Greater Noida Institute of Technology: Under-Water Welding

DEPARTMENT OF MECHANICAL ENGINEERING
Greater Noida institute of technology

(2015-16)
SEMINAR REPORT
ON
UNDER-WATER
WELDING
Submitted To:
Submitted By:
Mr. Syed Qaiser Husain
Varun Yadav
Department of Mechanical Engineering
1313240177 3rdys.
Certificate
This to certify that Mr. Varun Yadav student of 3rd year mechanical
engineering in Greater Noida Institute of Technology has submitted
a seminar report on Under Water Welding as a partial fulfilment
of degree of bachelor in technology from UPTU.
(Mr. Syed Qaiser Husain)
CONTENT
INTRODUCTION
CLASSIFICATION
WET WELDING
HYPERBARIC WELDING (DRY WELDING)
RISKS INVOLVED
ADVANTAGES & DISADVANTGES OF DRY WELDING
ADVANTAGES & DISADVANTGES OF WET WELDING
10
PRINCIPLE OF OPERATION OF WET WELDING
11
DEVELOPMENTS IN UNDER WATER WELDING
11
SCOPE
12
LIST OF FIGURES
WET WELDING
POWER SUPPLY DIAGRAM
INTRODUCTION
The fact that electric arc could operate was known for over a 100 years. The first ever
underwater welding was carried out by British Admiralty Dockyard for sealing leaking ship
rivets below the water line.
Underwater welding is an important tool for underwater fabrication works. In 1946, special
waterproof electrodes were developed in Holland by Van der Willingen. In recent years the
number of offshore structures including oil drilling rigs, pipelines, and platforms are being
installed significantly. Some of these structures will experience failures of its elements during
normal usage and during unpredicted occurrences like storms, collisions. Any repair method
will require the use of underwater welding
CLASSIFICATION
Underwater welding can be classified as
1. Wet Welding
2. Dry Welding
In wet welding the welding is performed underwater, directly exposed to the wet
environment. In dry welding, a dry chamber is created near the area to be welded and the
welder does the job by staying inside the chamber.
WET WELDING
Wet Welding indicates that welding is performed underwater, directly exposed to the wet
environment. A special electrode is used and welding is carried out manually just as one does
in open air welding. The increased freedom of movement makes wet welding the most
effective, efficient and economical method. Welding power supply is located on the surface
with connection to the diver/welder via cables and hoses.
In wet welding MMA (manual metal arc welding) is used.
Power Supply used: DC

Polarity: -ve polarity
When DC is used with +ve polarity, electrolysis will take place and cause rapid deterioration
of any metallic components in the electrode holder. For wet welding AC is not used on
account of electrical safety and difficulty in maintaining an arc underwater.
.
The power source should be a direct current machine rated at 300 or 400 amperes. Motor
generator welding machines are most often used for underwater welding in the wet. The
welding machine frame must be grounded to the ship. The welding circuit must include a
positive type of switch, usually a knife switch operated on the surface and commanded by the
welder-diver. The knife switch in the electrode circuit must be capable of breaking the full
welding current and is used for safety reasons. The welding power should be connected to the
electrode holder only during welding.
Direct current with electrode negative (straight polarity) is used. Special welding electrode
holders with extra insulation against the water are used. The underwater welding electrode
holder utilizes a twist type head for gripping the electrode. It accommodates two sizes of
electrodes.
The electrode types used conform to AWS E6013 classification. The electrodes must be
waterproofed. All connections must be thoroughly insulated so that the water cannot come in
contact with the metal parts. If the insulation does leak, seawater will come in contact with
7
the metal conductor and part of the current will leak away and will not be available at the arc.
In addition, there will be rapid deterioration of the copper cable at the point of the leak.
HYPERBARIC WELDING (DRY WELDING)

Hyperbaric welding is carried out in chamber sealed around the structure to be welded. The
chamber is filled with a gas (commonly helium containing 0.5 bar of oxygen) at the
prevailing pressure. The habitat is sealed onto the pipeline and filled with a breathable
mixture of helium and oxygen, at or slightly above the ambient pressure at which the welding
is to take place. This method produces high-quality weld joints that meet X-ray and code
requirements. The gas tungsten arc welding process is employed for this process. The area
under the floor of the Habitat is open to water. Thus the welding is done in the dry but at the
hydrostatic pressure of the sea water surrounding the Habitat.
RISKS INVOLVED
There is a risk to the welder/diver of electric shock. Precautions include achieving adequate
electrical insulation of the welding equipment, shutting off the electricity supply immediately
the arc is extinguished, and limiting the open-circuit voltage of MMA (SMA) welding sets.
Secondly, hydrogen and oxygen are produced by the arc in wet welding.
Precautions must be taken to avoid the build-up of pockets of gas, which are potentially
explosive. The other main area of risk is to the life or health of the welder/diver from nitrogen
introduced into the blood steam during exposure to air at increased pressure. Precautions
include the provision of an emergency air or gas supply, stand-by divers, and decompression
chambers to avoid nitrogen narcosis following rapid surfacing after saturation diving.
For the structures being welded by wet underwater welding, inspection following welding may
be more difficult than for welds deposited in air. Assuring the integrity of such underwater
welds may be more difficult, and there is a risk that defects may remain undetected.
ADVANTAGES OF DRY WELDING
1. Welder/Diver Safety Welding is performed in a chamber, immune to ocean

currents and marine animals. The warm, dry habitat is well illuminated and has its
own environmental control system (ECS).
2. Good Quality Welds This method has ability to produce welds of quality
comparable to open air welds because water is no longer present to quench the weld
and H2 level is much lower than wet welds.
3. Surface Monitoring Joint preparation, pipe alignment, NDT inspection, etc. are
monitored visually.
4. Non-Destructive Testing (NDT) NDT is also facilitated by the dry habitat
environment.
DISADVANTAGES OF DRY WELDING

