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QUALITY REPORT

STATISTICAL PRESENTATION on TECHNICAL QUALITY DATA

for
CLIENT: ENTERPRISE-PRODUCTS OPERATING L.P. PROJECT: HAYNESVILLE-ACADIAN PIPE SIZE: 42ODX0.529(13.44 mm) WT GRADE: API5L X70M PSL2 STEEL SOURCE : POSCO, KOREA 25-01-2010

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.

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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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Project Summary
RAW MATERIAL DETAILS TOTAL HEATS USED HEATS WITH YS < 540 MPa (COIL) HEATS WITH YS 540 MPa (COIL) COIL CONSUMED NUMBER 43 15 28 295

PRODUCTION SUMMARY

NUMBER

% -

FEET

% 98.36 0.06 0.48 0.10

TOTAL ORDER QUANTITY AVERAGE LENGTH AS PER ORDER (MINIMUM) TOTAL PIPE FORMING TOTAL PIPE TPI CLEARED AVERAGE LENGTH ACHIEVED PIPES REPAIRED PIPES REJECTED FORMATION TRIAL PIPE

2235

80445 36 82507 81150 39.57 50.66 395.11 80.94

2063 2051

99.42 2.62 0.48 0.10

54 10 2

Strictly Private & Confidential

Coil to Pipe Mechanical Properties Variation

Strictly Private & Confidential

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 138 138 138 138 138 138 138 138 Mean 541 682 36 0.79 550 650 37 0.85 StDev 13 13 1 0.02 12 12 1 0.02 CoefVar 2.3 1.9 3.7 2.83 2.1 1.8 3.5 2.20 Minimum 520 661 34 0.73 526 616 34 0.80 Maximum 581 722 40 0.84 595 686 41 0.90 Range 61 61 6 0.11 69 69 6 0.10

Observations: 1. Mean increase in YS from Coil to pipe = 9 MPa (1.66%). 2. CoV decrease in YS from Coil to pipe = 0.20% Reasons for observed changes are: 1. Unwinding of coils & forming strains resulting in reverse plasticity. The effect of reverse plasticity is almost negligible in this 13.44 mm as compared to 15.88 mm. 2. Different sample locations in coil & pipe 3. Flattening of samples for testing 4. The other important reason is D/t ratio where the effect of Bauschinger will be less in 42 OD pipe compared to 36 OD pipe.

Total no. of heats = 43


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YS Change from Coil to Pipe


Histogram of Coil YS, Pipe YS
70 60 50 No. of tests 40 30 20 10 0
0 20 13 8 3 14 6 1 1 0 22 37 34 49

LSL 485 MPa


65

USL 635 MPa


Variable C oil YS Pipe YS Mean StDev N 540.6 12.52 138 550.4 11.74 138

500 510 520 530 540 550 560 570 580 590 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 550.4 11.74 138 1.070 0.008

Percent

0.1% probability for YS < 509 MPa at 95 % confidence level.


470 480 490 500 510 520 530 540 550 560 570 580 590 600 610

Pipe YS, MPa


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UTS Change from Coil to Pipe


Histogram of Coil UTS, Pipe UTS
80 70
61

LSL 570 MPa

USL 760 MPa


Variable Coil UTS Pipe UTS 60 51 53 Mean StDev N 682.1 12.69 138 650.1 11.68 138

60 No. of tests 50 40 30 20 10 0 570 600


2 0 17 16 6 0 0

2 0

7 0

630

660 UTS, MPa

690

720

750

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YS/UTS Change from Coil to Pipe


Histogram of Coil YS/UTS, Pipe YS/UTS
80 70 60 No. of tests 50 40
32 Variable C oil YS/UTS Pipe YS/UTS Mean 0.7928 0.8468 StDev N 0.02242 138 0.01864 138 59 68

USL 0.92

40 36 27

30 20 10 0
6 0 0 0 5

2 0

0.72

0.77

0.82 YS/UTS ratio

0.87

0.92

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Elongation Change from Coil to Pipe


