Welspun Corporation Ltd

Gujarat, India

Welspun Corporation Ltd

Gujarat, India
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Goyal R.K.,Welspun Corporation Ltd | Kyada T.,Welspun Corporation Ltd | Kathayat T.S.,Welspun Corporation Ltd
Journal of Failure Analysis and Prevention | Year: 2017

Transverse to pipe axis cracks across the weld line of high frequency-electrical resistance weld (HF-ERW) pipes of IS 10748 Grade 2 and size 406.4 mm outside diameter and 7.75 mm wall thickness were observed. Analytical techniques such as ultrasonic testing, optical microscopy and scanning electron microscopy with energy-dispersive spectroscopy were used for analysis and determination of the root cause. © 2017 ASM International


Kathayat T.S.,Welspun Corporation Ltd. | Goyal R.K.,Welspun Corporation Ltd. | Hill R.,Welspun Corporation Ltd. | Kyada T.,Welspun Corporation Ltd.
ASME 2017 India Oil and Gas Pipeline Conference, IOGPC 2017 | Year: 2017

Hot pushed induction heating is a bending process used to bend pipes having a small bending radius with a large diameter. This is a complex process since it involves mechanical process of bending and thermal process of localized induction heating. This paper deals with the optimization of induction bending process parameters such as bending speed, water flow rate, water pressure, air pressure and induction coil to water coil distance. Mother pipes of size 464 mm OD x 20.60 mm and grade API 5L X65MS/MO were used to make trial bends of 5D radius in 30° angle. Trial bends were subjected to mechanical tests and microstructural analysis to evaluate the effects of selected process parameters. Copyright © 2017 ASME.


Patel J.,Welspun Corporation Ltd. | Chauhan G.,Welspun Corporation Ltd. | Raghuwanshi D.,Welspun Corporation Ltd. | Mohanan A.,Welspun Corporation Ltd.
ASME 2017 India Oil and Gas Pipeline Conference, IOGPC 2017 | Year: 2017

With the advent of automated measurement of physical dimensional parameters of steel line-pipes, the industry seems to have scaled newer heights, which were previously never even imagined. The dimensional accuracy of each pipe is very critical in the overall success of a line pipe project. The quality of girth welding of pipes during laying, depends upon the close dimensional tolerances of the pipe ends. Even a slight variation in out-of-roundness or end-chamfered profile could lead to drastic irregularities in the pipe-to-pipe joining process. And the manual measuring of the pipe parameters poses a serious question with regards to their accuracy and reliability, due to the effects of man, measurement method and instruments used. There is also a huge limitation of the sampled area measured not exactly resembling the whole pipe, due to the constraints of time and the manual process involved. This paper describes the rise of Automated Pipe Dimension Measurement System (APDMS), which measures a total of 19 dimensional parameters after real-time geometrical & trigonometrical calculations, using parametric data from 72 measurement laser scanners & sensors. The pipe coordinates are measured by laser triangulation technique principally, at each degree circumferentially and 10 mm apart lengthwise. A pipe that needs at least 45 minutes to measure all dimensional parameters manually, by 2 men and almost 25 instruments & accessories, is measured in 2.5 minutes by APDMS with mindboggling resolution and accuracy. All this is done with a simple push of a button after one-time entering of pipe size. The fully automated system then does its job efficiently to move the pipe accordingly and scan it. The back-end software calculates the required parameters from the measured raw coordinates, evaluates them against set criteria, viz. upper and lower limits, and generates a plot that shows the variation of a parameter along the length or circumference. A calibration system in incorporated to keep the system compliant with accuracy against calibrated and certified standard samples. Initially, we took more than 2000 trials on the whole range of pipe sizes we manufacture, after the installation of system on shop-floor. After trials and establishment, we have so far measured more than 3000 regular production pipes through this system with remarkable results. Analysis has been carried out continuously to ensure the repeatability and reproducibility of the system is as per industry standards. This new, contactless method aims to minimize dimensional variances for fluent and effortless installation of pipes at application site, by ensuring that the dimensions are well within the defined criteria, at each and every point on the pipe during its manufacturing. Copyright © 2017 ASME.


