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# QUALITY REPORT

## STATISTICAL PRESENTATION on TECHNICAL QUALITY DATA

for
CLIENT: ENTERPRISE-PRODUCTS OPERATING L.P. PROJECT: HAYNESVILLE-ACADIAN PIPE SIZE: 36ODX0.625(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
2

## 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.

## 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.

## 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.

## Strictly Private & Confidential

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

% 98.8 -

1984 1960

47 23 1

## Statistics of Coil & Pipe Mechanical Properties

Variable Coil YS, MPa Coil UTS, MPa Coil elongation, % Coil YS/UTS Pipe YS, MPa Pipe UTS, MPa Pipe elongation, % Pipe YS/UTS Count 149 149 149 149 149 149 149 149 Mean 542 676 38 0.80 532 660 40 0.81 StDev 10 12 1 0.02 14 14 1 0.02 CoefVar 1.9 1.8 2.2 2.14 2.6 2.1 3.0 3.08 Minimum 521 648 36 0.77 486 612 36 0.75 Maximum 568 704 41 0.85 576 707 42 0.88 Range 47 56 5 0.08 90 95 6 0.13

Observations: 1. Mean decrease in YS from Coil to pipe = 10 MPa (1.85%) 2. CoV increase in YS from Coil to pipe = 0.70% Reasons for observed changes are: 1. Unwinding of coils & forming strains resulting in reverse plasticity 2. Different sample locations in coil & pipe 3. Flattening of samples for testing

## Total no. of heats = 48

Strictly Private & Confidential

## YS Change from Coil to Pipe

Histogram of Coil YS, Pipe YS
60 50
43

58

## USL 635 MPa

Variable Coil YS Pipe YS Mean StDev N 542.1 10.15 149 532.2 13.98 149

40 No. 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

## Probability Plot of Pipe YS

Probability Plot of Pipe YS
Normal - 95% CI
99.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.1

## LSL 485 MPa

Mean StDev N AD P-Value 532.2 13.98 149 0.237 0.784

99.9 99 95 90 80 70 60 50 40 30 20 10 5

Percent

## 0.1% probability for YS < 485 MPa at 95 % confidence level.

480 500 520 540 Pipe YS, MPa 560 580

1 0.1

10

## UTS Change from Coil to Pipe

Histogram of Coil UTS, Pipe UTS
80 70 60 No. of tests 50 40
32 45 35 38 60

69

## USL 760 MPa

Variable C oil UTS Pipe UTS Mean StDev N 675.7 11.95 149 659.5 13.62 149

30 20 10 0 570
0 2 0 1 0 5 5 5 1

600

630

690

720

750

11

## YS/UTS Change from Coil to Pipe

Histogram of Coil YS/UTS, Pipe YS/UTS
70
62

USL 0.92
Variable Coil YS/UTS Pipe YS/UTS Mean 0.8024 0.8071 StDev N 0.01714 149 0.02485 149

60 50
44 48

No. of tests

40
34 31

30 20 10 0
18 17 23

10 6 0 2 3 0

0.75

0.79

0.87

0.91

12

## Elongation Change from Coil to Pipe

Histogram of Coil elongation, Pipe elongation
80 70 60 No. of tests 50 40 30 20 10
2 4 17 11 4 2

LSL 25%
Variable Coil elongation Pipe elongation Mean StDev N 37.97 0.8378 149 39.70 1.176 149

79

48 38 39

28 24

0 27 30 33 36 39 Elongation (2"GL), %
Strictly Private & Confidential

42

13

## Mechanical Testing Status for Pipe

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

## Mechanical Testing Status as per YS in Heats (RMTC)

Sr. No. 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. 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. 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. 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. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Heat 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 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. 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

