WELDING

Underwater welding explained

Patrick Feeleus of Netherlands-based Noordhoek Offshore BV provides UCi with a brief overview of wet underwater welding, and explains why the methodology should be considered for structural repairs
The quality of wet underwater welding has improved drastically over the years and is nowadays a repair methodology that is fully recognised by the various classification societies. Considering this drastic improved quality standard, the versatility (increased freedom of movement), the marginal costs (compared to other underwater water repair technologies such as repairs by habitat or cofferdam deployment), and the speed with which the preparation and operation can be carried out, the wet underwater welding process should definitely be considered as permanent and routine repair methodology on structural applications (rigs, platforms, FPSO/FPS, semi-submersibles, etc.). developed their own (confidential) flux formulations, filler metals and supplementary coatings, and consequently each electrode has it own specific wet welding characteristics. Selection of suitable wet welding electrodes can be done after proper understanding of the following, critical, selection criteria: G Base material composition G Required mechanical properties G Metallurgic requirements, G Cracking risks G Wet welding operating depth and weld type/position (i.e. 2G, 4F position) The last two points are greatly relating to each other, and are the most important criteria for selecting wet welding electrodes. The properties, relative to weldability and cracking risks, are mostly influenced by the so called welding-flux (the material used during welding to chemically clean the surfaces of the joint). The two most commonly used wet welding electrodes are basic hydrogen controlled electrodes and Rutile-based electrodes. Rutile electrodes do not offer low hydrogen levels in the weld materials because of the relatively high moisture proportions initiated during the electrode fabrication and storage, and should be considered for general purpose wet welding applications. Additives included with Rutile-based electrodes, such as cellulose or acid, can improve the mechanical properties and/or weldability, but hydrogen inclusion is still a concern. Hydrogen controlled electrodes generate a hydrogen percentage below the requirements specified in the codes because the moisture levels

Figure 1. Wet welding versus workshop welding

UNDERWATER WELDING PRINCIPLES

Underwater welding can be performed under wet or dry conditions. Dry underwater welding refers to underwater welding which is performed under hyperbaric conditions (an underwater habitat is displacing the water with a gas at the pre-

vailing pressure), and wet underwater welding refers to welding which is performed in fresh- or salt-water without a protecting habitat. Wet underwater welding will here after be referred to as wet welding, and wet/dry underwater welding will simply be referred to as underwater welding. The most commonly used wet welding technique is shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or informally as stick welding. The main differences for the welding equipment (wet welding equipment versus workshop welding equipment) are shown in Figure 1. Note that wet underwater welding is performed by using a (usually motor generated) power source generating DC current only (for wet welding AC is not used on account of electrical safety and difficulty in maintaining a welding arc underwater), the inclusion of a single or dual pole knife switch (circuit breaker), which protects a welding diver from electrocution, and the use of double insulated cables. Both the power source and

knife switch (capable of breaking the full wet welding current) are secured above water (grounded) and controlled (on the diver welders command) by an operator. The cross section of the welding cable is adjusted to the length of the cable and should be highly wear resistant (marine growth) and sufficiently flexible; special welding electrode holders are used with extra insulation against the ingress of water.

CONSUMABLES
Electrodes for wet welding of mild steel (C/Mn) and stainless/nickel steel (duplex type) materials are generally available and their requirements are specified in the AWS E6013 codes and standards. Apart from the existence of electrodes suitable for wet welding low alloy and exotic type of stainless steels grades, the main difference between dry welding electrodes and wet welding electrodes is an added waterproof coating, and sometimes an additional added paraffin coating (over the primary waterproof coating). Wet welding consumable suppliers have

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QUALITY, HEALTH AND SAFETY
Wet welding operations involve health and safety aspects on diving operations and, in addition, include specific health and safety aspects induced by the wet welding activity. In their own right, diving operations involve risks of drowning, respiration and circulation issues and hypothermia. In addition, the quantity of dives, dive repetitiveness, depth of the operations, time spent underwater and the exhausting nature of a specific task (i.e. cutting, grinding, cleaning and welding) increase these diving related risks significantly. These diving parameters are important in relation with the nitrogen levels of the blood stream. Precautions include the provision of an emergency air or gas supply, stand-by divers and decompression chambers. Such diving specific health and safety concerns are governed by guidelines formulated by the
521N/mm2 442N/mm2 17.2 % 31 joule 225HV 10 192HV 10 [490-630 N/mm2] [>414N/mm2] [>14%] [>27joule] [<325HV10] [<325HV10]

From left to right: Figure 2. 3F vertical down fillet weld; Figure 3. 1G groove weld; Figure 4. 2G groove weld

are better controlled during manufacturing (baking of electrodes) and storage (in a dry controlled environment).