Shant J.R.,University of Leeds | Shant J.R.,Welspun Corporation Ltd | Barker R.,University of Leeds | Neville A.,University of Leeds
ASME 2017 India Oil and Gas Pipeline Conference, IOGPC 2017 | Year: 2017

The inner surface of pipe plays a crucial role in top of line corrosion when condensation of droplet takes place. Condensation over inner periphery of pipeline takes place by droplet formation due to differential temperature inside the pipe and external environmental factors. To understand the change in corrosion rates with respect to droplet flow and temperature [40oC, 60oC and 80oC], a rig with curvature 80mm which simulates top of line corrosion is designed to carry out experiments at 0°, 15° and 30° inclinations in fixed 3 litre beaker. Droplet formation on the sample as well as on perpex surface has been captured at different temperatures to understand the droplet size formation. Corrosion rate calculation is done my weight loss methods which are generally preferred in on site analysis instead of electrochemical measurements. Surface analysis is carried out with the help of optical microscope and optical profilometer where corrosion rate, inclination were correlated to average surface roughness. Copyright © 2017 ASME.


Kathayat T.S.,Welspun Corporation Ltd. | Goyal R.K.,Welspun Corporation Ltd. | Shant J.R.,Welspun Corporation Ltd.
Proceedings of the Annual Offshore Technology Conference | Year: 2014

This paper presents the experiments and studies conducted on pipes for the assessment of Middle East to India Deepwater Pipeline (MEIDP) requirement. The MEIDP will be located in water depths up to 3500 m and consequently be subjected to very high external pressures which make the pipe collapse strength a major consideration for the project. The pipes of size 660.4 mm (26") OD x 37.1 mm WT and SAWL485 FDU manufactured by JCOE process were used for external pressure ring collapse testing in as-fabricated (AF) and thermal aged (HT) conditions. The simulation of ring collapse pressure using Finite Element Analysis (FEA) was also studied. The ring pressure collapse test results consistently demonstrated the advantage of heat soaked treatment at 3LLP coating temperature for enhanced external collapse pressure as compared to the as-fabricated pipes. A comparative study of ring collapse pressure testing, FE analyzed collapse pressure and DNV calculated collapse pressure is also presented along with tensile and compression behavior of pipe material. External ring collapse test facility developed in-house can be used to predict the collapse behavior and to simulate full scale collapse test. Finite element analysis was in agreement with the experiments and indicated all 3 modes of buckling both in as-fabricated and coating simulated rings. Out of Roundness (OoR) measurement was performed using caliper gauge by manual methods and by optical measurement system (OMS) system. The Out of Roundness as measured by OMS was slightly higher even after subtracting the peaking effect. Copyright 2014, Offshore Technology Conference.


Mannarsamy R.,Welspun Corporation Ltd | Shrivastava S.K.,Welspun Corporation Ltd | Thakor P.,Welspun Corporation Ltd | Chauhan G.,Welspun Corporation Ltd | And 2 more authors.
ASME 2015 India International Oil and Gas Pipeline Conference, IOGPC 2015 | Year: 2015

For achieving high productivity multiple wire submerged arc welding such as tandem wire, three wires and five wires submerged arc welding was introduced in recent past years. Due to adding of additional wires in a pipe mill faced process difficulties such as controlling the current supply to each wire and further challenges for consumable design in order to give effective slag characteristics and bead shape control at these higher welding speeds and heat inputs. To gain maximum productivity, welding speed must be as fast as possible (in excess of 2 m/min) consistent with reliable high speed wire feeding and the characteristics of the SAW flux considering these factors in determining the balance of heat input, penetration, bead shape, dilution, weld metal chemistry and mechanical properties such as toughness. Steels containing high strength low alloying elements like Manganese, Molybdenum, Titanium and boron have favorable physical properties such as higher subzero toughness, resistance to improve the mechanical properties because of which there is substantial saving in the material. High strength low alloy steels materials are utilized in offshore and onshore at critical services. However, such benefits can be exploited provided these steels can be welded with appropriate development of welding process such as cold wire addition® in multi wires with process controller using WINCC programmer, Z5 version to give better weldments, which will not compromise the integrity, and operating condition. To obtain higher productivity and quality, it is necessary to develop a welding procedure for butt joint of line pipe steels. This paper describes the recent work carried out by Welspun, in this regard to establish the welding procedure using GMAW and submerged arc welding process and evaluation of mechanical properties. Macro and micro structural analysis were also made to characterize the weld metal properties. Copyright © 2015 by ASME.


