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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

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 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 -

FEET 76014 36 76979.20 76048.73 38.80 42.34 852.36 34.28

% 98.79 0.06 1.11 0.04

1984 1960

47 23 1

2.4 1.2 0.1

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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 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


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YS Change from Coil to Pipe


Histogram of Coil YS, Pipe YS
60 50
43

LSL 485 MPa

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

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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

LSL 570 MPa


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

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
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

0.83 YS/UTS ratio

0.87

0.91

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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), %
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42

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)


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

Test status for heats YS 540 MPa

20 21 22 23 24

Strictly Private & Confidential

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

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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

Mean StDev N 538.9 8.857 111 532.2 13.98 111

No. of tests

30

20
16

10
2 (1.3%) 0 0 0

9 6 0 7 3 1 0

480

500

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 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

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 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

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 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

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Dimensional Variation in Pipes

Strictly Private & Confidential

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

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 2.52245 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

Strictly Private & Confidential

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

Strictly Private & Confidential

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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

Strictly Private & Confidential

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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

Strictly Private & Confidential

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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)
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

1500 No. of pipes

Mean StDev N 913.7 0.4898 1960 914.8 0.4156 1960

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

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

912.0

912.6

913.2

913.8

914.4

915.0

915.6

Outside diameter, 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), %

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%

No. of tests (2 pipes/heat)

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

No. of tests (2 pipes/heat)

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 and Rejection Details with Reasons

Strictly Private & Confidential

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, %

0.8 15 0.7 13 10 0.6 11 0.6

0.4 5 0.1 0.0 Slag Porosity Under cut Under fill

0.2 1

Weld defect
Strictly Private & Confidential

No. of pipes rejected 10 12 0 11 2 4 6 8

Strictly Private & Confidential

0.55

LOW THICKNESS (Excess grinning due to scratches)

Rejection Details

OFFSET

0.15

PITTING (Corrosion)

0.15

DWTT FAILED (Raw material defect)

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

SCAB (Raw material defect)

No. of pipes

Rejection, %

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


54

0.05 0.05 0.10 0.20 0.30 0.40

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

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