Report Final
Report Final
SEMINAR REPORT
ON
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
Submitted by
CERTIFICATE
This is to certify that the Seminar Entitled
INNOVATION IN UNDERWATER WELDING
Submitted by
Piyush Kailas Chaudhari
PRN No: 2254491612503
is a bonafide work carried out by him/her under the supervision of Prof. Yogesh Sonawane
and it is submitted towards the partial fulfillment of the requirement of degree of Bachelor of
Technology in Mechanical Engineering from Dr. Babasaheb Ambedkar Technological
University (DBATU), Lonere.
HOD Principal
I
Acknowledgments
II
Abstract
Underwater welding stands at the forefront of marine engineering, playing a pivotal role in
various underwater construction and repair activities. This seminar report delves into the realm
of innovation within underwater welding, exploring the latest advancements, prevalent
challenges, and the promising future prospects in this specialized field.The report begins by
outlining the fundamental principles and techniques of underwater welding, encompassing both
wet and dry welding methodologies. It then proceeds to highlight recent innovations in
equipment, materials, and techniques, such as the development of advanced welding electrodes,
robotic automation, and novel shielding technologies.Moreover, the seminar delves into the
significant challenges faced by underwater welders, including safety concerns, environmental
factors, and technical limitations. It addresses the ongoing efforts to mitigate these challenges
through improved training programs, enhanced safety protocols, and the integration of cutting-
edge technologies. Furthermore, the report explores the potential applications of underwater
welding beyond traditional marine construction, including salvage operations, offshore energy
installations, and underwater infrastructure maintenance. It underscores the role of innovation in
expanding the scope and efficacy of underwater welding across diverse industries.In conclusion,
this seminar report underscores the critical role of innovation in driving advancements in
underwater welding, while also acknowledging the persistent challenges that must be addressed.
By embracing innovation and leveraging emerging technologies, the future of underwater
welding holds tremendous promise for enhancing efficiency, safety, and sustainability in
underwater operations.
III
Contents
3 Discussions 3
4 Summary and Conclusions 16
5 References 17
IV
List of Figures
V
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.
1
Chapter 2
CLASSIFICATION
1)Dry Welding: Dry welding involves creating a sealed chamber or habitat around
the welding area, allowing the welding to be conducted in a dry environment despite
being submerged underwater. There are two main types of dry welding methods:
3) Wet Welding: Wet welding, also known as underwater welding, involves conducting
welding operations directly underwater without the need for a sealed chamber.
Specialized equipment and techniques are employed to overcome the challenges
posed by the presence of water. Wet welding can further be classified based on the
welding technique and equipment used:
b. Gas Tungsten Arc Welding (GTAW): Also known as TIG (Tungsten Inert Gas)
welding, GTAW can be adapted for underwater welding with the use of specialized
equipment and techniques. This method offers high precision and quality welds,
making it suitable for certain underwater applications.
These classifications provide an overview of the different methods and techniques used in
underwater welding, each with its own advantages and limitations depending on the specific
requirements of the welding operation and the underwater environment.
2
Chapter 3
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.
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.
Power
Electrode holder
Supply
- +
Electrode
Work
Knife switch
3
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 coppercable 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 confusingweld 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.
4
Figure 1 Shielding of the welding arc and molten pool with a covered stick electrode
The electrodes themselves may be either carbon manganese (C/Mn) or mild steelif
you prefer, and stainless steel (duplex). With the rutile mild steel electrodes being the most
widely used, but more about electrodes later.
5
Figure 3 -Picture of wet welding
6
Chapter 4
The principle of operation behind wet welding, also known as underwater welding, lies in
overcoming the challenges posed by working in a submerged environment to join metal
components effectively. Specialized electrodes are carefully selected to create a protective
gas shield around the weld area, preventing water from interfering with the welding process.
These electrodes, often low-hydrogen to mitigate hydrogen embrittlement risks, are
complemented by shielded metal arc welding (SMAW) techniques. In SMAW, the flux
coating on the electrode decomposes upon heating, releasing gases like carbon dioxide and
hydrogen, which envelop the weld area,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.
execute wet welding, a diver-welder utilizes specialized equipment designed to withstand water
pressure and deliver the necessary electric current for welding. Typically, a waterproof electrode
holder is used to hold the welding electrode, which is connected to a welding power source on the
surface via an insulated cable. The electric current generated by the welding power source passes
through the electrode and creates an arc between the electrode and the workpiece, melting both the
electrode and the base metal. One of the key challenges in wet welding is maintaining a stable arc
and preventing the formation of hydrogen bubbles, which can compromise the integrity of the weld.
Specialized welding techniques and coatings are often employed to mitigate these challenges.
Additionally, divers must contend with reduced visibility, buoyancy issues, and the need for
specialized safety procedures to ensure the welder's safety and the quality of the weld.