20 21 22 23 24

15

## 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

Statistics of Coil YS & Pipe YS for - Heats YS < 540 MPa (RMTC)
Variable Coil YS, MPa Coil UTS, MPa Coil elongation, % Coil YS/UTS Pipe YS, MPa Pipe UTS, MPa Pipe elongation, % Pipe YS/UTS Count 111 111 111 111 111 111 111 111 Mean 539 674 38 0.80 532 659 40 0.81 StDev 9 12 1 0.02 14 13 1 0.03 CoefVar 1.6 1.7 2.3 2.13 2.6 2.0 3.1 3.18 Minimum 521 648 36 0.77 486 612 36 0.75 Maximum 562 703 41 0.85 567 695 42 0.88 Range 41 55 5 0.08 81 83 6 0.13

Observations: 1. Mean decrease in YS from Coil to pipe = 5 MPa (0.93%) 2. CoV increase in YS from Coil to pipe = 1.0% Reasons for observed changes are: 1. Unwinding of coils & forming strains resulting in reverse plasticity 2. Different sample locations in coil & pipe 3. Flattening of samples for testing

## Total no. of heats (YS < 540 MPa) = 24

Strictly Private & Confidential

17

## YS Change from Coil to Pipe - Heats YS < 540 MPa (RMTC)

Histogram of Coil YS, Pipe YS
50 LSL 485 MPa
48

## USL 635 MPa

Variable C oil YS (< 540 MPa) Pipe YS

40
30 29 27 23 21

No. of tests

30

20
16

10
2 (1.3%) 0 0 0

9 6 0 7 3 1 0

480

500

520

540

580

600

620

18

## Probability Plot of Pipe YS Heats YS < 540 MPa (RMTC)

Probability Plot of Pipe YS
Normal - 95% CI
99.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0.1

## LSL 485 MPa

Mean StDev N AD P-Value 532.2 13.98 111 0.233 0.794

Percent

## 0.1% probability for YS < 485 MPa at 95 % confidence level.

480 500 520 540 Pipe YS, MPa 560 580

19

## Statistics of Coil YS & Pipe YS Heats YS 540 MPa (RMTC)

Variable Coil YS, MPa Coil UTS, MPa Coil elongation, % Coil YS/UTS Pipe YS, MPa Pipe UTS, MPa Pipe elongation, % Pipe YS/UTS Count 38 38 38 38 38 38 38 38 Mean 552 680 38 0.81 532 662 40 0.80 StDev 7 12 1 0.01 14 15 1 0.02 CoefVar 1.4 1.7 1.7 1.72 2.7 2.2 2.5 2.76 Minimum 540 653 36 0.78 503 638 38 0.76 Maximum 568 704 39 0.84 576 707 42 0.86 Range 28 51 3 0.06 73 69 3 0.10

Observations: 1. Mean decrease in YS from Coil to pipe = 7 MPa (1.27%) 2. CoV increase in YS from Coil to pipe = 1.3% Reasons for observed changes are: 1. Unwinding of coils & forming strains resulting in reverse plasticity 2. Different sample locations in coil & pipe 3. Flattening of samples for testing

## Total no. of heats (YS 540 MPa) = 24

Strictly Private & Confidential

20

## YS Change from Coil to Pipe Heats YS 540 MPa (RMTC)

Histogram of Coil YS, 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 551.6 7.478 38 532.2 14.17 38

No. of tests

15

10
5 4

5
1 0

5 3

1 0

500

520

540

580

600

620

21

## Probability Plot of Pipe YS Heats YS 540 MPa (RMTC)

Probability Plot of Pipe YS
Normal - 95% CI
99

## LSL 485 MPa

Mean StDev N AD P-Value 532.2 14.17 38 0.381 0.384

95 90 80

Percent

70 60 50 40 30 20 10 5

1% probability for YS < 490 MPa at 95 % confidence level. 0.1% probability for YS < 485 MPa at 95 % confidence level.
480 500 520 540 560 580

## Pipe YS, MPa

Strictly Private & Confidential

22

## 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 2.875 S ample N 1960 S tD ev (Within) 0.510917 S tD ev (O v erall) 0.597073 P otential (Within) C apability Cp * C PL * C P U 1.39 C pk 1.39 O v erall C apability Pp PPL PPU P pk * * 1.19 1.19

