 0 2 0 3 27 3 3 20 41 54 0 912.4 915.4 mm Max.8 914.6 Outside diameter.

Conformance to Chemical Composition Strictly Private & Confidential .

% 96 0.9 0. of heats = 48 Strictly Private & Confidential 48 .16 0.35 0.03 CE(IIW). % 96 0.418 0.06 No.18 0.012 2.Statistics of CE (Pcm) & CE (IIW) Variable Count Mean StDev CoefVar Minimum Maximum Range CE(Pcm).39 0.9 0.191 0.005 2.

21% No.005193 96 49 USL 0. of tests (2 pipes/heat) 40 30 22 20 10 4 8 8 5 0 0 0.1780 0.20 0.18 CE(Pcm).17 0.CE (Pcm) – 48 Heats Histogram of CE(Pcm) 50 Mean StDev N 0.19 0.21 Strictly Private & Confidential 49 . % 0.16 0.

36 0.35 0.3939 0.41 0.42 CE(IIW).40 0. % Strictly Private & Confidential 50 .37 0.CE (IIW) – 48 Heats Histogram of CE(IIW) 60 Mean StDev N 0.38 0.39 0.01155 96 53 No. of tests (2 pipes/heat) 50 40 30 20 9 3 1 4 17 10 8 1 0 0.

Repair and Rejection Details with Reasons Strictly Private & Confidential .

% 0. % 1.05 0.7 0.1 2.15 0.05 1.4 TOTAL 47 REJECTION SUMMARY Reason LOW THICKNESS (Excess grinning due to scratches) OFFSET PITTING (Corrosion) DWTT FAILED (Raw material defect) INDENTATION MARK (Raw material defect) OVER DIAMETER SCAB (Raw material defect) SHORT LENGTH No.16 TOTAL Strictly Private & Confidential 23 52 .1 0.05 0. of pipes 22 13 11 1 Repair.55 0. of pipes 11 3 3 2 1 1 1 1 Rejection.05 0.6 0.10 0.Repair & Rejection Summary WELD REPAIR SUMMARY Weld defect Slag Porosity Under cut Under fill No.15 0.

6 11 0.0 Slag Porosity Under cut Under fill 0. of pipes 1.0 % of pipes repaired (based on no. of pipe formed & welded) 53 Repair.8 15 0.1 0. of pipe formed & welded = 1984 1. of pipes repaired 22 Total no.1 20 No.Repair Details 25 1.4 5 0.2 1 0 Weld defect Strictly Private & Confidential .7 13 10 0.2 No.6 0. % 0.

55 LOW THICKNESS (Excess grinning due to scratches) 3 Rejection Details OFFSET 0.20 0.40 0.05 SCAB (Raw material defect) No.50 0.30 0. of pipes rejected 10 12 0 11 2 4 6 8 Strictly Private & Confidential 0.15 3 PITTING (Corrosion) 0.00 SHORT LENGTH INDENTATION MARK (Raw material defect) OVER DIAMETER 0.No.10 Total no. % % of pipes rejected (based on no. of pipes Rejection.10 0. of pipe formed & welded) 54 0.05 0.05 0. of pipe formed & welded = 1984 Reason 1 1 1 1 0.60 .05 0.15 2 DWTT FAILED (Raw material defect) 0.

Fish-bone Diagram for Slag Method More dust along with flux due to improper cleaning Due to heavy rust on the coil Material Due to scale on the coil surface Due to loose scale & dust on coil surface Improper grinding during SMA welding repair Slag Improper grinding during tack repair Due to improper dust cleaning prior to back repair & ID/OD welding Open arc due to improper flux boat Incorrect flow of flux from hopper Improper flux screening During RSI/RSO. improper flux level/imbalance in welding parameters (very high voltage at start) Setting of very high / very low voltage Man Machine 55 Strictly Private & Confidential .

grease & oil presence in edge groove Due to loose scale & dust on coil surface Usages of damp/hydrogen entrapped fluxes Improper gas shielding during MIG (auto & manual) welding Improper grinding during tack repair Improper flux backing/ preheating Porosity During RSI/RSO. paint.Fish-bone Diagram for Porosity Method More dust along with flux due to improper cleaning Material Due to moisture. improper flux level/imbalance in welding parameters (very high voltage at start) Due to improper dust cleaning prior to back repair & ID/OD welding Improper flux shielding (shallow flux level) – open arc problem Setting of very high / very low voltage Open arc due to improper flux boat Incorrect flow of flux from hopper Man Machine 56 Strictly Private & Confidential .

voltage & speed Malfunction of laser if laser temp. exceeds 50 deg C Improper laser tracking as temp.Fish-bone Diagram for Undercut Method Improper edge milling leading to distorted bevel/groove geometry Material Presence of dents on groove edges Improper travel of welding head due to more/less pipe pitch length Under Cut Improper setting /manipulation of lasers Setting of incorrect wire angle/incorrect stick-out RSI/RSO weld bead not matching with the original weld bead Setting of high current. exceeds the limit Wire bending due to absence of wire straightener Man Strictly Private & Confidential Machine 57 .