Report U.W.W PDF

A
Seminar
Report on
“UNDER WATER WELDING”
Submitted in partial fulfillment for the award of degree of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
Submitted To: Submitted By:

MR. Md SHABBIR ALAM PADAM NABH GAUTAM
Assistant Professor 16EGJME079
Mechanical Engg.
DEPARTMENT OF MECHANICAL ENGINEERING

GLOBAL INSTITUTE OF TECHNOLOGY, JAIPUR
(RAJASTHAN)-302022
SEMINAR ON U.W.W. GIT (DME)
GLOBAL INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGEENRING
JAIPUR (RAJASTHAN)
CERTIFICTE
This is to certify that this seminar report on “UNDER WATER

WELDING” is submitted by (PADAM NABH GAUTAM) and
(16EGJME079) to the Department of Mechanical Engineering, GIT,
Jaipur, for the award of the degree in B.Tech Mechanical Engineering
is a bona fide record of work carried out by him. The contents of this
Seminar Report, in full or in parts have not been submitted to any other
Institute or University for the award of any degree.
Seminar Coordinator HEAD OF DEPARTMENT

_
(MR. Md SHABBIR ALAM) (MR. GHANSHYAM MISHRA)
Page No. i
Batch 2016-2020
ACKNOWLEDGEMENT
I feel very happy in forwarding this seminar report as an image of sincere efforts. No work
would be perfect without guidance. First and foremost I extend my thanks and gratitude to “MR.
Md SHABBIR ALAM, In Global Institute of Technology, Jaipur,” under their guidance this
seminar could be accomplished.
PADAM NABH GAUTAM
Page No. ii
BATCH 2016-2020
ABSTRACT
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.
Page No. iii

BATCH 2016-2020
CONTENT
CHAPTER PAGE NO
Certificate (I)
Acknowledgment (II)
Abstract (III)
List of Content (IV)
List of Figures (VII)
CHAPTER 1 INTRODUCTION 1
CHAPTER 2 UNDERWATER WELDING EQUIPMENTS 2-9

2.1 DIVING HELMET 2
2.2 U.W.W. DIVING ACCESSORIES 3
2.2.1 DIVING KNIFE 3
2.2.2 UMBILICAL CORD 4
2.2.3 HARNESS 4
2.2.4 GAS PANEL AND COMPRESSOR 5
2.2.5 BAILOUT GAS 5
2.2.6 KNIFE SWITCH 6
2.3 DIVING SUIT 6
2.4 ELECTRODES 7
2.4.1 WATER-RESISTANT COATING 7
2.4.2 HIGH YEILD STRENGTH 7
2.5 STINGER 8
2.6 POWER SUPPLY 9
Page No. iv
BATCH 2016-2020
CHAPTER 3 TYPES OF UNDERWATER WELDING 11
CHAPTER 4 WET WELDING 12
CHAPTER 5 PRINCIPAL OF WET WELDING 16
CHAPTER 6 ADVANTAGES OF WET WELDING 17
CHAPTER 7 DISADVANTAGES OF WET WELDING 18
CHAPTER 8 DRY WELDING 19
CHAPTER 9 ADVANTAGES OF DRY WELDING 21
CHAPTER 10 DISADVANTAGES OF DRY WELDING 22
CHAPTER 11 EFFECT OF WET ENVIOURNMENT 23

11.1 POROSITY TROBLE SHOOTER BY INCLUDING
CALCIUM CARBONATE 23
11.2 MECHANICAL PROPERTIES 24
11.3 CHEMICAL COMPOSITIONS 25
11.4 EFFECT OF ALLOYING ELEMENT ON WELD METAL
MICROSTRUCTURE 27
CHAPTER 12 RISK INVOLVED 28
CHAPTER 13 SAFETY MEASURES 29
CHAPTER 14 DEVELOPMENT IN UNDER WATER WELDING 30-32

14.1TESTING FACILITY 30
14.2WATER EXCLUSION DEVICE 31
14.3ROBOTIC STUDY FOR UNDER WATER WELDING 31
Page No. v
BATCH 2016-2020
CHAPTER 15 APPLICATION OF UNDER WATER WELDING 33