Histogram of Coil elongation, Pipe elongation
60 50 40 No. of tests 30 20 10
1

LSL 25%
Variable C oil elongation Pipe elongation Mean StDev N 35.68 1.323 138 37.03 1.278 138 32 29 56

48 45

16 12 7 0 11 7 7 4

0 25 26 27 28 29 30 31 32 33 34 35 36 37 Elongation (2"GL), %
Strictly Private & Confidential

1 0

38

39

40

41

13

Mechanical Testing Status for Pipe


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

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Mechanical Testing Status as per YS in Heats (RMTC)


No. of pipes Sr. No. Heat No. Formed Tested
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 20 21 22 23 24 25 26 27 28 Heat No. SP41257 SP41262 SP41346 SP41358 SP41478 SP41647 SP41699 SP41706 SP41708 SP41711 SP41858 SQ68380 SQ68383 SQ68386 SQ68545 SQ68550 SQ68653 SQ68790 SQ68815 SQ68822 SQ68890 SQ68892 SQ68900 SQ68906 SQ68951 SQ68954 SQ69001 SQ69167 Total
No. of pipes Formed Tested

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

SP41476 SQ68373 SQ68641 SQ68646 SQ68649 SQ68800 SQ68883 SQ68887 SQ68909 SQ68912 SQ68943 SQ68948 SQ69003 SQ69007 SQ69160 Total

42 42 49 49 56 56 49 61 63 63 49 56 56 63 49 803

5 5 5 5 6 6 5 7 7 7 1 6 6 7 5 83

Test status for heats YS 540 MPa

49 35 21 42 35 35 42 63 42 49 42 56 49 35 49 49 35 42 42 56 63 49 42 63 63 63 28 21 1260

1 1 1 1 4 4 1 2 1 1 1 6 1 1 1 1 1 1 1 2 7 1 1 2 7 2 1 1 55

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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 83 83 83 83 83 83 83 83 Mean 533 682 36 0.78 550 650 37 0.85 StDev 6 12 1 0.02 11 11 1 0.02 CoefVar 1.2 1.8 2.0 2.51 2.1 1.7 3.5 2.23 Minimum 520 663 34 0.73 526 621 34 0.80 Maximum 539 713 37 0.81 583 678 41 0.88 Range 19 50 3 0.08 58 57 6 0.08

Observations: 1. Mean increase in YS from Coil to pipe = 17 MPa (3.19%) 2. CoV increase in YS from Coil to pipe = 0.9% Reasons for observed changes are: 1. Unwinding of coils & forming strains resulting in reverse plasticity. The effect of reverse plasticity is almost negligible in this 13.44 mm as compared to 15.88 mm. 2. Different sample locations in coil & pipe 3. Flattening of samples for testing 4. The other important reason is D/t ratio where the effect of Bauschinger will be less in 42 OD pipe compared to 36 OD pipe.

Total no. of heats (YS < 540 MPa) = 15


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


Histogram of Coil YS, Pipe YS
60 50 40
32

LSL 485 MPa


50

USL 635 MPa


Variable Coil YS (< 540 MPa) Pipe YS Mean StDev N 532.6 6.238 83 549.8 11.28 83

No. of tests

30 20 10
5 20 13 22 18

0 500

2 0

4 0

520

540

560 YS, MPa

580

600

620

Strictly Private & Confidential

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 549.8 11.28 83 0.801 0.036

Percent

0.1% probability for YS < 509 MPa at 95 % confidence level.


470 480 490 500 510 520 530 540 550 Pipe YS, MPa 560 570 580 590 600

Strictly Private & Confidential

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 55 55 55 55 55 55 55 55 Mean 553 681 36 0.81 551 650 37 0.85 StDev 10 13 2 0.01 12 13 1 0.02 CoefVar 1.8 2.0 5.3 1.38 2.3 1.9 3.4 2.17 Minimum 540 661 34 0.78 527 616 35 0.80 Maximum 581 722 40 0.84 595 686 40 0.90 Range 41 61 6 0.06 67 69 5 0.10

Observations: 1. Mean decrease in YS from Coil to pipe = 2 MPa (0.36%) 2. CoV increase in YS from Coil to pipe = 0.5% Reasons for observed changes are: 1. Unwinding of coils & forming strains resulting in reverse plasticity. The effect of reverse plasticity is almost negligible in this 13.44 mm as compared to 15.88 mm. 2. Different sample locations in coil & pipe 3. Flattening of samples for testing 4. The other important reason is D/t ratio where the effect of Bauschinger will be less in 42 OD pipe compared to 36 OD pipe.

