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3 .Statistical Report for 36ODX15.88 Mm (0.625) WT

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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
**

2

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.

Strictly Private & Confidential

3

**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.

Strictly Private & Confidential

4

**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

5

73 38.4 1.04 1984 1960 47 23 1 2.80 42.34 852.28 % 98.06 1.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 % 98.11 0.8 - FEET 76014 36 76979.2 0.20 76048.1 Strictly Private & Confidential 6 .36 34.79 0.

Coil to Pipe Mechanical Properties Variation Strictly Private & Confidential .

88 Range 47 56 5 0.2 2.14 2. MPa Coil UTS. CoV increase in YS from Coil to pipe = 0.13 Observations: 1. Unwinding of coils & forming strains resulting in reverse plasticity 2.77 486 612 36 0. % Coil YS/UTS Pipe YS. MPa Pipe elongation.Statistics of Coil & Pipe Mechanical Properties Variable Coil YS.02 14 14 1 0.9 1.08 Minimum 521 648 36 0. % Pipe YS/UTS Count 149 149 149 149 149 149 149 149 Mean 542 676 38 0.1 3.85 576 707 42 0. MPa Coil elongation.02 CoefVar 1.81 StDev 10 12 1 0.8 2.70% Reasons for observed changes are: 1.85%) 2. of heats = 48 Strictly Private & Confidential 8 .08 90 95 6 0. Mean decrease in YS from Coil to pipe = 10 MPa (1. Flattening of samples for testing Total no.80 532 660 40 0.6 2.75 Maximum 568 704 41 0. MPa Pipe UTS.0 3. Different sample locations in coil & pipe 3.

MPa Strictly Private & Confidential 9 . 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.2 13.1 10.15 149 532. 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.98 149 40 No.

1 Strictly Private & Confidential 10 . MPa 560 580 1 0.784 99.95% CI 99.9 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 0.1 LSL 485 MPa Mean StDev N AD P-Value 532.98 149 0.1% probability for YS < 485 MPa at 95 % confidence level.2 13.Probability Plot of Pipe YS Probability Plot of Pipe YS Normal . 480 500 520 540 Pipe YS.237 0.

7 11.UTS Change from Coil to Pipe Histogram of Coil UTS.5 13. 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. Pipe UTS 80 70 60 No. MPa 690 720 750 Strictly Private & Confidential 11 .95 149 659.62 149 30 20 10 0 570 0 2 0 1 0 5 5 5 1 0 600 630 660 UTS.

87 0. Pipe YS/UTS 70 62 USL 0.YS/UTS Change from Coil to Pipe Histogram of Coil YS/UTS.79 0.91 Strictly Private & Confidential 12 .75 0. of tests 40 34 31 30 20 10 0 18 17 23 10 6 0 2 3 0 0.01714 149 0.8071 StDev N 0.83 YS/UTS ratio 0.02485 149 60 50 44 48 No.8024 0.92 Variable Coil YS/UTS Pipe YS/UTS Mean 0.

of tests 50 40 30 20 10 2 4 17 11 4 2 LSL 25% Variable Coil elongation Pipe elongation Mean StDev N 37.Elongation Change from Coil to Pipe Histogram of Coil elongation. Pipe elongation 80 70 60 No. % Strictly Private & Confidential 0 42 13 .176 149 79 48 38 39 28 24 0 27 30 33 36 39 Elongation (2"GL).97 0.70 1.8378 149 39.

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

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 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 20 21 22 23 24 Heat 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 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. No.Mechanical Testing Status as per YS in Heats (RMTC) Sr. 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. 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. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Heat 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 .