WET WELDING QUALITY

Historically wet welds have lacked ductility, have high hardness values and have suffered from hydrogen cracking and brittleness. The internal properties of wet welds have improved with the currently available wet welding electrodes, and the majority of these properties are accurately under control. See

Figures 2 to 4 for example results of performed underwater wet welding. The decrease in ductility and hydrogen inclusions in the heat affected zone can be improved by selection of the proper wet welding electrode base materials, and can nowadays be brought to an acceptable level by proper design (unit stress reduction and welding position) of the wet welded joints, and development of a suitable welding procedure specification. Other important aspects influ-

encing the quality levels achieved with wet welding are workmanship, water depths, visibility (debris and lack of light in open waters) and environmental conditions (currents and sea state). Apart from workmanship, the other parameters can not be influenced. Typical wet welding mechanical properties achieved in our test-basin facilities (at eightmetre water depth) on a S355J2G3 to S355J2H base material (formerly known as Steel 52) with a 4mm welding electrode in a 3G down position are summarised in Table 1. The requirements stated in brackets are according the AWS D3.6 Class B wet welding codes.
Tensile strength Rp-0.2% Elongation Lo = 5xD Av. Impact Resistance at -20C Av. Hardness (cap-on 1.5mm) Av. Hardness (root on 1.5mm)

Table 1. Typical wet welding mechanical properties achieved in test-basin facilities (at eight-metre water depth) on a S355J2G3 to S355J2H base material (formerly known as Steel 52) with a 4mm welding electrode in a 3G down position

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work procedures, permits, etc.

CODES, STANDARDS AND QUALIFICATIONS

Industry standards for wet and dry underwater welding have been set by the American Welding Society (AWS), standard D3.6. The most important aspects defined within this code are briefly explained in the following paragraphs. Classification of wet welds: Underwater welding is specified using three quality levels, Class A, B and C. Class O is recognised as underwater welding following other, usually as stringent as Class A, quality criteria which are usually specified by client requirements. The weld classifications for wet underwater welding or dry underwater welding are similar. Class A underwater welding covers a stand-alone set of requirements comparable to welds produced above water (suitable for structural applications) in accordance with AWS D1.1 or ASME Section IX. The performed underwater welds are qualified on the basis of visual and X-ray examination, reduced section tension, all weld-metal tension, 2T to 21/3T bends, macro-etch, hardness and impact tests. Tests for underwater welded fillet welds include fillet-weld-break and fillet-weld-shear tests. The acceptance criteria for Class A underwater welding are similar to those above water. Class B underwater welding covers an intermediate set of mechanical and examination requirements representing a

Figure 5. Turtle between platform bracings

International Marine Contractors Association (IMCA) and/or government legislations. The main wet welding related health and safety issues involve electric shock and explosion risks. Precautions on electric shocks include adequate electrical insulation of the welding equipment, shutting off the electricity supply immediately after the arc is extinguished (knife switch), and limiting the opencircuit voltage of 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 generates a potentially explosive mixture. Other important health and safety aspects of wet welding involve eye-protection and electrolysis deterioration of diving and welding equipment. It is obviously of the utmost importance to recognise, manage and control these wet welding and diving associated risks in any project through the development of projectspecific health and safety plans, general risk assessments, job hazard analysis,