15.1 CLADING 33
15.2 GROOVE WELDING 34
CHAPTER 16 SCOPE OF FURTHER DEVELOPMENT 35
CHAPTER 17 CONCLUSION 36
CHAPTER 18 REFRENCES 37
Page No. vi
BATCH 2016-2020
LIST OF FIGURES
S no. Name of figure Page no.
Figure2.1 DIVING HELMET 2
Figure2.2 DIVING KNIFE 3
Figure2.3 UMBILIUCAL CORD 4
Figure2.4 HARNESS 4
Figure2.5 BAILOUT GAS 5
Figure2.6 KNIFE SWITCH 6
Figure2.7 DIVING SUIT 7
Figure2.8 ELECTRODES 8
Figure2.9 STINGER 8
Figure2.10 TIG-MMA-ARC WELDER POWER SUPPLY 9
Figure3.1 WET WELDING 11
Figure3.2 DEY WELDING 11
Figure4.1 WET WELDING DIAGRAM 12
Figure4.2 SHIELDING OF THE WELDING ARC 14
Figure4.3 ARRAGMENTS OF UNDER WATER WELDING 14
Figure4.4 PICTURE OF WET WELDING 15
Figure8.1 DRY WELDING 19
Figure8.2 LARGE HABITATE 20
Figure8.3 MINI HABITATE 20
Figure11.1 POROSITY V/S WATER PRESSURE 23
Figure11.2 WEIGHT % V/S UNDER WATER WELDING 25
Figure11.3 % OXYGEN V/S UNDER WATER WELDING 26
Page No. vii

BATCH 2016-2020
Figure11.4 EFFECT OF ALLOYING ELEMENT ON WELD METAL
MICROSTRUCTURE 27
Figure14.1 HYPERBARIC TESTING MACHINE 30
Page No. viii

BATCH 2016-2020
CHAPTER – 1
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. In 1932, Russian metallurgist (Konstantin Khrenov) invented under
water welding.
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. Welding is an unavoidable process of modern engineering
– civil, electrical, mechanical, automobiles, marine aeronautical – in all branches. It is used in
fabrications and erections in infrastructures and installation. It joins metals or thermoplastics.
Forming a pool of molten mass – the weld puddle – and allowing it to cool to become a strong
joint is the basis of the process of welding. For repairing to be carried out underwater, there is a
separate process. That is called underwater welding. If damaged ships are to be repaired,
underwater welding is the basic technology to be used. It is a highly-specialized profession –
more employed in the oil or shipping industry and also in the defense operations.
Page No.1
BATCH 2016-2020
CHAPTER – 2
UNDERWATER WELDING EQUIPMENTS
To weld properly underwater, a commercial divers use five main tools:
1. Diving helmet
2. Accessories
3. Diving suit
4. Electrodes
5. Stinger
6. Power supply
2.1 Diving Helmet:-
Figure 2.1 Diving Helmets
Page No.2
BATCH 2016-2020
The figure shows the diving helmet for the underwater welding process. It is essential to wear
safe diving helmet for their work.
During the welding process helmet, protect our eyes and face. Also, the diving helmet allows
breathing for the welder-diver in underwater, so that’s it used in underwater purpose.
A welding screen that attaches to the front of their mask for eye protection. Some of these
welding screens flip up or down like a welding hood, and they all come in different colors.
2.2 Underwater Welding Accessories:-

Welder-diver will use these diving accessories:
2.2.1 Diving Knife:-
Figure 2.2 Diving Knife
It is a tool for every situation, whether they need to cut into project, wedge opens a door or free
them from a critical condition a diving knife works.
Page No.3
BATCH 2016-2020
2.2.2 Umbilical Cord:-
Figure 2.3 Umbilical Cord
This is gas is pumped from the diver tool and from the surface.
2.2.3 Harness:-
Figure 2.2.3 Harness
To keep the diver floating in one place while doing his work.
Page No.4
BATCH 2016-2020
2.2.4 Gas Panel and Compressor:-