Total no. of heats (YS 540 MPa) = 28


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
22

USL 635 MPa


Variable Coil YS ( 540 MPa) Pipe YS Mean StDev N 552.7 9.661 55 551.4 12.43 55

20
17 16 15 14

No. of tests

15

10

5
0

3 0

3 1 2 1 1 0

0 500

520

540

560 YS, MPa

580

600

620

Strictly Private & Confidential

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 551.4 12.43 55 0.630 0.096

95 90 80

Percent

70 60 50 40 30 20 10 5

1% probability for YS < 516 MPa at 95 % confidence level.


470 480 490 500 510 520 530 540 550 560 570 580 590 600 610

Pipe YS, MPa


Strictly Private & Confidential

22

Dimensional Variation in Pipes

Strictly Private & Confidential

Pipe Dimensions Out of Roundness (mm)


SPECIFICATION LIMITS: USL = 5.0 mm

BODY OUT OF ROUNDNESS


USL
P rocess D ata LS L * Target * USL 5 S ample M ean 2.70453 S ample N 2051 S tD ev (Within) 0.464885 S tD ev (O v erall) 0.545021 P otential (Within) C apability Cp * C PL * C P U 1.65 C pk 1.65 O v erall C apability Pp PPL PPU P pk * * 1.40 1.40

W ithin O v erall

1
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 2.67382 S ample N 2051 S tD ev (Within) 0.428127 S tD ev (O v erall) 0.501113 P otential (Within) C apability Cp * C PL * C P U 1.81 C pk 1.81 O v erall C apability Pp PPL PPU P pk * * 1.55 1.55

W ithin O v erall

2
Strictly Private & Confidential

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 2.49586 S ample N 2051 S tD ev (Within) 0.46748 S tD ev (O v erall) 0.522057 P otential (Within) C apability Cp * C PL * C P U 1.79 C pk 1.79 O v erall C apability Pp PPL PPU P pk * * 1.60 1.60

W ithin O v erall

2
Strictly Private & Confidential

26

Pipe Dimensions Body Diameter (mm)


SPECIFICATION LIMITS: LSL = 1063 mm, USL = 1071 mm

BODY DIA METER ( B - 1 )


LSL
P rocess D ata LS L 1063 Target * USL 1071 S ample M ean 1067.02 S ample N 2051 S tD ev (Within) 0.304065 S tD ev (O v erall) 0.355906 P otential (Within) C apability Cp 4.39 C P L 4.41 C P U 4.36 C pk 4.36 O v erall C apability Pp 3.75 P P L 3.77 P P U 3.73 P pk 3.73 C ov 0.1%

USL

W ithin O v erall

1063.2
Strictly Private & Confidential

1064.4

1065.6

1066.8

1068.0

1069.2

1070.4

27

Pipe Dimensions Body Diameter (mm)


SPECIFICATION LIMITS: LSL = 1063 mm, USL = 1071 mm

BODY DIA METER ( B - 2 )


LSL
P rocess D ata LS L 1063 Target * USL 1071 S ample M ean 1066.76 S ample N 2051 S tD ev (Within) 0.34501 S tD ev (O v erall) 0.406815 P otential (Within) C apability Cp 3.86 C P L 3.63 C P U 4.09 C pk 3.63 O v erall C apability Pp PPL PPU P pk C ov 3.28 3.08 3.47 3.08 0.1%

USL

W ithin Ov erall

1063.2
Strictly Private & Confidential

1064.4

1065.6

1066.8

1068.0

1069.2

1070.4

28

Pipe Dimensions Body Diameter (mm)


SPECIFICATION LIMITS: LSL = 1063 mm, USL = 1071 mm

BODY DIA METER ( B - 3 )