W ithin Ov erall

2
Strictly Private & Confidential

24

## Pipe Dimensions Out of Roundness (mm)

SPECIFICATION LIMITS: USL = 5.0 mm

## F END OUT OF ROUNDNESS

USL
P rocess D ata LS L * Target * USL 5 S ample M ean 2.59235 S ample N 1960 S tD ev (Within) 0.440773 S tD ev (O v erall) 0.520771 P otential (Within) C apability Cp * C PL * C P U 1.82 C pk 1.82 O v erall C apability Pp PPL PPU P pk * * 1.54 1.54

W ithin Ov erall

25

## Pipe Dimensions Out of Roundness (mm)

SPECIFICATION LIMITS: USL = 5.0 mm

## T END OUT OF ROUNDNESS

USL
P rocess D ata LS L * Target * USL 5 S ample M ean 2.52245 S ample N 1960 S tD ev (Within) 0.467473 S tD ev (O v erall) 0.530351 P otential (Within) C apability Cp * C PL * C P U 1.77 C pk 1.77 O v erall C apability Pp PPL PPU P pk * * 1.56 1.56

W ithin Ov erall

26

## Pipe Dimensions Body Diameter (mm)

SPECIFICATION LIMITS: LSL = 910 mm, USL = 918 mm

BODY DIAMETER ( B - 1)
LSL
P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.482 S ample N 1960 S tD ev (Within) 0.411585 S tD ev (O v erall) 0.472412 P otential (Within) C apability Cp 3.24 C P L 3.63 C P U 2.85 C pk 2.85 O v erall C apability Pp 2.82 P P L 3.16 P P U 2.48 P pk 2.48 C ov 0.1%

USL

W ithin O v erall

910.8
Strictly Private & Confidential

911.9

913.0

914.1

915.2

916.3

917.4

27

## Pipe Dimensions Body Diameter (mm)

SPECIFICATION LIMITS: LSL = 910 mm, USL = 918 mm

BODY DIAMETER ( B - 2)
LSL
P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.452 S ample N 1960 S tD ev (Within) 0.404797 S tD ev (O v erall) 0.454726 P otential (Within) C apability Cp 3.29 C P L 3.67 C P U 2.92 C pk 2.92 O v erall C apability Pp 2.93 P P L 3.26 P P U 2.60 P pk 2.60 C ov 0.1%

USL

W ithin O v erall

910.8
Strictly Private & Confidential

911.9

913.0

914.1

915.2

916.3

917.4

28

## Pipe Dimensions Body Diameter (mm)

SPECIFICATION LIMITS: LSL = 910 mm, USL = 918 mm

BODY DIAMETER ( B - 3)
LSL
P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.416 S ample N 1960 S tD ev (Within) 0.444973 S tD ev (O v erall) 0.490112 P otential (Within) C apability Cp 3.00 C P L 3.31 C P U 2.68 C pk 2.68 O v erall C apability Pp PPL PPU P pk C ov 2.72 3.00 2.44 2.44 0.1%

USL

W ithin Ov erall

910.8
Strictly Private & Confidential

911.9

913.0

914.1

915.2

916.3

917.4

29

## Pipe Dimensions Body Diameter (mm)

SPECIFICATION LIMITS: LSL = 910 mm, USL = 918 mm

BODY DIAMETER ( B - 4)
LSL
P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.401 S ample N 1960 S tD ev (Within) 0.399276 S tD ev (O v erall) 0.452829 P otential (Within) C apability Cp 3.34 C P L 3.67 C P U 3.00 C pk 3.00 O v erall C apability Pp PPL PPU P pk C ov 2.94 3.24 2.65 2.65 0.1%

USL

W ithin Ov erall

910.8
Strictly Private & Confidential

911.9

913.0

914.1

915.2

916.3

917.4

30

## Pipe Dimensions End Diameter (mm)

SPECIFICATION LIMITS: LSL = 912.41 mm, USL = 915.59 mm

## F END DIA METER

LSL
P rocess D ata LS L 912.41 Target * USL 915.59 S ample M ean 914.173 S ample N 1960 S tD ev (Within) 0.403475 S tD ev (O v erall) 0.457802 P otential (Within) C apability Cp 1.31 C P L 1.46 C P U 1.17 C pk 1.17 O v erall C apability Pp PPL PPU P pk C ov 1.16 1.28 1.03 1.03 0.1%