7
Chapter 5
HYPERBARIC WELDING (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 ofoxygen) at the prevailing
pressure. The habitat is sealed onto the pipeline and filled with abreathable 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 The process of hyperbaric welding typically
involves two main methods: dry chamber welding and habitat welding. In dry chamber
welding, the welder and the welding equipment are enclosed within a rigid chamber that is
pressurized with a gas such as helium or a mixture of gases to match the pressure of the
surrounding water. The welder operates through special gloves attached to the chamber, using
conventional welding techniques to join the metal components.In habitat welding, the welder
operates from inside a flexible, inflatable habitat or enclosure known as a habitat bag. This
habitat is sealed around the area to be welded and then pressurized to keep water out. The
welder works inside the habitat, using welding equipment that extends through the habitat
wall to perform the weld.Hyperbaric welding offers several advantages over wet welding,
including better weld quality and reduced risk of defects due to the absence of water
contamination. Additionally, hyperbaric welding allows for greater control over welding
parameters and improved visibility, which can result in higher productivity and efficiency.
However, hyperbaric welding requires specialized equipment and facilities, making it more
complex and expensive than wet welding.Despite its challenges and costs, hyperbaric welding
is widely used in industries such as offshore oil and gas, marine construction, and underwater
infrastructure for critical welding applications where high-quality, defect-free welds are
essential. Its ability to provide a dry environment for welding underwater makes it invaluable
for complex and precision welding projects in challenging underwater conditions.
8
Chapter 6
RISKS INVOLVED
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.
9
Chapter 7
ADVANTAGES OF DRY WELDING
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.
Longer Weld Life: Welds produced through dry welding tend to have greater
durability and longevity compared to wet welds. The absence of water
contamination and hydrogen embrittlement results in stronger, more reliable welds
that are less prone to corrosion and degradation over time.
10
Chapter 8
DISADVANTAGES OF DRY WELDING
High Initial Investment: Setting up a hyperbaric welding operation requires
significant initial investment in specialized equipment, including pressurized
chambers or habitats, gas supply systems, and safety gear. These upfront costs can be
prohibitive for smaller welding projects or companies with limited budgets.
Complexity: Dry welding operations are more complex and technically challenging
compared to wet welding. Welders must undergo specialized training to work in
pressurized environments and follow strict safety protocols to prevent decompression
sickness and other health risks associated with hyperbaric conditions.
11
Chapter 9
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: -
Lower Cost: Compared to dry welding, wet welding typically requires less
specialized equipment and infrastructure, resulting in lower initial investment costs.
This makes wet welding a more accessible option for smaller welding projects or
companies with limited budgets.
Flexibility: Wet welding allows for greater flexibility and mobility compared to dry
welding. Welders can move freely underwater to access different weld locations and
work on a variety of submerged structures, including ships, pipelines, and offshore
platforms.
12
Chapter 10
Although wet welding is widely used for underwater fabrication works, it suffers
from the following drawbacks: -
1. Reduced Weld Quality: The presence of water during wet welding can
introduce impurities and contaminants into the weld, leading to reduced weld
quality and integrity. Factors such as hydrogen embrittlement and the
formation of porosity or cracks can compromise the strength and durability of
wet welds.
2. Hydrogen Embrittlement: Wet welding exposes the weld and base metal to
water, which can lead to the absorption of hydrogen gas into the weld zone.
Hydrogen embrittlement can weaken the weld metal, making it more
susceptible to cracking and failure over time, especially in high-stress
environments.
3. Limited Visibility: Underwater visibility is often poor, particularly in murky
or turbid waters, which can hinder the welder's ability to see the weld pool and
workpiece clearly. Poor visibility increases the risk of welding defects and
makes it challenging to ensure proper weld penetration and alignment.
4. Buoyancy and Stability Issues: Welders working underwater must contend
with buoyancy forces that can affect their stability and control while welding.
Maintaining proper positioning and stability can be challenging, particularly in
strong currents or turbulent underwater conditions, leading to difficulties in
achieving consistent weld quality.
5. Safety Concerns: Wet welding poses unique safety risks to welders, including
the potential for electric shock, drowning, and injury from underwater hazards
such as marine life, entanglement, and underwater debris. Welders must
undergo specialized training and adhere to strict safety protocols to mitigate
these risks and ensure their safety while working underwater.
6. Corrosion and Contamination: The underwater environment is highly
corrosive, with seawater containing salts and other corrosive agents that can
accelerate metal corrosion.
13
Chapter 10
DEVELOPMENTS IN UNDER WATER WELDING
several developments have occurred in underwater welding, aimed at improving efficiency,
safety, and the quality of welds. Some notable advancements include:
15
Chapter 12
CONCLUSION
Conclude by reaffirming the importance of innovation in underwater welding and its role in
advancing various industries. Stress the need for collaboration between researchers, industry
professionals, and policymakers to continue driving innovation in this field. Finally, express
optimism about the future of underwater welding and its potential to revolutionize underwater
construction and maintenance practices.
16
REFERENCES
17