Figure 6. Wet underwater welding result

slightly lower level of quality, but still resulting in an underwater weld of predictable strength. Class B underwater welds are intended for less critical applications where reduced ductility and increased porosity can be tolerated. The main difference over Class A performed wet welding are the larger allowable bending radius and the expanded acceptance limits of porosity (visual and X-ray). Class C underwater welding satisfies with lesser requirements than the other types of underwater welding and are intended for applications where the loadbearing function is not a primary consideration. Class C underwater welding is usually performed for temporary welds or minor attachments to structures. The qualification criteria basically ensure that the primary structural integrity is not impaired. Underwater Welding Procedure Qualifications Variables: Relative to the base metal of the underwater welding electrodes, and the water depth of the underwater welding operation, the qualifications should be performed within a limiting depth envelope. For instance, the qualifications for a underwater welding operating with carbon steel filler material designated at a water depth of 10 metres should be performed within a maximum 20-metre and minimum two-metre envelope. Qualification for underwater welding with austenitic stainless steel filler material at the same operating depth should be performed within a maximum 13metre and minimum

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two-metre envelope. Position of the performed underwater welding is also a relevant parameter for weld qualifications. Underwater welding positions are inline with the positions for groove and fillet welds specified in the ISO-6947 or ANSI/AWS A3.0. After a groove underwater weld procedure for a plate has been qualified in one position, a smaller test plate and fewer tests are required to qualify addition positions. Joint configuration is another essential variable for welding procedures. Like within dry welding codes, distinction is made between groove welds and fillet welds. For instance, a singepass fillet weld is not qualified by groove welds qualification. Joint assembly tolerances for underwater welding shall be developed during the welding procedure qualification and shall be properly identified herein.

UNDERWATER WELDING INSPECTION

Assurance on the integrity of underwater welds can be given by using the normally available NDT techniques. These inspections are often accomplished as a team effort (the diver as NDT operator, plus a topside inspector). Means of underwater welding inspection, or underwater inspections in general, can be performed by visual examina-

Figure 7. Crack in platform bracing

tion, radiographic examination, ultrasonic examination, magnetic particle examination/ inspection or eddy current examination.

WET WELDING PROJECT DEVELOPMENT

The development of a wet welding project starts with an inventory on the possibilities and limiting strength aspects in relation to the structural and electrode base materials. The minimum requirements are incorporated in the design (repair or construction project) and verified on technical and practical feasibility. It is important to recognise the wet welding quality limitations relating to the joint configuration and position (i.e try to avoid overhead wet welding). Secondarily, the wet welding contractor qualifies a wet welding procedure specification (WPS), which the company then owns. As mentioned, the wet welding WPS variables include water depth, consumables, base metal, carbon content and equivalent of the base metal, joint design, joint position, diving equipment used, water temperature, and power supply. The type of wet welding WPS for which a company wants to qualify depends on the engineering solution. It is often required to develop and qualify more than one wet welding WPS. Upon satisfactory completion of the wet welding WPS, and

Figure 9. Structural analysis

subsequent weldment testing, the wet welding contractor receives client and associated governing code or specification body approval. The wet welding WPS can then be used to qualify the needed number of diver/welders for the job.

NOORDHOEK CAPABILITIES
The Subsea Repair Department of the Noordhoek Offshore BV is recognised in the offshore underwater repair segment and has extensive experience in operating in offshore environments related to oil and gas business. The Department is specialised in turnkey execution of subsea repair and/or maintenance projects related to offshore equipment and or (floating) facilities. Apart from wet welding, Noordhoek is also

capable to perform underwater repairs by deploying habitats or cofferdams. Besides project-works, wet welding is currently performed on a daily basis with the installation of 270 tonnes anodes (7250 pieces) in the harbours of Rotterdam, the Netherlands. In 2006, Noordhoek spent 450man days on wet welding. 2007 will include a minimum of 1400-man days. Details Please see the www.noordhoek.net website for further information or contact P Feeleus (commercial manager, Subsea Repair) on tel: +31 111 456000 or email: p.feeleus@noordhoek.net
References [1] Specification for Underwater Welding, document AWS D3.6M:1999 Disclaimer Noordhoek has taken all reasonable measures to ensure that material contained in this article is correct. However, Noordhoek gives no warranty and accepts no responsibility for the accuracy or the completeness of the material; no reliance should be made by any user on this material. Noordhoek reserves the right at any time to make changes, as it deems appropriate.

Figure 8. Completed repair

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