USL

W ithin O v erall

912.5

913.0

913.5

914.0

914.5

915.0

915.5

31

## Pipe Dimensions End Diameter (mm)

SPECIFICATION LIMITS: LSL = 912.41 mm, USL = 915.59 mm

## T END DIA METER

LSL
P rocess D ata LS L 912.41 Target * USL 915.59 S ample M ean 913.773 S ample N 1960 S tD ev (Within) 0.432718 S tD ev (O v erall) 0.485496 P otential (Within) C apability Cp 1.22 C P L 1.05 C P U 1.40 C pk 1.05 O v erall C apability Pp PPL PPU P pk C ov 1.09 0.94 1.25 0.94 0.1%

USL

W ithin Ov erall

912.5
Strictly Private & Confidential

913.0

913.5

914.0

914.5

915.0

915.5

32

## Pipe Dimensions Wall Thickness (mm)

SPECIFICATION LIMITS: LSL = 15.4 mm, USL = 17.46 mm

## F END WALL THICKNESS

LSL
P rocess D ata LS L 15.24 Target * USL 17.46 S ample M ean 15.9468 S ample N 1960 S tD ev (Within) 0.0530829 S tD ev (O v erall) 0.0676287 P otential (Within) C apability Cp 6.97 C P L 4.44 C P U 9.50 C pk 4.44 O v erall C apability Pp PPL PPU P pk C ov 5.47 3.48 7.46 3.48 0.4%

USL

W ithin Ov erall

15.3
Strictly Private & Confidential

15.6

15.9

16.2

16.5

16.8

17.1

17.4

33

## Pipe Dimensions Wall Thickness (mm)

SPECIFICATION LIMITS: LSL = 15.4 mm, USL = 17.46 mm

## T END WALL THICKNESS

LSL
P rocess D ata LS L 15.24 Target * USL 17.46 S ample M ean 15.942 S ample N 1960 S tD ev (Within) 0.0525398 S tD ev (O v erall) 0.0604384 P otential (Within) C apability Cp 7.04 C P L 4.45 C P U 9.63 C pk 4.45 O v erall C apability Pp PPL PPU P pk C ov 6.12 3.87 8.37 3.87 0.4%

USL

W ithin Ov erall

15.3
Strictly Private & Confidential

15.6

15.9

16.2

16.5

16.8

17.1

17.4

34

## Pipe Dimensions Root Face (mm)

SPECIFICATION LIMITS: LSL = 0.8 mm, USL = 2.4 mm

## F END ROOT FACE

LSL
P rocess D ata LS L 0.8 Target * USL 2.4 S ample M ean 1.76321 S ample N 1960 S tD ev (Within) 0.110239 S tD ev (O v erall) 0.120949 P otential (Within) C apability Cp 2.42 C P L 2.91 C P U 1.93 C pk 1.93 O v erall C apability Pp PPL PPU P pk 2.20 2.65 1.75 1.75

USL

W ithin Ov erall

0.9
Strictly Private & Confidential

1.2

1.5

1.8

2.1

2.4

35

## Pipe Dimensions Root Face (mm)

SPECIFICATION LIMITS: LSL = 0.8 mm, USL = 2.4 mm

## T END ROOT FACE

LSL
P rocess D ata LS L 0.8 Target * USL 2.4 S ample M ean 1.78332 S ample N 1960 S tD ev (Within) 0.103903 S tD ev (O v erall) 0.115568 P otential (Within) C apability Cp 2.57 C P L 3.15 C P U 1.98 C pk 1.98 O v erall C apability Pp PPL PPU P pk 2.31 2.84 1.78 1.78