Chauhan G.,Welspun Corporation Ltd | Thakor P.,Welspun Corporation Ltd | Samavedam S.,Welspun Corporation Ltd | Mannarsamy R.,Welspun Corporation Ltd | And 2 more authors.
ASME 2015 India International Oil and Gas Pipeline Conference, IOGPC 2015 | Year: 2015

The mechanical properties of welding material is correlative with the diffusible hydrogen content in weld metal and level of moisture content in flux. Minitab16program to predict mechanical properties correlated to diffusible hydrogen content in weld metal and level of moisture content in flux, such as yield strength, tensile strength, elongation and average Charpy impact toughness of welding material is established by using submerged arc welding process in line pipe manufacturing. The present paper aims to experiment and investigate the line pipe SAW Flux used for offshore /onshore applications. Flux moisture content has been studied under Karl Fischer Coulometer method. Subsequently, flux was then used to make weld to analysis for 'diffusible hydrogen content in weld metal' through mercury displacement method. This detailed study envisages and explains the correlations between the mechanical properties and micro structures of weldments. Evaluating the variance of moisture level in flux and diffusible hydrogen content in weld metal proves the advantage of restricting the moisture content along with good practices to accomplish better weld quality. Copyright © 2015 by ASME.


Kathayat T.S.,Welspun Corporation Ltd | Goyal R.K.,Welspun Corporation Ltd | Hill R.T.,Technical Consultant to Welspun | Raghu Shant J.,Welspun Corporation Ltd
NACE - International Corrosion Conference Series | Year: 2013

The presence of severe corrosive environment along with higher external pressure in the Black sea has led to develop high strength heavy wall offshore sour service linepipe. The paper will cover the successful development of high strength API 5L X70 Sour Service, Fracture arrest properties, Dimensions, High Utilization (SFDU) (33 inch OD x 39.5 mm WT) linepipe manufactured by the J-C-OE technology. Pipe rolling and welding parameters were controlled to minimize the circumferential residual stress and weld and Heat Affected Zone (HAZ) hardness in order to enhance the Hydrogen Induced Cracking (HIC) / Sulphide Stress Corrosion (SSC) resistance. The proper selection of wire and flux has resulted in average Charpy V-Notch (CVN) energy >100 J at -30°C in the weld centerline. The study of weld microstructure showed the co-relation of weld ductility (measured in all-weld specimens) with grain boundary ferrite. The hardness of the weld centerline was <225 HV 10 kgf even with overmatching of weld tensile strength. Plate selection with respect to alloy design and microstructure was critical to obtaining good HIC and SSC resistance for heavy wall linepipe. The levels of S<0.0010% and P<0.008% along with low value of Nb+V+Ti <0.055%, Parameter crack measurement (Pcm)<0.15% and Carbon Equivalent (CE)<0.38% were obtained in the plates. © 2013 by NACE International.


Kyada T.,Welspun Corporation Ltd. | Raghu Shant J.,Welspun Corporation Ltd. | Goyal D.,Welspun Corporation Ltd. | Goyal R.K.,Welspun Corporation Ltd. | Kathayat T.S.,Welspun Corporation Ltd.
Journal of Failure Analysis and Prevention | Year: 2015

A metallurgical root cause analysis was performed on Electric Resistance Welded (ERW) pipes having Ultrasonic Test (UT) indication near the weld line. Fine subsurface cracks have been observed in the ERW cracks which are found to be parallel to the weld flow line. A metallurgical cross section was drawn at UT indicated area on the ERW pipes of 406.40 mm (16 inch) diameter by 7.40 mm wall thickness and API 5L X70 PSL2 grade. Failure analysis is carried out by optical microscope and scanning electron microscopy with energy dispersive spectroscopy. © 2015, ASM International.


Kishor R.,Welspun Corporation Ltd | Kyada T.,Welspun Corporation Ltd | Goyal R.K.,Welspun Corporation Ltd | Kathayat T.S.,Welspun Corporation Ltd
IOP Conference Series: Materials Science and Engineering | Year: 2015

Metallurgical failure analysis was carried out for cracks observed on the outer surface of a boiler tube made of ASME SA 210 GR A1 grade steel. The cracks on the surface of the tube were observed after 6 months from the installation in service. A careful visual inspection, chemical analysis, hardness measurement, detailed microstructural analysis using optical and scanning electron microscopy coupled with energy dispersive X-ray spectroscopy were carried out to ascertain the cause for failure. Visual inspection of the failed tube revealed the presence of oxide scales and ash deposits on the surface of the tube exposed to fire. Many cracks extending longitudinally were observed on the surface of the tube. Bulging of the tube was also observed. The results of chemical analysis, hardness values and optical micrographs did not exhibit any abnormality at the region of failure. However, detailed SEM with EDS analysis confirmed the presence of various oxide scales. These scales initiated corrosion at both the inner and outer surfaces of the tube. In addition, excessive hoop stress also developed at the region of failure. It is concluded that the failure of the boiler tube took place owing to the combined effect of the corrosion caused by the oxide scales as well as the excessive hoop stress.

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