80 532 659 40 0.77 486 612 36 0.0% Reasons for observed changes are: 1.13 Observations: 1. Different sample locations in coil & pipe 3. Flattening of samples for testing Total no.88 Range 41 55 5 0.81 StDev 9 12 1 0.08 81 83 6 0.1 3.7 2.18 Minimum 521 648 36 0.6 2.75 Maximum 562 703 41 0. % Coil YS/UTS Pipe YS.03 CoefVar 1. MPa Coil UTS.85 567 695 42 0. Unwinding of coils & forming strains resulting in reverse plasticity 2. Mean decrease in YS from Coil to pipe = 5 MPa (0.Statistics of Coil YS & Pipe YS for .02 14 13 1 0. MPa Pipe UTS.0 3. MPa Pipe elongation. of heats (YS < 540 MPa) = 24 Strictly Private & Confidential 17 .13 2. CoV increase in YS from Coil to pipe = 1.93%) 2. % Pipe YS/UTS Count 111 111 111 111 111 111 111 111 Mean 539 674 38 0.3 2. MPa Coil elongation.Heats YS < 540 MPa (RMTC) Variable Coil YS.6 1.

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. MPa 580 600 620 Strictly Private & Confidential 18 .857 111 532.9 8.2 13. of tests 30 20 16 10 2 (1.YS Change from Coil to Pipe . 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 538.98 111 No.

98 111 0. MPa 560 580 Strictly Private & Confidential 19 .794 Percent 0.1% probability for YS < 485 MPa at 95 % confidence level.2 13.Probability Plot of Pipe YS – Heats YS < 540 MPa (RMTC) Probability Plot of Pipe YS Normal .1 LSL 485 MPa Mean StDev N AD P-Value 532.9 99 95 90 80 70 60 50 40 30 20 10 5 1 0. 480 500 520 540 Pipe YS.95% CI 99.233 0.

7 1. CoV increase in YS from Coil to pipe = 1.27%) 2.3% Reasons for observed changes are: 1. MPa Coil UTS.84 576 707 42 0.01 14 15 1 0.10 Observations: 1. MPa Pipe elongation.7 1. % Coil YS/UTS Pipe YS.2 2.76 Maximum 568 704 39 0.02 CoefVar 1.7 2.4 1. % Pipe YS/UTS Count 38 38 38 38 38 38 38 38 Mean 552 680 38 0.81 532 662 40 0. MPa Coil elongation.80 StDev 7 12 1 0.78 503 638 38 0.5 2. Flattening of samples for testing Total no. Different sample locations in coil & pipe 3.72 2. MPa Pipe UTS.76 Minimum 540 653 36 0. Mean decrease in YS from Coil to pipe = 7 MPa (1.86 Range 28 51 3 0. Unwinding of coils & forming strains resulting in reverse plasticity 2.06 73 69 3 0.Statistics of Coil YS & Pipe YS – Heats YS ≥ 540 MPa (RMTC) Variable Coil YS. of heats (YS ≥ 540 MPa) = 24 Strictly Private & Confidential 20 .

478 38 532. 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 .6 7.YS Change from Coil to Pipe – Heats YS ≥ 540 MPa (RMTC) Histogram of Coil YS.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.

17 38 0. 0.1% probability for YS < 485 MPa at 95 % confidence level.95% CI 99 LSL 485 MPa Mean StDev N AD P-Value 532. 480 500 520 540 560 580 1 Pipe YS.384 95 90 80 Percent 70 60 50 40 30 20 10 5 1% probability for YS < 490 MPa at 95 % confidence level.Probability Plot of Pipe YS – Heats YS ≥ 540 MPa (RMTC) Probability Plot of Pipe YS Normal .381 0.2 14. MPa Strictly Private & Confidential 22 .

Dimensional Variation in Pipes Strictly Private & Confidential .

39 O v erall C apability Pp PPL PPU P pk * * 1.19 W ithin Ov erall 2 Strictly Private & Confidential 3 4 5 24 .510917 S tD ev (O v erall) 0.875 S ample N 1960 S tD ev (Within) 0.0 mm OUT OF ROUNDNESS BODY USL P rocess D ata LS L * Target * USL 5 S ample M ean 2.19 1.39 C pk 1.Pipe Dimensions – Out of Roundness (mm) SPECIFICATION LIMITS: USL = 5.597073 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 * * 1.0 mm F END OUT OF ROUNDNESS USL P rocess D ata LS L * Target * USL 5 S ample M ean 2.Pipe Dimensions – Out of Roundness (mm) SPECIFICATION LIMITS: USL = 5.520771 P otential (Within) C apability Cp * C PL * C P U 1.440773 S tD ev (O v erall) 0.54 1.54 W ithin Ov erall 1 2 3 4 5 Strictly Private & Confidential 25 .59235 S ample N 1960 S tD ev (Within) 0.