A qualified team controls the gas gauge and keeps the steady supply of air coming below in the
diver. Divers also observe these directly. Many uses a low-pressure gas because of its low
maintenance is almost unlimited air supply.
2.2.5 Bailout Gas:-
Figure 2.5 Bailout Gas
It is used for emergency situations, in the case of poor SSA equipment, this gas is usually done
by the diver as a secondary gas supply. It comes in the form of a small SCUBA tank.
2.2.6 Knife Switch:-

Not the same as a diving Knife. It is used when using electrical appliances underwater like wet
welding. Built in the form of a simple liver, it regulates the flow of electricity from the upper
side to power your device.
Page No.5
BATCH 2016-2020
Figure 2.6 Knife Switch
2.3 Diving Suit:-

For the diving purpose divers must use a dry suit because it provides better protection against
climate control than a wetsuit.
Depending on the environment in which you diving, dry suits either are neoprene, rubber or
shell.
However, as extra external layer of protection, some underwater welders wear cover alls the top
of their suit.
If a molten metal directly hits its suit,them it can burn through it. Coverall prevents it from
occuring.
To protrction of hands, welder-divers wear thick rubber linemen’s gloves over several pairs of
latex. To prevent the water from being in gloves, they can snap a rubber band around the wrist
section.
Page No.6
BATCH 2016-2020
Figure 2.7 Diving Suit
2.4 Electrodes:-
The electrodes are the most important tool of underwater welding it provides materials for the
weld. Underwater electrodes should be extremely water-resistant coating and high yield strength.
2.4.1 Water-resistant coating:-

The longer it can hold up in a hostile marine environment, the better.
2.4.2 High yield strength:-

Better quality material in the electrode provides a high-density weld which will last for a long
time.
Page No.7
BATCH 2016-2020
Figure 2.8 Electrodes
2.5 Stinger
Figure 2.9 Stinger
Stinger holds the electrodes, and they are made of lightweight plastic materials to reduce the
possibility of twinge and fatigue. The stinger has the following characteristics.
Page No.8
BATCH 2016-2020
• It should be insulated.
• It should have Ergonomic and lightweight.
• Angled correctly.
2.6 Power Supply:-