USL

W ithin Ov erall

0.9
Strictly Private & Confidential

1.2

1.5

1.8

2.1

2.4

36

## Pipe Dimensions Straightness (mm)

SPECIFICATION LIMITS: USL = 10.0 mm

STRAIGHTNESS
USL
P rocess D ata LS L * Target * USL 10 S ample M ean 4.63571 S ample N 1960 S tD ev (Within) 0.854847 S tD ev (O v erall) 0.94836 P otential (Within) C apability Cp * C PL * C P U 2.09 C pk 2.09 O v erall C apability Pp PPL PPU P pk * * 1.89 1.89

W ithin Ov erall

10

37

## Pipe Dimensions Squareness (mm)

SPECIFICATION LIMITS: USL = 1.6 mm

F END SQUARENESS
USL
P rocess D ata LS L * Target * USL 1.6 S ample M ean 0.484643 S ample N 1960 S tD ev (Within) 0.0915487 S tD ev (O v erall) 0.0997387 P otential (Within) C apability Cp * C PL * C P U 4.06 C pk 4.06 O v erall C apability Pp PPL PPU P pk C pm * * 3.73 3.73 *

W ithin Ov erall

0.2
Strictly Private & Confidential

0.4

0.6

0.8

1.0

1.2

1.4

1.6

38

## Pipe Dimensions Squareness (mm)

SPECIFICATION LIMITS: USL = 1.6 mm

F END SQUARENESS
USL
P rocess D ata LS L * Target * USL 1.6 S ample M ean 0.484643 S ample N 1960 S tD ev (Within) 0.0915487 S tD ev (O v erall) 0.0997387 P otential (Within) C apability Cp * C PL * C P U 4.06 C pk 4.06 O v erall C apability Pp PPL PPU P pk * * 3.73 3.73

W ithin Ov erall

0.2
Strictly Private & Confidential

0.4

0.6

0.8

1.0

1.2

1.4

1.6

39

## Pipe Dimensions Peaking (mm)

SPECIFICATION LIMITS: USL = 1.6 mm

F END PEAKING
USL
P rocess D ata LS L * Target * USL 1.6 S ample M ean 0.615102 S ample N 1960 S tD ev (Within) 0.142278 S tD ev (O v erall) 0.153191 P otential (Within) C apability Cp * C PL * C P U 2.31 C pk 2.31 O v erall C apability Pp PPL PPU P pk * * 2.14 2.14

W ithin O v erall

0.2
Strictly Private & Confidential

0.4

0.6

0.8

1.0

1.2

1.4

1.6

40

## Pipe Dimensions Peaking (mm)

SPECIFICATION LIMITS: USL = 1.6 mm

T END PEAKING
USL
P rocess D ata LS L * Target * USL 1.6 S ample M ean 0.643367 S ample N 1960 S tD ev (Within) 0.151193 S tD ev (O v erall) 0.165155 P otential (Within) C apability Cp * C PL * C P U 2.11 C pk 2.11 O v erall C apability Pp PPL PPU P pk C pm * * 1.93 1.93 *

W ithin O v erall

0.2
Strictly Private & Confidential

0.4

0.6

0.8

1.0

1.2

1.4

1.6

41

## Pipe Dimensions Peaking (mm)

SPECIFICATION LIMITS: USL = 3.2 mm

PEAKING BODY
USL
P rocess D ata LS L * Target * USL 3.2 S ample M ean 0.608316 S ample N 1960 S tD ev (Within) 0.0902816 S tD ev (O v erall) 0.104014 P otential (Within) C apability Cp * C PL * C P U 9.57 C pk 9.57 O v erall C apability Pp PPL PPU P pk C pm * * 8.31 8.31 *

W ithin O v erall

0.4

0.8

1.2

1.6

2.0

2.4

2.8

3.2

42

## Increase in Pipe OD After Hydro-testing Body

Histogram of BODY (Before HT), BODY (After HT)
2000 LSL 910 mm
Variable BODY (Before HT) BODY (A fter HT)

USL 918 mm
Mean shift after hydrotesting = 1.1 mm Max. shift after hydro-testing = 2.0 mm