Pipe Dimensions – Out of Roundness (mm) SPECIFICATION LIMITS: USL = 5.467473 S tD ev (O v erall) 0.530351 P otential (Within) C apability Cp * C PL * C P U 1.0 mm T END OUT OF ROUNDNESS USL P rocess D ata LS L * Target * USL 5 S ample M ean 2.77 C pk 1.56 W ithin Ov erall 1 2 3 4 5 Strictly Private & Confidential 26 .52245 S ample N 1960 S tD ev (Within) 0.56 1.77 O v erall C apability Pp PPL PPU P pk * * 1.

Pipe Dimensions – Body Diameter (mm) SPECIFICATION LIMITS: LSL = 910 mm.3 917.2 916.85 O v erall C apability Pp 2.85 C pk 2.63 C P U 2.1% USL W ithin O v erall 910.482 S ample N 1960 S tD ev (Within) 0.0 914.24 C P L 3.16 P P U 2.472412 P otential (Within) C apability Cp 3. USL = 918 mm BODY DIAMETER ( B .4 27 .48 P pk 2.1) LSL P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.8 Strictly Private & Confidential 911.1 915.411585 S tD ev (O v erall) 0.9 913.48 C ov 0.82 P P L 3.

9 913.26 P P U 2.92 C pk 2.60 C ov 0.0 914.8 Strictly Private & Confidential 911.1 915.Pipe Dimensions – Body Diameter (mm) SPECIFICATION LIMITS: LSL = 910 mm. USL = 918 mm BODY DIAMETER ( B .3 917.4 28 .92 O v erall C apability Pp 2.1% USL W ithin O v erall 910.2 916.2) LSL P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.67 C P U 2.404797 S tD ev (O v erall) 0.29 C P L 3.454726 P otential (Within) C apability Cp 3.60 P pk 2.93 P P L 3.452 S ample N 1960 S tD ev (Within) 0.

68 C pk 2.31 C P U 2.4 29 .3) LSL P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.68 O v erall C apability Pp PPL PPU P pk C ov 2.2 916.44 2.416 S ample N 1960 S tD ev (Within) 0.490112 P otential (Within) C apability Cp 3.72 3.1 915.9 913.0 914.8 Strictly Private & Confidential 911.1% USL W ithin Ov erall 910.00 2.444973 S tD ev (O v erall) 0. USL = 918 mm BODY DIAMETER ( B .44 0.00 C P L 3.3 917.Pipe Dimensions – Body Diameter (mm) SPECIFICATION LIMITS: LSL = 910 mm.

399276 S tD ev (O v erall) 0.34 C P L 3.24 2.67 C P U 3.8 Strictly Private & Confidential 911.00 C pk 3.1 915.65 2.0 914.3 917.4) LSL P rocess D ata LS L 910 Target * USL 918 S ample M ean 914.1% USL W ithin Ov erall 910.452829 P otential (Within) C apability Cp 3.65 0.401 S ample N 1960 S tD ev (Within) 0.94 3.9 913.2 916.Pipe Dimensions – Body Diameter (mm) SPECIFICATION LIMITS: LSL = 910 mm.4 30 .00 O v erall C apability Pp PPL PPU P pk C ov 2. USL = 918 mm BODY DIAMETER ( B .

03 1.41 Target * USL 915.5 913.17 C pk 1.403475 S tD ev (O v erall) 0.59 S ample M ean 914.Pipe Dimensions – End Diameter (mm) SPECIFICATION LIMITS: LSL = 912. USL = 915.173 S ample N 1960 S tD ev (Within) 0.0 914.28 1.457802 P otential (Within) C apability Cp 1.5 915.17 O v erall C apability Pp PPL PPU P pk C ov 1.59 mm F END DIA METER LSL P rocess D ata LS L 912.1% USL W ithin O v erall 912.0 913.5 Strictly Private & Confidential 31 .31 C P L 1.41 mm.46 C P U 1.16 1.0 915.03 0.5 914.

