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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
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)
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
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
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
58
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
99.9 99 95 90 80 70 60 50 40 30 20 10 5
Percent
1 0.1
10
30 20 10 0 570
0 2 0 1 0 5 5 5 1
600
630
690
720
750
11
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
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
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 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
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
17
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
Percent
19
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
20
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
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
22
W ithin Ov erall
2
Strictly Private & Confidential
24
W ithin Ov erall
25
W ithin Ov erall
26
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
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
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
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
USL
W ithin O v erall
912.5
913.0
913.5
914.0
914.5
915.0
915.5
31
USL
W ithin Ov erall
912.5
Strictly Private & Confidential
913.0
913.5
914.0
914.5
915.0
915.5
32
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
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
USL
W ithin Ov erall
0.9
Strictly Private & Confidential
1.2
1.5
1.8
2.1
2.4
35
USL
W ithin Ov erall
0.9
Strictly Private & Confidential
1.2
1.5
1.8
2.1
2.4
36
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
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
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
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
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
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
USL 918 mm
Mean shift after hydrotesting = 1.1 mm Max. shift after hydro-testing = 2.0 mm
1326
1390
1000
487
494
49 913.5 914.5
5 915.5
27 0 916.5 917.5
Outside diameter, mm
Strictly Private & Confidential
44
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
USL 915.59 mm
200
Mean shift after hydrotesting = 0.4 mm Max. shift after hydro-testing = 2.0 mm
107
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
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
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
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
50
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, %
0.2 1
Weld defect
Strictly Private & Confidential
0.55
Rejection Details
OFFSET
0.15
PITTING (Corrosion)
0.15
0.10
Reason 1 1 1 1 0.00
SHORT LENGTH INDENTATION MARK (Raw material defect) OVER DIAMETER
0.05 0.05
No. of pipes
Rejection, %
0.50
0.60
Material
Due to scale on the coil surface
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
During RSI/RSO, improper flux level/imbalance in welding parameters (very high voltage at start)
Man
Machine
55
Material
Due to moisture, paint, grease & oil presence in edge groove
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
Material
Presence of dents on groove edges
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