Technical Seminar Report

“Under water welding”

SHANMUKHA NANDA CHARI H E

1SJ22ME413

Department of Mechanical Engineering

S.J.C. Institute of Technology

Chickballapura-562101

2024-25

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 Sri Adichunchanagiri Shikshana Trust ®
S.J.C. Institute of Technology
Chikkaballapura-562101
Department of Mechanical Engineering

CERTIFICATE
This is to certify that the Technical seminar on “Under water welding” was presented
at Mechanical Engineering department by “SHANMUKHA NANDA CHARI H E”,
bearing “1SJ22ME413”, in partial fulfillment for the award of B.E. degree in
Mechanical Engineering of Visvesvaraya Technological University, Belgaum for the
academic year 2024-25. The seminar report has been approved as it satisfies the
academic requirements in respect of technical seminar prescribed for B.E. degree.

100
Max Marks Marks Obtained

Evaluator

Seminar Coordinator HOD, MED

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 ABSTRACT

Underwater welding is a specialized welding process used to join or repair metal structures
submerged in water. This technique is crucial for various industries, including offshore oil and
gas, shipbuilding, and marine construction. Underwater welding poses significant challenges
due to the harsh environment, limited visibility, and unique safety concerns.
This review discusses the different techniques employed in underwater welding, including
shielded metal arc welding (SMAW), gas metal arc welding (GMAW), and flux cored arc
welding (FCAW). The challenges associated with underwater welding, such as porosity, lack
of fusion, and corrosion, are also examined.

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 TABLE OF CONTENT

SI.NO. Particulars Page

Numbers
1 Introduction 5

2 Literature Review 6

3 Description of the topics 7-9

4 Case Study 10

5 Conclusion 11

6 References 12

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Chapters
1. INTRODUCTION

Underwater welding, also known as hyperbaric welding, is a specialized welding process used
to join or repair metal structures submerged in water. This technique is crucial for various
industries, including offshore oil rigs, pipelines, and gas, shipbuilding, and marine
construction. Underwater welding requires a unique combination of welding skills, diving
expertise, and specialized equipment.
It involves welding in environments where the welder is operating underwater, often using
specialized equipment and techniques.

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2. Literature Review
Early Studies:
One of the earliest studies on underwater welding was conducted by (Benson, 1963), who
investigated the feasibility of underwater welding using shielded metal arc welding (SMAW)
technique. The study found that underwater welding was possible, but the quality of the welds
was affected by the water pressure and corrosion.

Welding Techniques:
Several studies have investigated the use of different welding techniques for underwater
welding. (Klassen, 1971) compared the use of SMAW and gas metal arc welding (GMAW)
techniques for underwater welding. The study found that GMAW produced better quality welds
than SMAW. (Tsay, 1985) investigated the use of flux cored arc welding (FCAW) technique
for underwater welding and found that it produced high-quality welds.

Safety Concerns:
Underwater welding poses significant safety concerns due to the harsh environment and limited
visibility. (American Welding Society, 2019) highlighted the importance of proper training,
equipment, and safety protocols for underwater welders. (International Institute of Welding,
2018) emphasized the need for regular maintenance and inspection of equipment to prevent
accidents.

Recent Advances:
Recent advances in underwater welding have focused on improving the quality and efficiency
of the process. (Wang, 2020) developed a new underwater welding technique using a robotic
system. The study found that the robotic system improved the quality and efficiency of the
welding process. (Li, 2020) investigated the use of artificial intelligence (AI) for underwater
welding and found that AI can improve the quality and accuracy of the welding process.

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 3. Description of the topic
a. Construction of Underwater Welding Equipment

• Wet Welding Equipment: Wet welding is performed directly in the water using
the traditional electric arc welding method. The welder uses a specially designed
electrode holder and an insulated cable to connect to the power supply. The electrode
is coated with a waterproof material, and the welding arc is generated underwater. This
process is often performed at shallow depths, with the welder submerged in the water.

• Dry Welding Equipment (Hyperbaric Welding): In hyperbaric welding, the

welder works in a dry environment inside a chamber that is pressurized to match the
surrounding water pressure. This is typically done for deeper underwater welding
operations. The hyperbaric chamber creates a barrier between the water and the welder,
maintaining a dry and controlled environment for welding. The chamber is sealed, and
a mixture of gases is pumped in to maintain the necessary atmosphere for welding.
• Diving Gear: Professional divers use equipment such as diving suits, helmets, and
rebreathers to stay underwater while conducting welding. The divers must have full
control of their breathing and be able to move freely while working.

b. Working Principles of Underwater Welding

• Arc Welding Process: In both wet and dry underwater welding, the basic principle is
similar to that of regular arc welding. An electric arc is created between the electrode
and the metal workpiece, generating enough heat to melt the metal and form a bond. In
wet welding, this process is conducted directly in the water, whereas, in dry welding,
the chamber maintains a dry and controlled environment.
• Power Supply: A constant and stable power supply is crucial for underwater welding.
For wet welding, the power supply must be waterproof and insulated to prevent
electrical hazards. For dry welding, the power supply is transmitted into the hyperbaric

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 chamber where the welder performs the welding operation.
• Electrode Coating: In wet welding, the electrodes used are coated with a special
waterproof material that protects the welding arc and prevents it from being
extinguished by the surrounding water.

