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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
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 43 15 28 295
PRODUCTION SUMMARY
NUMBER
% -
FEET
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
2063 2051
54 10 2
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.
500 510 520 530 540 550 560 570 580 590 YS, MPa
Strictly Private & Confidential
Percent
10
2 0
7 0
630
690
720
750
11
USL 0.92
40 36 27
30 20 10 0
6 0 0 0 5
2 0
0.72
0.77
0.87
0.92
12
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
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
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
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 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.
17
No. of tests
30 20 10
5 20 13 22 18
0 500
2 0
4 0
520
540
580
600
620
18
Percent
19
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.
20
20
17 16 15 14
No. of tests
15
10
5
0
3 0
3 1 2 1 1 0
0 500
520
540
580
600
620
21
95 90 80
Percent
70 60 50 40 30 20 10 5
22
W ithin O v erall
1
Strictly Private & Confidential
24
W ithin O v erall
2
Strictly Private & Confidential
25
W ithin O v erall
2
Strictly Private & Confidential
26
USL
W ithin O v erall
1063.2
Strictly Private & Confidential
1064.4
1065.6
1066.8
1068.0
1069.2
1070.4
27
USL
W ithin Ov erall
1063.2
Strictly Private & Confidential
1064.4
1065.6
1066.8
1068.0
1069.2
1070.4
28
USL
W ithin Ov erall
1063.2
Strictly Private & Confidential
1064.4
1065.6
1066.8
1068.0
1069.2
1070.4
29
USL
W ithin O v erall
30
USL
W ithin O v erall
1065.5
Strictly Private & Confidential
1066.0
1066.5
1067.0
1067.5
1068.0
1068.5
31
USL
W ithin Ov erall
1065.5
Strictly Private & Confidential
1066.0
1066.5
1067.0
1067.5
1068.0
1068.5
32
USL
W ithin O v erall
13.00
Strictly Private & Confidential
13.26
13.52
13.78
14.04
14.30
14.56
33
USL
W ithin O v erall
13.00
Strictly Private & Confidential
13.26
13.52
13.78
14.04
14.30
14.56
34
USL
W ithin O v erall
0.9
Strictly Private & Confidential
1.2
1.5
1.8
2.1
2.4
35
USL
W ithin O v 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 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
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
38
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
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
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
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
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
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
LSL 1065.41 mm
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
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
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
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
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
48
CE (Pcm) 43 Heats
Histogram of CE(Pcm)
50
Mean StDev N 0.1797 0.003557 86 45
USL 0.21%
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
0.40
0.41
50
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
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
Rejection, %
0.10
0.20 0.15
0.05 0.05 0.05 0.05
Scratch
Reason
Strictly Private & Confidential
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