Pipe Dimensions – End Diameter (mm) SPECIFICATION LIMITS: LSL = 912.09 0.94 0.41 Target * USL 915.0 913.0 915.432718 S tD ev (O v erall) 0.5 32 .1% USL W ithin Ov erall 912.773 S ample N 1960 S tD ev (Within) 0.59 S ample M ean 913.5 914.05 O v erall C apability Pp PPL PPU P pk C ov 1.25 0.40 C pk 1.59 mm T END DIA METER LSL P rocess D ata LS L 912.41 mm.05 C P U 1.94 1.0 914.5 915.485496 P otential (Within) C apability Cp 1.22 C P L 1.5 Strictly Private & Confidential 913. USL = 915.

44 O v erall C apability Pp PPL PPU P pk C ov 5.44 C P U 9.4 33 .97 C P L 4.0530829 S tD ev (O v erall) 0.50 C pk 4.47 3.9468 S ample N 1960 S tD ev (Within) 0.1 17.Pipe Dimensions – Wall Thickness (mm) SPECIFICATION LIMITS: LSL = 15.5 16.46 3.46 S ample M ean 15.4 mm.46 mm F END WALL THICKNESS LSL P rocess D ata LS L 15.0676287 P otential (Within) C apability Cp 6. USL = 17.48 0.9 16.2 16.48 7.8 17.24 Target * USL 17.4% USL W ithin Ov erall 15.3 Strictly Private & Confidential 15.6 15.

12 3.04 C P L 4.45 O v erall C apability Pp PPL PPU P pk C ov 6.6 15.942 S ample N 1960 S tD ev (Within) 0.5 16.4 34 .1 17.0604384 P otential (Within) C apability Cp 7.87 8.24 Target * USL 17.45 C P U 9.Pipe Dimensions – Wall Thickness (mm) SPECIFICATION LIMITS: LSL = 15.87 0.4 mm.63 C pk 4.8 17.46 mm T END WALL THICKNESS LSL P rocess D ata LS L 15.3 Strictly Private & Confidential 15.37 3.4% USL W ithin Ov erall 15.2 16.9 16.46 S ample M ean 15.0525398 S tD ev (O v erall) 0. USL = 17.

75 USL W ithin Ov erall 0.Pipe Dimensions – Root Face (mm) SPECIFICATION LIMITS: LSL = 0.110239 S tD ev (O v erall) 0.76321 S ample N 1960 S tD ev (Within) 0.75 1.4 S ample M ean 1.5 1. USL = 2.93 O v erall C apability Pp PPL PPU P pk 2.8 Target * USL 2.120949 P otential (Within) C apability Cp 2.4 35 .1 2.20 2.4 mm F END ROOT FACE LSL P rocess D ata LS L 0.93 C pk 1.65 1.8 mm.9 Strictly Private & Confidential 1.91 C P U 1.8 2.42 C P L 2.2 1.

78332 S ample N 1960 S tD ev (Within) 0.Pipe Dimensions – Root Face (mm) SPECIFICATION LIMITS: LSL = 0.2 1.4 S ample M ean 1.84 1.8 2.78 1.15 C P U 1.9 Strictly Private & Confidential 1.78 USL W ithin Ov erall 0.103903 S tD ev (O v erall) 0.5 1.8 Target * USL 2.4 mm T END ROOT FACE LSL P rocess D ata LS L 0.98 O v erall C apability Pp PPL PPU P pk 2.4 36 .31 2.8 mm.1 2.115568 P otential (Within) C apability Cp 2.57 C P L 3.98 C pk 1. USL = 2.

94836 P otential (Within) C apability Cp * C PL * C P U 2.89 1.Pipe Dimensions – Straightness (mm) SPECIFICATION LIMITS: USL = 10.09 O v erall C apability Pp PPL PPU P pk * * 1.09 C pk 2.89 W ithin Ov erall 2 4 6 8 10 Strictly Private & Confidential 37 .854847 S tD ev (O v erall) 0.63571 S ample N 1960 S tD ev (Within) 0.0 mm STRAIGHTNESS USL P rocess D ata LS L * Target * USL 10 S ample M ean 4.