For every welding process, the power supply must be required. In underwater welding, DC
power source is usually used.
Figure 2.10 TIG-MMA-Arc welder power supply
The power source for under-water manual metal arc (MMA, SMA / SNA) welding should be
direct current welding generator type, which is able to produce at least 300 a on 65v open circuit
(OC).
Page No.9
BATCH 2016-2020
Equipment welding circuit should include a DC circuit breaker (twin pole single action, 400 A
minimum).
Page No.10
BATCH 2016-2020
CHAPTER – 3
CLASSIFICATION OF UNDER WATER WELDING
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.
Figure 3.1 Wet Welding Figure 3.2 Dry Welding
Page No.11
BATCH 2016-2020
CHAPTER – 4
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.
Figure 4.1 Diagram of Wet Welding
Page No.12
BATCH 2016-2020
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 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.
In underwater welding the arc does not behave as in air. The activity of the gas bubbles being
particularly important, as this tends to create a rather unstable arc condition, compared with
surface welding, together with a somewhat more confusing weld puddle, which must be
mastered by the diver before successful welding can take is no difference between surface MA
welding and underwater wet-stick welding. Place. Apart from this, with regard to the actual
physical principles of operation, there both processes use basically the same equipment with the
exception of necessary waterproofing for the electrodes and certain other safety equipment.
The electrodes themselves may be either carbon manganese (C/Mn) or mild steel if you prefer,
and stainless steel (duplex). With the retiled mild steel electrodes being the most widely used,
but more about electrodes later.
Page No.13
BATCH 2016-2020
Figure 4.2 Shielding of the welding arc and molten pool with a covered stick electrode
Figure 4.3 arrangements of underwater welding
Page No.14
BATCH 2016-2020
Figure 4.4 Picture of wet welding
Page No.15
BATCH 2016-2020
CHAPTER – 5
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.
Page No.16
BATCH 2016-2020
CHAPTER – 6
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: -
• 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.
• It is less costly compared to dry welding.
• .The welder can reach portions of offshore structures that could not be welded using other
methods.
• 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.
Page No.17
BATCH 2016-2020
CHAPTER - 7
DISADVANTEGES OF WET WELDING
Although wet welding is widely used for underwater fabrication works, it suffers from the
following drawbacks: -
• 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 well-meant and increases porosity and hardness.
• 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.
• Another disadvantage is poor visibility. The welder sometimes is not able to weld
properly.
Page No.18
BATCH 2016-2020
CHAPTER – 8
DRY WELDING
Hyperbaric welding is carried out in chamber sealed around the structure o 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.
Figure 8.1 Dry Welding
8.1USING LARGE HABITAT:-
Page No.19
BATCH 2016-2020
Figure 8.2 large habitat
8.2USING MINI HABITAT:-
Figure 8.3 mini habitat
Page No.20
BATCH 2016-2020
CHAPTER – 9
ADVANTAGES OF DRY WELDING
• 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).
• 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.
• Surface Monitoring – Joint preparation, pipe alignment, NDT inspection, etc. are
monitored visually.
• Non-Destructive Testing (NDT) – NDT is also facilitated by the dry habitat
environment.
Page No.21
BATCH 2016-2020
CHAPTER – 10
DISADVANTAGES OF DRY WELDING
• The habitat welding requires large quantities of complex equipment and much support
equipment on the surface. The chamber is extremely complex.
• 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 – a $ 80000 charge for a single weld job. One
cannot use the same chamber for another job, if it is a different one.
Page No.22
BATCH 2016-2020
CHAPTER – 11
EFFECT OF WET ENVIRONMENT
11.1 Porosity-trouble-shooter by including Calcium carbonate:-
Figure 11.1 Porosity v/s Water Pressure
Page No.23
BATCH 2016-2020
11.2 Mechanical properties:-
Page No.24
BATCH 2016-2020
11.3 Chemical composition:-
Figure 11.2 weight % v/s underwater depths
Page No.25
BATCH 2016-2020
Figure 11.3 %oxygen v/s underwater depths
Page No.26
BATCH 2016-2020
11.4 effect of alloying element on weld metal microstructure:-
Page No.27
BATCH 2016-2020
CHAPTER – 12
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. Both the welder
and the structure are at risk. The welder has to protect himself from electric shocks. The welder
has to be insulated. The voltage of the welding sets has to be controlled. Pockets of oxygen and
hydrogen built up by the arc will be potentially explosive. The welder has to take precaution
because nitrogen will be built up in the blood stream of the welder, when exposed to air at high
pressure under the water surface. Inspection, although very difficult, is a mandatory requirement.
No defects should remain. In addition to all these precautions, safe arc-welding precautions are
to be taken.
Underwater welding is mostly employed in marine engineering products – in installations of oil

and gas rigs. Underwater welding can be classified depending upon the types of equipments and
the types of procedures involved. The most common underwater welding process, known as
manual metal arc building (MMA), is employed for deep water repairing activities. Cofferdam
welding process and Hyperbaric welding process are normally carried out for underwater
welding operations. They are employed for welding steel pipelines, other offshore structures,
submerged parts of large ships and underwater structures supporting a harbour. The safety
measures include emergency air or gas supply, stand-by divers and decompression chambers.
Page No.28
BATCH 2016-2020
CHAPTER – 13
SAFTEY MEASURES
• Start cutting at the highest point and work downward
• By withdrawing the electrode every few seconds to allow water to enter the cut
• Gases may be vented to the surface with a vent tube (flexible hose) secured in place from
the high point where gases would collect to a position above the waterline.
• Precautions include achieving adequate electrical insulation of the welding equipment
• Areas and voids must be vented or made inert
Page No.29
BATCH 2016-2020
CHAPTER – 14
DEVELOPMENT IN UNDERWATER WELDING
14.1Testing Facility:-
Underwater welding using the Plasma Transferred Arc (PTA) process was performed in a 1.22m
(47.6 in.) diameter, 2.44m (95 in.) high hyperbaric chamber. The hyperbaric chamber is partially
filled with water and pressurized with gas to simulate water depths of up b 30m (98 ft). This
simulates the water depths down to the vessel "zero" elevation. A photograph of the hyperbaric
chamber is shown in Figure1. Welding power and control of the inert gas flow rate is performed
using a modified commercially available PTA welding system. Water cleanliness in the system is
maintained by a water filtration and ion resin exchange unit. Inside the hyperbaric chamber is a
three-axis manipulator which supports the test piece and provides the motion for the torch
(Figure-2). Motion commands for the manipulator are provided by a custom designed
programmable controller.
Figure 14.1 Hyperbaric Testing Facilities
Page No.30
BATCH 2016-2020
14.2Water Exclusion Device:-