1. The habitat welding requires large quantities of complex equipment and much support
equipment on the surface. The chamber is extremely complex.
2. Cost of habitat welding is extremely high and increases with depth. Work depth has
an effect on habitat welding. At greater depths, the arc constricts and corresponding
higher voltages are required. The process is costly an $ 80000 charge for a single
weld job. One cannot use the same chamber for another job, if it is a different one.
ADVANTAGES OF WET WELDING

Wet underwater MMA welding has now been widely used for many years in the repair of
offshore platforms. The benefits of wet welding are: I.
II.
The versatility and low cost of wet welding makes this method highly desirable.
Other benefits include the speed. With which the operation is carried out.
III.
It is less costly compared to dry welding.
IV.
The welder can reach portions of offshore structures that could not be welded using
other methods.
V.
No enclosures are needed and no time is lost building. Readily available standard
welding machine and equipments are used. The equipment needed for mobilization
of a wet welded job is minimal.
DISADVANTAGES OF WET WELDING

Although wet welding is widely used for underwater fabrication works, it suffers from the
following drawbacks: I.
There is rapid quenching of the weld metal by the surrounding water. Although
quenching increases the tensile strength of the weld, it decreases the ductility and
impact strength of the weldment and increases porosity and hardness.
II.
Hydrogen Embrittlement Large amount of hydrogen is present in the weld region,

resulting from the dissociation of the water vapour in the arc region. The H2 dissolves
in the Heat Affected Zone (HAZ) and the weld metal, which causes Embrittlement,
cracks and microscopic fissures. Cracks can grow and may result in catastrophic
failure of the structure.
III.
Another disadvantage is poor visibility. The welder sometimes is not able to weld
properly.
10
Principle of operation of Wet Welding

The process of underwater wet welding takes in the following manner:
The work to be welded is connected to one side of an electric circuit, and a metal electrode to
the other side. These two parts of the circuit are brought together, and then separated slightly.
The electric current jumps the gap and causes a sustained spark (arc), which melts the bare
metal, forming a weld pool. At the same time, the tip of electrode melts, and metal droplets
are projected into the weld pool. During this operation, the flux covering the electrode melts
to provide a shielding gas, which is used to stabilize the arc column and shield the transfer
metal. The arc burns in a cavity formed inside the flux covering, which is designed to burn
slower than the metal barrel of the electrode.
DEVELOPMENTS IN UNDER WATER WELDING

Wet welding has been used as an underwater welding technique for a long time and is still
being used. With recent acceleration in the construction of offshore structures underwater
welding has assumed increased importance. This has led to the development of alternative
welding methods like friction welding, explosive welding, and stud welding. Sufficient
literature is not available of these processes.
11
SCOPE FOR FURTHER DEVELOPMENTS
Wet MMA is still being used for underwater repairs, but the quality of wet welds is poor and
are prone to hydrogen cracking. Dry Hyperbaric welds are better in quality than wet welds.
Present trend is towards automation. THOR 1 (TIG Hyperbaric Orbital Robot) is developed
where diver performs pipefitting, installs the trac and orbital head on the pipe and the rest
process is automated.
Developments of diverless Hyperbaric welding system is an even greater challenge calling
for annexe developments like pipe preparation and aligning, automatic electrode and wire
reel changing functions, using a robot arm installed. This is in testing stage in deep waters.
Explosive and friction welding are also to be tested in deep waters.
12

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DEPARTMENT OF MECHANICAL ENGINEERING

Greater Noida institute of technology

Mr. Syed Qaiser Husain

Department of Mechanical Engineering

(Mr. Syed Qaiser Husain)

HYPERBARIC WELDING (DRY WELDING)

ADVANTAGES & DISADVANTGES OF DRY WELDING

ADVANTAGES & DISADVANTGES OF WET WELDING

PRINCIPLE OF OPERATION OF WET WELDING

DEVELOPMENTS IN UNDER WATER WELDING

POWER SUPPLY DIAGRAM

In wet welding MMA (manual metal arc welding) is used.

Power Supply used: DC

HYPERBARIC WELDING (DRY WELDING)

ADVANTAGES OF DRY WELDING

1. Welder/Diver Safety Welding is performed in a chamber, immune to ocean

DISADVANTAGES OF DRY WELDING

ADVANTAGES OF WET WELDING

It is less costly compared to dry welding.

DISADVANTAGES OF WET WELDING

Hydrogen Embrittlement Large amount of hydrogen is present in the weld region,

Principle of operation of Wet Welding

DEVELOPMENTS IN UNDER WATER WELDING

SCOPE FOR FURTHER DEVELOPMENTS

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