06 O v erall C apability Pp PPL PPU P pk C pm * * 3.4 1.6 0.2 1.2 Strictly Private & Confidential 0.6 mm F END SQUARENESS USL P rocess D ata LS L * Target * USL 1.Pipe Dimensions – Squareness (mm) SPECIFICATION LIMITS: USL = 1.73 3.8 1.6 S ample M ean 0.6 38 .0997387 P otential (Within) C apability Cp * C PL * C P U 4.0915487 S tD ev (O v erall) 0.06 C pk 4.73 * W ithin Ov erall 0.0 1.484643 S ample N 1960 S tD ev (Within) 0.4 0.

2 1.4 0.06 O v erall C apability Pp PPL PPU P pk * * 3.484643 S ample N 1960 S tD ev (Within) 0.6 mm F END SQUARENESS USL P rocess D ata LS L * Target * USL 1.6 0.73 3.8 1.6 S ample M ean 0.6 39 .2 Strictly Private & Confidential 0.73 W ithin Ov erall 0.0915487 S tD ev (O v erall) 0.4 1.0997387 P otential (Within) C apability Cp * C PL * C P U 4.Pipe Dimensions – Squareness (mm) SPECIFICATION LIMITS: USL = 1.0 1.06 C pk 4.

142278 S tD ev (O v erall) 0.2 1.615102 S ample N 1960 S tD ev (Within) 0.Pipe Dimensions – Peaking (mm) SPECIFICATION LIMITS: USL = 1.14 2.31 O v erall C apability Pp PPL PPU P pk * * 2.6 0.6 mm F END PEAKING USL P rocess D ata LS L * Target * USL 1.0 1.6 S ample M ean 0.153191 P otential (Within) C apability Cp * C PL * C P U 2.4 1.14 W ithin O v erall 0.6 40 .4 0.2 Strictly Private & Confidential 0.31 C pk 2.8 1.

93 1.93 * W ithin O v erall 0.2 Strictly Private & Confidential 0.0 1.Pipe Dimensions – Peaking (mm) SPECIFICATION LIMITS: USL = 1.11 O v erall C apability Pp PPL PPU P pk C pm * * 1.151193 S tD ev (O v erall) 0.6 41 .165155 P otential (Within) C apability Cp * C PL * C P U 2.643367 S ample N 1960 S tD ev (Within) 0.4 0.6 0.4 1.6 S ample M ean 0.6 mm T END PEAKING USL P rocess D ata LS L * Target * USL 1.11 C pk 2.8 1.2 1.

8 1.57 C pk 9.8 3.4 0.2 mm PEAKING BODY USL P rocess D ata LS L * Target * USL 3.104014 P otential (Within) C apability Cp * C PL * C P U 9.0902816 S tD ev (O v erall) 0.4 2.2 Strictly Private & Confidential 42 .6 2.31 * W ithin O v erall 0.0 2.2 1.608316 S ample N 1960 S tD ev (Within) 0.2 S ample M ean 0.31 8.57 O v erall C apability Pp PPL PPU P pk C pm * * 8.Pipe Dimensions – Peaking (mm) SPECIFICATION LIMITS: USL = 3.

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

5 27 0 916.5 917.Increase in Pipe OD After Hydro-testing – Body Histogram of BODY (Before HT). mm Strictly Private & Confidential 44 . of pipes Mean StDev N 913.4898 1960 914.5 911.5 487 494 49 913.0 mm 1500 No.4156 1960 1326 1390 1000 500 0 4 910.5 Outside diameter.5 138 0 912.5 914. BODY (After HT) 2000 LSL 910 mm Variable BODY (Before HT) BODY (A fter HT) USL 918 mm Mean shift after hydrotesting = 1.7 0.5 0 5 915.1 mm Max.8 0. shift after hydro-testing = 2.