In the last two decades, underwater welding methods have been based primarily on fully-wet
welding or hyperbaric air chamber conditions, in which either the torch tip and weld area were
directly exposed to the water environment, or in which the entire torch and weld area was kept
completely dry. A recent trend in underwater welding is to provide a local, moving dry
environment only around the torch tip and nearby substrate. This alternate concept for
underwater welding can have the following advantages: • Increases flexibility of torch movement
over contours • Suitable for flat, horizontal, vertical, or overhead positions • Reduces cost and
schedule relative to hyperbaric air chambers • Provides weld quality equal to hyperbaric chamber
PTA welding • Operates compatibly with automatic voltage control systems • Suitable for
cladding, fillet or groove welding applications • Allows direct video camera vision of the weld
pool area • Improves weld quality relative to "wet" welding practice A unique design for a water
exclusion device (WED) using the local, moving dry area approach, has been recently developed.
The basic WED design has the ability to effectively displace water within the device to obtain a
dry substrate surface and torch tip while the device is moving over greatly changing contours.
Variations of the basic design are able to conform to the increasing weld bead height when
performing cladding or fillet welds, or the decreasing depth of a groove weld as the groove is
progressively filled. The device has sufficient compliance to be able to simultaneously seal the
substrate outer surface and the groove interior, even with deep-groove sidewall angles as steep as
15 degrees. The basic WED design for a horizontal welding position. Consisting of an enclosure
around the torch, which contains a seal design with an exceptionally high mechanical compliance
and displacement range. Filler metal addition is achieved by feeding wire into the weld pool in
the conventional manner. Forward and lateral movements of the WED and torch assembly are
achieved using a multi-axis underwater robot manipulator.
14.3Robotic Study for Underwater Welding:-