LSL
P rocess D ata LS L 1063 Target * USL 1071 S ample M ean 1066.8 S ample N 2051 S tD ev (Within) 0.357023 S tD ev (O v erall) 0.414773 P otential (Within) C apability Cp 3.73 C P L 3.55 C P U 3.92 C pk 3.55 O v erall C apability Pp PPL PPU P pk C ov 3.21 3.06 3.37 3.06 0.1%

USL

W ithin Ov erall

1063.2
Strictly Private & Confidential

1064.4

1065.6

1066.8

1068.0

1069.2

1070.4

29

Pipe Dimensions Body Diameter (mm)


SPECIFICATION LIMITS: LSL = 1063 mm, USL = 1071 mm

BODY DIA METER ( B - 4 )


LSL
P rocess D ata LS L 1063 Target * USL 1071 S ample M ean 1066.8 S ample N 2051 S tD ev (Within) 0.349542 S tD ev (O v erall) 0.399545 P otential (Within) C apability Cp 3.81 C P L 3.62 C P U 4.01 C pk 3.62 O v erall C apability Pp PPL PPU P pk C ov 3.34 3.17 3.51 3.17 0.1%

USL

W ithin O v erall

1063.65 1064.70 1065.75 1066.80 1067.85 1068.90 1069.95 1071.00


Strictly Private & Confidential

30

Pipe Dimensions End Diameter (mm)


SPECIFICATION LIMITS: LSL = 1065.41 mm, USL = 1068.59 mm

F END DIA METER


LSL
P rocess D ata LS L 1065.41 Target * USL 1068.59 S ample M ean 1066.44 S ample N 2051 S tD ev (Within) 0.247544 S tD ev (O v erall) 0.289477 P otential (Within) C apability Cp 2.14 C P L 1.39 C P U 2.89 C pk 1.39 O v erall C apability Pp PPL PPU P pk C ov 1.83 1.19 2.47 1.19 0.1%

USL

W ithin O v erall

1065.5
Strictly Private & Confidential

1066.0

1066.5

1067.0

1067.5

1068.0

1068.5

31

Pipe Dimensions End Diameter (mm)


SPECIFICATION LIMITS: LSL = 1065.41 mm, USL = 1068.59 mm

T END DIA METER


LSL
P rocess D ata LS L 1065.41 Target * USL 1068.59 S ample M ean 1066.55 S ample N 2051 S tD ev (Within) 0.29558 S tD ev (O v erall) 0.335931 P otential (Within) C apability Cp 1.79 C P L 1.29 C P U 2.30 C pk 1.29 O v erall C apability Pp PPL PPU P pk C ov 1.58 1.13 2.02 1.13 0.1%

USL

W ithin Ov erall

1065.5
Strictly Private & Confidential

1066.0

1066.5

1067.0

1067.5

1068.0

1068.5

32

Pipe Dimensions Wall Thickness (mm)


SPECIFICATION LIMITS: LSL = 12.90 mm, USL = 14.78 mm

F END WALL THICKNESS


LSL
P rocess D ata LS L 12.9 Target * USL 14.78 S ample M ean 13.4202 S ample N 2051 S tD ev (Within) 0.0747881 S tD ev (O v erall) 0.0866555 P otential (Within) C apability Cp 4.19 C P L 2.32 C P U 6.06 C pk 2.32 O v erall C apability Pp PPL PPU P pk C ov 3.62 2.00 5.23 2.00 0.6%

USL

W ithin O v erall

13.00
Strictly Private & Confidential

13.26

13.52

13.78

14.04

14.30

14.56

33

Pipe Dimensions Wall Thickness (mm)


SPECIFICATION LIMITS: LSL = 12.90 mm, USL = 14.78 mm

T END WALL THICKNESS


LSL
P rocess D ata LS L 12.9 Target * USL 14.78 S ample M ean 13.4258 S ample N 2051 S tD ev (Within) 0.06927 S tD ev (O v erall) 0.081361 P otential (Within) C apability Cp 4.52 C P L 2.53 C P U 6.52 C pk 2.53 O v erall C apability Pp PPL PPU P pk C ov 3.85 2.15 5.55 2.15 0.6%