1326

1390

1000

## 500 0 4 910.5 911.5 138 0 912.5

487

494

49 913.5 914.5

5 915.5

27 0 916.5 917.5

Outside diameter, mm
Strictly Private & Confidential

44

## Increase in Pipe OD After Hydro-testing T-End

Histogram of T-END (Before HT), T-END (After HT)
350 300 250 No. 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 912.41 mm
Variable T-END (Before HT) T-END (A fter HT) Mean 913.3 913.8 StDev N 0.4807 1960 0.4855 1960 205 190 150 294 305 294 315 319

USL 915.59 mm
Mean shift after hydrotesting = 0.5 mm Max. shift after hydro-testing = 2.0 mm
230

287

229

222

142

912.0

912.6

913.2

913.8

914.4

915.0

915.6

Outside diameter, mm
Strictly Private & Confidential

45

## Increase in Pipe OD After Hydro-testing F-end

Histogram of F-END (Before HT), F-END (After HT)
400 LSL 912.41 mm
Variable F-END (Before HT) F-END (After HT) Mean StDev N 913.8 0.4987 1960 914.2 0.4577 1960 292 269 252 353 347 315 313 297

USL 915.59 mm

## 300 No. of pipes

200

Mean shift after hydrotesting = 0.4 mm Max. shift after hydro-testing = 2.0 mm
107

## 181 163 134 103 75 53 29 5 0 16 0

100
44 0 0 2 0 3 27 3 3 20 41 54

912.0

912.6

913.2

913.8

914.4

915.0

915.6

Outside diameter, mm
Strictly Private & Confidential

46

## Statistics of CE (Pcm) & CE (IIW)

Variable

Count

Mean

StDev

CoefVar

Minimum

Maximum

Range

CE(Pcm), %

96

0.18

0.005

2.9

0.16

0.191

0.03

CE(IIW), %

96

0.39

0.012

2.9

0.35

0.418

0.06

No. of heats = 48

## Strictly Private & Confidential

48

CE (Pcm) 48 Heats
Histogram of CE(Pcm)
50
Mean StDev N 0.1780 0.005193 96 49

USL 0.21%

40

30
22

20

10
4

8 5

0.16

0.17

0.18 CE(Pcm), %

0.19

0.20

0.21

## Strictly Private & Confidential

49

CE (IIW) 48 Heats
Histogram of CE(IIW)
60
Mean StDev N 0.3939 0.01155 96 53

50

40

30

20
9 3 1 4

17

10

8 1

## 0 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 CE(IIW), %

Strictly Private & Confidential

50

## Repair & Rejection Summary

WELD REPAIR SUMMARY
Weld defect
Slag Porosity Under cut Under fill

No. of pipes
22 13 11 1

Repair, %
1.1 0.7 0.6 0.1 2.4

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. of pipes
11 3 3 2 1 1 1 1

Rejection, %
0.55 0.15 0.15 0.10 0.05 0.05 0.05 0.05 1.16

TOTAL
Strictly Private & Confidential

23

52

Repair Details
25 1.1 20 No. of pipes repaired 22
Total no. of pipe formed & welded = 1984

1.2 No. of pipes 1.0 % of pipes repaired (based on no. of pipe formed & welded)
53

Repair, %

## 0.4 5 0.1 0.0 Slag Porosity Under cut Under fill

0.2 1

Weld defect
Strictly Private & Confidential

0.55

## LOW THICKNESS (Excess grinning due to scratches)

Rejection Details

OFFSET

0.15

PITTING (Corrosion)

0.15

0.10

## Total no. of pipe formed & welded = 1984

Reason 1 1 1 1 0.00
SHORT LENGTH INDENTATION MARK (Raw material defect) OVER DIAMETER

0.05 0.05

No. of pipes

Rejection, %

54

0.50

0.60

## 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

## 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)

Man

Machine
55

## Fish-bone Diagram for Porosity

Method
More dust along with flux due to improper cleaning

Material
Due to moisture, paint, grease & oil presence in edge groove

## 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, 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

Man

Machine
56

## 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, voltage & speed Malfunction of laser if laser temp. exceeds 50 deg C Improper laser tracking as temp. exceeds the limit Wire bending due to absence of wire straightener

Man
Strictly Private & Confidential

Machine
57