Underwater BWR repairs will require welding in a low radiation field at depths up to 30m (98
ft). A programmable robot arm design, capable of cutting, inspection and welding, is currently
being studied for this application. The size and reach of this tool will be governed by vertical and
horizontal access limits to subsurface work areas. To reach a typical underwater repair, the robot
tool will have to be lowered through a long narrow corridor that is free from piping or other
Page No.31
BATCH 2016-2020
obstructions. After reaching its working depth, the robot will have to attach itself to a pre-
installed track and travel to the actual repair site. Computer simulation software has been adapted
to study vertical insertion and horizontal travel options inside a BWR. Simulation studies will
investigate manipulator motion, equipment size, track-attachment schemes and cable
management techniques. Using specialized robot simulation tools, cinematically correct models
will be tested in an array of simulated 3-D work environments. Motion and accessibility will be
the primary outputs of this process. The ultimate goal of this phase will be the development of a
scaleable, generic robot that is capable of handling a wide array of underwater repairs. Motion
control for this underwater tool will be similar to that of a standard robot system. All robot
motion will take place in the curvilinear work frame. This frame will be based on the curvature
of the track, which will run tangent to the repair surface. A specialized curvilinear subsystem
will monitor between actual and programmed joint position variables. The robot system will
operate in the programmed mode during repetitive repair sequences. Operator override control
will allow for real-time process adjustment. This system will also operate in a 'tele-operational'
mode to perform inspection and small machining tasks. In an ideal underwater repair, viewing
systems will be positioned to watch the work from many different locations. Operators will be
able to continually scan between 3 separate types of visual inputs: simulation representation,
real-time remote video, and weld pool observation.
Page No.32
BATCH 2016-2020
CHAPTER - 15
APPLICATION OF UNDERWATER WELDING
15.1Cladding:-
The work reported in this paper is an extension of the underwater welding PTA welding
development reported in Reference 1. Weld ability testing was performed using the underwater
PTA systems under pressurized water conditions. Testing was focused in two different areas; (1)
determination of the general weld ability of materials in the underwater environment with the
underwater PTA welding process, and (2) the application of cladding. The weld ability of four
austenitic base metals and two Ni-base metal substrates were examined.
In addition, testing was performed with noble metal doped Ni-base alloy cladding (Alloy 82
+Pd). The stress corrosion resistance benefits from noble metal doped surfaces are described in
Reference 2. The Alloy 82+Pd underwater cladding reported here was applied to stainless steel
and Ni-base alloy substrates. Assessment of the weld ability was determined primarily using
metallographic examination, but testing was also performed to determine mechanical properties
and hot cracking propensity for selected materials. A summary of the results is provided below.
Metallographic examination of all base and filler metal combinations showed that no weld ability
problems existed when underwater PTA was applied using the GE water exclusion device. The
microstructures of the weld deposits and heat affected zones (HAZ) are very similar to welds
performed in air, with one exception. The heat affect zone in the base metal of the underwater
PTA welds is smaller than from welds made in air with identical welding parameters. A typical
example of underwater PTA cladding on three different base metal types is shown in Figure-4. A
higher magnification view of the microstructure for the Alloy 82 + Pd applied to Alloy 600 is
shown in Figure-5. The photomicrograph shows that a complete metallurgical bond is achieved
between the cladding and the Alloy 600 substrate. In addition the photomicrograph shows that
the weld is free of porosity and other harmful weld defects.
Page No.33
BATCH 2016-2020
15.2Groove Welding:-
As an extension of the local, moving dry zone concept beyond the initial corrosion resistant
cladding application described above, fillet welding was also successfully performed with the
underwater PTA process. These fillet welds were made using Type 304L stainless steel plate and
Type ER 308L filler wire. Complete water exclusion was obtained with the WED design
modified for fillet welding, as evidenced by the defect-free condition seen on the face of the
completed welds. A defect-free condition was also found in metallographic cross-sections of
these welds. Due to the effectiveness of the WED design, reasonably low torch gas flow rates
and WED purge rates were sufficient to produce smooth, silver-colored weld beads. In order to
further extend the functional capability of the underwater PTA cladding system, the WED was
significantly modified to seal within a welding groove, which could exist, for example, after
component in-service cracking was removed. A waterproof torch was designed and built for
underwater welding in a reduced-width groove, and is shown Figure-6. Initial underwater
welding trials were made in grooves cut in the face of 38 mm (1.5 inch) thick, Type 304 stainless
steel plates in the flat position. The filler metal used for the groove welding was Type ER 308L.
Welds were successfully completed at water pressures ranging from 0.22 to Q31 MPa (30 to 45
psi). A photograph of a typical flat-position welded plate is shown in Figure-7. The
corresponding photo-macrographs and micrographs of this plate are shown in Figures-8 and -9,
and demonstrate the high internal quality of the weld deposit. No evidence of porosity or any
other type of defect was seen on the photo micrographs or radiographic examinations. The
absence of any defects or weld oxidation demonstrates the effectiveness of the WED in
maintaining excellent water exclusion.
Page No.34
BATCH 2016-2020
CHAPTER – 16
SCOPE FOR FURTHER DEVELOPMENTS
Wet MMA is still being used for underwater repairs, but the quality of wet welds is poor and is
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 trace and orbital head on the pipe and the rest process is
automated.
Developments of driverless 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.
Page No.35
BATCH 2016-2020
CHAPTER – 17
CONCLUSION
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.
Page No.36
BATCH 2016-2020
CHAPTER – 18
REFERENCES
• D. J Keats, Manual on Wet Welding.