USL

W ithin O v erall

13.00
Strictly Private & Confidential

13.26

13.52

13.78

14.04

14.30

14.56

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 1.67114 S ample N 2051 S tD ev (Within) 0.0894309 S tD ev (O v erall) 0.106178 P otential (Within) C apability Cp 2.98 C P L 3.25 C P U 2.72 C pk 2.72 O v erall C apability Pp PPL PPU P pk 2.51 2.73 2.29 2.29

USL

W ithin O v 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 1.70878 S ample N 2051 S tD ev (Within) 0.0937122 S tD ev (O v erall) 0.105604 P otential (Within) C apability Cp 2.85 C P L 3.23 C P U 2.46 C pk 2.46 O v erall C apability Pp PPL PPU P pk 2.53 2.87 2.18 2.18

USL

W ithin O v 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 5.03998 S ample N 2051 S tD ev (Within) 0.74814 S tD ev (O v erall) 0.796554 P otential (Within) C apability Cp * C PL * C P U 2.21 C pk 2.21 O v erall C apability Pp PPL PPU P pk * * 2.08 2.08

W ithin O v erall

3
Strictly Private & Confidential

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 0.466017 S ample N 2051 S tD ev (Within) 0.0788791 S tD ev (O v erall) 0.0910678 P otential (Within) C apability Cp * C PL * C P U 4.79 C pk 4.79 O v erall C apability Pp PPL PPU P pk * * 4.15 4.15

W ithin O v erall

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

Strictly Private & Confidential

38

Pipe Dimensions Squareness (mm)


SPECIFICATION LIMITS: USL = 1.6 mm

T END SQUARENESS
USL
P rocess D ata LS L * Target * USL 1.6 S ample M ean 0.476451 S ample N 2051 S tD ev (Within) 0.0784034 S tD ev (O v erall) 0.0923212 P otential (Within) C apability Cp * C PL * C P U 4.78 C pk 4.78 O v erall C apability Pp PPL PPU P pk * * 4.06 4.06

W ithin O v 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 0.66509 S ample N 2051 S tD ev (Within) 0.152007 S tD ev (O v erall) 0.166982 P otential (Within) C apability Cp * C PL * C P U 2.05 C pk 2.05 O v erall C apability Pp PPL PPU P pk * * 1.87 1.87

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 0.693905 S ample N 2051 S tD ev (Within) 0.15339 S tD ev (O v erall) 0.171327 P otential (Within) C apability Cp * C PL * C P U 1.97 C pk 1.97 O v erall C apability Pp PPL PPU P pk * * 1.76 1.76

W ithin O v erall

0.4
Strictly Private & Confidential

0.6

0.8

1.0

1.2

1.4

1.6

41

Pipe Dimensions Peaking (mm)


SPECIFICATION LIMITS: USL = 3.2 mm

BODY PEAKING
USL
P rocess D ata LS L * Target * USL 3.2 S ample M ean 0.612921 S ample N 2051 S tD ev (Within) 0.0999827 S tD ev (O v erall) 0.119934 P otential (Within) C apability Cp * C PL * C P U 8.63 C pk 8.63 O v erall C apability Pp PPL PPU P pk * * 7.19 7.19

W ithin O v erall

0.4
Strictly Private & Confidential

0.8

1.2

1.6

2.0

2.4

2.8

3.2

42

Pipe Outside Diameter Before & After Hydro-Testing (HT)

Strictly Private & Confidential

Increase in Pipe OD After Hydro-testing Body


Histogram of Body (Before HT), Body (After HT)
(At 97% SMYS)

2800 2400 2000 No. of pipes

LSL 1063 mm
Mean shift after hydrotesting = 1.0 mm Max. shift after hydro-testing = 2.0 mm

USL 1071 mm
Variable Body (Before HT) Body (After HT) Mean 1066 1067 StDev N 0.3804 2051 0.3254 2051

1750

1600 1200 800


440

1526

400 0
1 0 2 1 0 13 77

277 5 9 0 0 1

1064

1065

1066

1067

1068

1069

1070

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)
1200 1000
883 828

LSL 1065.41 mm

(At 97% SMYS)

