FPSO piping

Distributorsulsan, KR

STAR (+4 pts)
APPROVED

Basic Information

Overview

The project was a new build FPSO ( Oil & Gas) in South Korea. The material was used super duplex stainless steel (UNS 32760). The biggest challenge was the shortest lead time with highest quality welding consumables complying Impact requirement of 80J @ -50 deg C and Corrosion test ASTM G48 Method A , No pitting and maximum weight loss of 4gm/m2 at 40 deg C after 24 hrs. In the project ER2594 consumable delivery lead time was only 2 weeks or maximum 15 days with quantity requirements of 12MT. Welding Alloys China made a very good progress with the OEM supplier who managed to draw and produce this entire 12 tons welding wires in 14 days and managed to deliver the goods in Korea on time along with the mechanical and corrosion testing. Customer was very happy with the quality and on time delivery for their successfully completion of the project. Our biggest competitor was Korean manufacturing like Hyundai & Kiswel, but even being a Korean company in Korea they were not been able to deliver the welding consumables within 2 weeks.

Industry

Distributors

Location

ulsan, KR

Component/Workpiece

FPSO piping

Business Type

Consumable Sales

Job Type

New

Type of Wear

Corrosion

Base Metal

Super Duplex stainless steel UNS32760

General Dimensions (mm)

2" to 6" pipe

Problem Description

The challenge the customer was facing

1. Short lead time of 2 weeks delivery of 12 tons of Super Duplex stainless Soild TIG rods. 2. CVN requirement of Avg. 80J @ -50 deg C 3. Corrosion test ASTM G48 Method A with Zero pitting and maximum weight loss of 4gm/m2 at 40 degC after 24 hrs.

Previous Service Life

1d 1h

Competitor

Hyundai, Kiswel

Welding Alloys Solution

How WA solved the challenge

WAChina supplied WA TSS2594 welding rods of 12MT in 2 weeks.

Product Category

Consumables

WA Product Used

WA TSS 2594

Diameter

2.4 mm

Job Duration

2w

Technical Advantages

WA TSS 2594 passed the test of Impact test with Avg. CVN value of 150 J @ -40 deg C and corrosion test ASTM G48 Method A passed with zero pitting and maximum weight loss < 4gm/ m2 at 40 degC after 24 hrs. also delivered the goods in 2 weeks which local korean companies also did not managed to do.

Images (3)

Photos and visuals for this case study

Case study image 1Case study image 2Case study image 3

Cost Reduction Analysis

Annual Cost Before

$350,000.00

Annual Cost After

$260,000.00

Annual Savings

$90,000.00

26.0% reduction

Annual Cost Comparison
Previous Solution$350,000.00
WA Solution$260,000.00

Cost Breakdown

Part Information
Cost of Part (A):$350,000.00
Cost of WA Solution (B):$260,000.00
Parts Used/Year (E):1
Solution Lifetime Comparison
Previous Solution:3.0 years
WA Solution:3.0 years
Before (Previous Solution)
Maintenance/Repair (F):-
Disassembly Cost (G):-
Downtime/Event (H):-
After (WA Solution)
Maintenance/Repair (F):-
Disassembly Cost (G):-
Downtime/Event (H):-
Formula Used

Annual Cost = (A × E) + (E − 1) × (F + G + H)

Where: A = Cost of Part, E = Parts/Year, F = Maintenance, G = Disassembly, H = Downtime

Welding Procedure Specification (WPS)

2 layer(s) documented

Submission Details

Contributor

Sukamal Naskar

sukamal.naskar@welding-alloys.com

Created

April 25, 2026

Submitted

April 25, 2026

Approved By

Bastien Gerard

April 26, 2026