• Annon, Recent advances in dry underwater pipeline welding, Welding Engineer, 1974.
• Lythall, Gibson, Dry Hyperbaric underwater welding, Welding Institute.
• Wiucas, International conference on computer technology in welding.
• Stepath M. D, Underwater welding and cutting yields slowly to research, Welding
Engineer, April 1973.
• Silva, Hazlett, Underwater welding with iron — powder electrodes, Welding Journal,
1971
Page No.37
BATCH 2016-2020

Report U.W.W PDF

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Report U.W.W PDF

Загружено:

Авторское право:

Доступные форматы

A

“UNDER WATER WELDING”

Submitted in partial fulfillment for the award of degree of

Submitted To: Submitted By:

DEPARTMENT OF MECHANICAL ENGINEERING

GLOBAL INSTITUTE OF TECHNOLOGY

This is to certify that this seminar report on “UNDER WATER

Seminar Coordinator HEAD OF DEPARTMENT

PADAM NABH GAUTAM

Page No. iii

List of Content (IV)

List of Figures (VII)

CHAPTER 2 UNDERWATER WELDING EQUIPMENTS 2-9

CHAPTER 3 TYPES OF UNDERWATER WELDING 11

CHAPTER 4 WET WELDING 12

CHAPTER 5 PRINCIPAL OF WET WELDING 16

CHAPTER 6 ADVANTAGES OF WET WELDING 17

CHAPTER 7 DISADVANTAGES OF WET WELDING 18

CHAPTER 8 DRY WELDING 19

CHAPTER 9 ADVANTAGES OF DRY WELDING 21

CHAPTER 10 DISADVANTAGES OF DRY WELDING 22

CHAPTER 11 EFFECT OF WET ENVIOURNMENT 23

CHAPTER 12 RISK INVOLVED 28

CHAPTER 13 SAFETY MEASURES 29

CHAPTER 14 DEVELOPMENT IN UNDER WATER WELDING 30-32

CHAPTER 15 APPLICATION OF UNDER WATER WELDING 33

CHAPTER 16 SCOPE OF FURTHER DEVELOPMENT 35

Figure2.2 DIVING KNIFE 3

Figure2.3 UMBILIUCAL CORD 4

Figure2.5 BAILOUT GAS 5

Figure2.6 KNIFE SWITCH 6

Figure2.7 DIVING SUIT 7

Figure2.10 TIG-MMA-ARC WELDER POWER SUPPLY 9

Figure3.1 WET WELDING 11

Figure3.2 DEY WELDING 11

Figure4.1 WET WELDING DIAGRAM 12

Figure4.2 SHIELDING OF THE WELDING ARC 14

Figure4.3 ARRAGMENTS OF UNDER WATER WELDING 14

Figure4.4 PICTURE OF WET WELDING 15

Figure8.1 DRY WELDING 19

Figure8.2 LARGE HABITATE 20

Figure8.3 MINI HABITATE 20

Figure11.1 POROSITY V/S WATER PRESSURE 23

Figure11.2 WEIGHT % V/S UNDER WATER WELDING 25

Figure11.3 % OXYGEN V/S UNDER WATER WELDING 26

Page No. vii

Figure11.4 EFFECT OF ALLOYING ELEMENT ON WELD METAL

Figure14.1 HYPERBARIC TESTING MACHINE 30

Page No. viii

UNDERWATER WELDING EQUIPMENTS

To weld properly underwater, a commercial divers use five main tools:

2.1 Diving Helmet:-

Figure 2.1 Diving Helmets

2.2 Underwater Welding Accessories:-

2.2.1 Diving Knife:-

Figure 2.2 Diving Knife

2.2.2 Umbilical Cord:-

Figure 2.3 Umbilical Cord

Figure 2.2.3 Harness

2.2.4 Gas Panel and Compressor:-

2.2.5 Bailout Gas:-

Figure 2.5 Bailout Gas

2.2.6 Knife Switch:-