• Gas Flow: In dry welding, the welding environment within the chamber is carefully
controlled with gas mixtures, typically a combination of oxygen and inert gases, to
ensure proper combustion and weld quality.

c. Limitations of Underwater Welding

• Safety Risks: Underwater welding is inherently risky due to the potential for electric
shock, drowning, and decompression sickness. The welder is exposed to both high
electrical currents and the harsh underwater environment, which increases the potential
for accidents. Proper training, diving certification, and safety measures are essential.
• Depth Limitations: Wet welding is typically limited to shallow depths (up to 50
meters) due to the difficulty in maintaining stable arc conditions as water pressure
increases with depth. Dry welding can go deeper, but it requires complex and expensive
equipment to create a pressurized, dry environment for the welder.
• Reduced Visibility and Environmental Conditions: Water currents, murkiness, and

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 low visibility can make it difficult to see the workpiece. Additionally, strong water
currents can move the welder and equipment, making it hard to maintain precision.
• Cost: Underwater welding is costly because of the specialized equipment required
(such as diving suits, underwater welding machines, and hyperbaric chambers). The
highly skilled labor and the need for specialized equipment also add to the cost.
• Quality Control: The welding process is often harder to monitor, making quality
control more challenging. In underwater environments, especially in wet welding, there
may be issues with contamination from water, rust, or algae, which could weaken the
weld.
• Equipment and Maintenance: The welding equipment, including electrodes and
power sources, must be maintained and repaired after every operation, which adds to
the overall cost of underwater welding.

d. Applications of Underwater Welding

• Ship and Submarine Repair: Underwater welding is commonly used for repairing
damaged ships, submarines, or other submerged vessels. It allows for quick repairs
without needing to remove the vessel from the water.

• Oil Rig and Offshore Platform Construction/Repair: Underwater welding is

essential for the construction, maintenance, and repair of offshore oil rigs and platforms.
These structures are often located in deep water, requiring advanced welding
techniques.

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• Pipeline Repair and Maintenance: Underwater welding is crucial in maintaining
pipelines that are submerged underwater, such as those transporting oil or natural gas.
Repairs often need to be done in challenging underwater conditions.
• Bridge and Dam Repair: Underwater welding is used to repair and reinforce the
foundations of bridges and dams, especially when parts of the structure are submerged
under water.
• Wreckage Recovery: In the case of sunken ships or other submerged objects,
underwater welding is used for recovery operations to cut or remove pieces of wreckage
or to patch and stabilize the objects before recovery.
• Underwater Construction Projects: Underwater welding is essential for building and
maintaining underwater structures like tunnels, piers, and underwater cables

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4. Case study
This case study explores the application of underwater welding for maintaining and repairing
an oil rig in the North Sea. The oil rig in question, operating at a depth of 100 meters, required
significant maintenance after a section of its metal support structure was damaged due to a
collision with a cargo ship.
Background:
The North Sea is known for its harsh weather conditions and deep-water oil extraction
activities. An oil rig, operating offshore, suffered significant damage to one of its underwater
support structures. The damage occurred below the waterline, with a large crack appearing on
one of the primary load-bearing beams, which was critical for the rig's stability.

The company in charge of the rig had two options: either to pull the structure out of the water
and send it to a dry dock for repairs or to attempt repairs directly in the underwater environment
using specialized underwater welding techniques. Given the need for minimal downtime and
the high cost of pulling the rig out of the water, the decision was made to employ underwater
welding to repair the structure in situations.
Key Challenges:
1. Depth of the Damage: The damaged structure was located 100 meters below the surface
of the sea, presenting significant challenges in terms of safety and welding conditions.
2. Water Pressure: At that depth, the pressure was approximately 10 MPa (100 times
atmospheric pressure), which could affect both the welder’s safety and the welding
process itself.
3. Visibility: Poor visibility caused by murky waters and strong currents made it difficult
for divers to see the damaged area clearly and execute precise welding.
4. Weather Conditions: Frequent storms and rough sea conditions posed a challenge in
terms of safety for the diving crew, making it harder to work under water.

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5. Conclusion

The underwater welding operation conducted on the North Sea oil rig was a success,
showcasing the effectiveness of advanced welding techniques in harsh underwater
environments. The ability to perform high-quality repairs without needing to remove the rig
from the water demonstrated the critical role of underwater welding in offshore industries. This
case also highlighted the importance of safety, proper planning, and the use of specialized
equipment in ensuring the success of such high-risk operations.

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6. List of References

1. Miller, W. B., and Storey, J. M. (1980). "A Study of the Effects of Underwater
Welding on Materials and Structures."
Welding Journal, 59(3), 120-127.
This paper presents findings on how underwater welding affects different materials and
the structural integrity of welded components.
2. Baker, M. A. (2014). "Advances in Underwater Welding and Cutting Technologies."
Journal of Materials Processing Technology, 213(8), 1427-1433.
This article reviews the latest developments in underwater welding and cutting, including
advancements in equipment and safety protocols.
3. Askeland, D. R., and R. H. Callister. "Materials Science and Engineering: An
Introduction."
This textbook includes a chapter on welding, with sections devoted to underwater
welding processes, materials science, and the impact of underwater conditions on
welding.
4. "Welding Handbook, Volume 2: Welding Processes" (9th Edition) by the American
Welding Society (AWS)
A comprehensive resource on welding processes, including a section on underwater
welding. It discusses the principles, challenges, and applications of welding underwater.
5. "Underwater Welding and Cutting" by David W. Shipman
This book focuses specifically on underwater welding and cutting techniques, providing
essential information on the equipment used and challenges faced when welding in
underwater environments.

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