T-END (After HT) 350 300 250 No.4 915.8 StDev N 0.0 915.Increase in Pipe OD After Hydro-testing – T-End Histogram of T-END (Before HT).6 Outside diameter.0 mm 230 287 229 222 142 0 912.2 913.6 913.0 912.4807 1960 0.8 914. 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 912.59 mm Mean shift after hydrotesting = 0.41 mm Variable T-END (Before HT) T-END (A fter HT) Mean 913.5 mm Max. mm Strictly Private & Confidential 45 . shift after hydro-testing = 2.3 913.4855 1960 205 190 150 294 305 294 315 319 USL 915.

6 913.8 0.4 mm Max. mm Strictly Private & Confidential 46 .0 915.2 0.41 mm Variable F-END (Before HT) F-END (After HT) Mean StDev N 913.2 913.8 914.0 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 0 912.0 912.6 Outside diameter.4577 1960 292 269 252 353 347 315 313 297 USL 915. shift after hydro-testing = 2.4 915.Increase in Pipe OD After Hydro-testing – F-end Histogram of F-END (Before HT).4987 1960 914. F-END (After HT) 400 LSL 912.59 mm 300 No. of pipes 200 Mean shift after hydrotesting = 0.

Conformance to Chemical Composition Strictly Private & Confidential .

% 96 0.03 CE(IIW). % 96 0.012 2.06 No.35 0.9 0.191 0. of heats = 48 Strictly Private & Confidential 48 .39 0.9 0.18 0.Statistics of CE (Pcm) & CE (IIW) Variable Count Mean StDev CoefVar Minimum Maximum Range CE(Pcm).418 0.005 2.16 0.

18 CE(Pcm).005193 96 49 USL 0.CE (Pcm) – 48 Heats Histogram of CE(Pcm) 50 Mean StDev N 0. % 0.17 0.21 Strictly Private & Confidential 49 . of tests (2 pipes/heat) 40 30 22 20 10 4 8 8 5 0 0 0.1780 0.20 0.21% No.16 0.19 0.

40 0. % Strictly Private & Confidential 50 .41 0.42 CE(IIW).01155 96 53 No.3939 0.35 0.39 0.38 0.37 0.36 0.CE (IIW) – 48 Heats Histogram of CE(IIW) 60 Mean StDev N 0. 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 .

16 TOTAL Strictly Private & Confidential 23 52 .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.6 0.05 0.1 0.15 0.05 0.15 0.Repair & Rejection Summary WELD REPAIR SUMMARY Weld defect Slag Porosity Under cut Under fill No.1 2.55 0. of pipes 22 13 11 1 Repair.7 0. % 0.05 1.05 0.10 0. % 1.

of pipes repaired 22 Total no.2 1 0 Weld defect Strictly Private & Confidential .Repair Details 25 1. of pipe formed & welded) 53 Repair.6 0.7 13 10 0.2 No.1 20 No.6 11 0.1 0. % 0. of pipes 1. of pipe formed & welded = 1984 1.4 5 0.0 Slag Porosity Under cut Under fill 0.0 % of pipes repaired (based on no.8 15 0.

No.20 0.50 0.60 . of pipe formed & welded = 1984 Reason 1 1 1 1 0. of pipes rejected 10 12 0 11 2 4 6 8 Strictly Private & Confidential 0.15 2 DWTT FAILED (Raw material defect) 0. of pipes Rejection.55 LOW THICKNESS (Excess grinning due to scratches) 3 Rejection Details OFFSET 0. % % of pipes rejected (based on no.05 SCAB (Raw material defect) No.10 0. of pipe formed & welded) 54 0.05 0.40 0.10 Total no.00 SHORT LENGTH INDENTATION MARK (Raw material defect) OVER DIAMETER 0.30 0.15 3 PITTING (Corrosion) 0.05 0.05 0.

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 .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.

paint. 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 .Fish-bone Diagram for Porosity Method More dust along with flux due to improper cleaning Material Due to moisture. 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.

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. voltage & speed Malfunction of laser if laser temp. exceeds the limit Wire bending due to absence of wire straightener Man Strictly Private & Confidential Machine 57 .

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