USL 1068.59 mm
Variable T-END (Before HT) T-END (After HT) 929 Mean StDev N 1066 0.3139 2051 1067 0.3359 2051 692

No. of pipes

800 600 400 200 0


1 0 0 1 162 8 186 201 149 19

Mean shift after hydrotesting = 1.0 mm Max. shift after hydro-testing = 1.0 mm

24 6

8 2

3 0

1064.8

1065.6

1066.4

1067.2

1068.0

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)
(At 97% SMYS)

LSL 1065.41 mm
1124 1008

USL 1068.59 mm
Variable F-END (Before HT) F-END (A fter HT) Mean StDev N 1066 0.3013 2051 1066 0.2895 2051 678 521

1000

No. of pipes

750

500
295

Mean shift after hydrotesting = 0 mm Max. shift after hydro-testing = 0.9 mm

250
0 3

233 115 94 11 1 0

10 2

2 1

1065.6

1066.4

1067.2

1068.0

Outside daimeter, mm
Strictly Private & Confidential

46

Conformance to Chemical Composition

Strictly Private & Confidential

Statistics of CE (Pcm) & CE (IIW)

Variable

Count

Mean

StDev

CoefVar

Minimum

Maximum

Range

CE(Pcm), %

86

0.18

0.004

2.0

0.17

0.189

0.02

CE(IIW), %

86

0.39

0.006

1.4

0.38

0.408

0.03

No. of heats = 43

Strictly Private & Confidential

48

CE (Pcm) 43 Heats
Histogram of CE(Pcm)
50
Mean StDev N 0.1797 0.003557 86 45

USL 0.21%

No. of tests (2 pipes/heat)

40

30
21

20

17

10
1 1 1

0 0.165 0.170 0.175 0.180 0.185 0.190 0.195 0.200 0.205 0.210 0.215 CE(Pcm), %
Strictly Private & Confidential

49

CE (IIW) 43 Heats
Histogram of CE(IIW)
70 60 No. of tests (2 pipes/heat)
52 Mean StDev N 0.3941 0.005665 86

50 40 30 20 10
3 3 28

0 0.38 0.39 CE(IIW), %


Strictly Private & Confidential

0.40

0.41

50

Repair and Rejection Details with Reasons

Strictly Private & Confidential

Repair & Rejection Summary


WELD REPAIR SUMMARY
Weld defect
Under cut Slag Porosity Under fill Gas pocket

No. of pipes
23 18 11 1 1

Repair, %
1.11 0.87 0.53 0.05 0.05

TOTAL

54

2.62 Rejection, %
0.20 0.10 0.10 0.05 0.05 0.05 0.05

REJECTION SUMMARY
Reason
Low thickness (Excess grinding due to scratch) Formation trial pipe Sliver Indentation mark (Raw material defect) Over diameter Scratch Excess weld repair

No. of pipes
4 2 2 1 1 1 1

TOTAL
Strictly Private & Confidential

12

0.59
52

Repair Details
25
1.11
Total no. of pipe formed & welded = 2063

2.5 Repair, % % of pipes repaired (based on no. of pipe formed & welded)
53

No. of pipes 2.0

23 20 No. of pipes repaired


0.87

18 15
0.53

1.5

10

11

1.0

5
0.05 0.05

0.5 1 1 0.0 Porosity Gas pocket Under cut Slag Under fill

Weld defect
Strictly Private & Confidential

Rejection Details
4.5
0.20

4.0 4 No. of pipes rejected 3.5 3.0 2.5


0.10

Rejection, %

0.40 0.35 0.30 0.25

2.0 2 1.5 1.0 0.5 0.0


Low thickness (Excess grinding due to scratch)

0.10

0.20 0.15
0.05 0.05 0.05 0.05

2 0.10 1 1 1 0.05 0.00


Over diameter Sliver Indentation mark (Raw material)

Formation trial pipe

Scratch

Reason
Strictly Private & Confidential

Excess weld repair

% of pipes rejected (based on no. of pipe formed & welded)


54

Total no. of pipe formed & welded = 2063

0.45 No. of pipes

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

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

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, 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 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