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 underwa-
ter 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 coffer-
dam deployment), and the
speed with which the prepara-
tion and operation can be car-
ried out, the wet underwater
welding process should definite-
ly be considered as permanent
and routine repair methodology
on structural applications (rigs,
platforms, FPSO/FPS, semi-sub-
mersibles, etc.).
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-
Figure 1. Wet welding versus “workshop” welding
vailing pressure), and wet
underwater welding refers to
welding which is performed in
fresh- or salt-water without a
protecting habitat. Wet under-
water welding will here after be
referred to as “wet welding”,
and wet/dry underwater weld-
ing 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 dif-
ferences for the welding equip-
ment (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 electrocu-
tion, and the use of double
insulated cables.
Both the power source and
knife switch (capable of break-
ing the full wet welding cur-
rent) 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 sufficient-
ly flexible; special welding elec-
trode holders are used with
extra insulation against the
ingress of water.
CONSUMABLES
Electrodes for wet welding of
mild steel (C/Mn) and stain-
less/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 differ-
ence between dry welding elec-
trodes and wet welding elec-
trodes is an added waterproof
coating, and sometimes an
additional added paraffin coat-
ing (over the primary water-
proof coating). Wet welding
consumable suppliers have
developed their own (confiden-
tial) flux formulations, filler
metals and supplementary
coatings, and consequently
each electrode has it own spe-
cific wet welding characteristics.
Selection of suitable wet weld-
ing electrodes can be done after
proper understanding of the fol-
lowing, critical, selection criteria:
● Base material composition
● Required mechanical prop-
erties
● Metallurgic requirements,
● Cracking risks
● 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 elec-
trodes. 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 rela-
tively high moisture propor-
tions initiated during the elec-
trode 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 prop-
erties and/or weldability, but
hydrogen inclusion is still a
concern. Hydrogen controlled
electrodes generate a hydrogen
percentage below the require-
ments specified in the codes
▲
because the moisture levels
25
 WELDING
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 elec-
trodes) and storage (in a dry
controlled environment).
WET WELDING QUALITY
Historically wet welds have
lacked ductility, have high hard-
ness values and have suffered
from hydrogen cracking and
brittleness. The internal proper-
ties of wet welds have improved
with the currently available wet
welding electrodes, and the
majority of these properties are
accurately under control. See
ADVERT
26
Figures 2 to 4 for example
results of performed underwa-
ter 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 materi-
als, 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 weld-
ing 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 envi-
ronmental conditions (currents
and sea state). Apart from
workmanship, the other param-
eters can not be influenced.
Typical wet welding mechani-
cal properties achieved in our
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” posi-
tion 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 -20°C
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
ADVERT
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 cir-
culation issues and hypother-
mia. 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. cut-
ting, grinding, cleaning and
welding) increase these diving
related risks significantly. These
diving parameters are impor-
tant in relation with the nitro-
gen levels of the blood stream.
Precautions include the provi-
sion 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 [490-630 N/mm2]
442N/mm2 [>414N/mm2]
17.2 % [>14%]
31 joule [>27joule]
225HV 10 [<325HV10]
192HV 10 [<325HV10]

work procedures, permits, etc.
CODES, STANDARDS AND
QUALIFICATIONS
Industry standards for wet and
dry underwater welding have
been set by the American Weld-
ing Society (AWS), standard
D3.6. The most important
aspects defined within this code
are briefly explained in the fol-
lowing paragraphs.
Classification of wet welds:
Underwater welding is specified
Figure 5. Turtle between platform bracings using three quality levels, Class
A, B and C. Class O is recog-
International Marine Contrac- taken to avoid the build-up of nised as underwater welding
tors Association (IMCA) and/or pockets of gas, which generates a following other, usually as strin-
government legislations. potentially explosive mixture. gent as Class A, quality criteria
The main wet welding related Other important health and which are usually specified by
health and safety issues involve safety aspects of wet welding client requirements. The weld
electric shock and explosion involve eye-protection and elec- classifications for wet underwa-
risks. Precautions on electric trolysis deterioration of diving ter welding or dry underwater
shocks include adequate electri- and welding equipment. welding are similar.
cal insulation of the welding It is obviously of the utmost Class A underwater welding
equipment, shutting off the elec- importance to recognise, man- covers a stand-alone set of
tricity supply immediately after age and control these wet requirements comparable to
the arc is extinguished (knife welding and diving associated welds produced above water
switch), and limiting the open- risks in any project through (suitable for structural applica-
circuit voltage of welding sets. the development of project- tions) in accordance with AWS
Secondly, hydrogen and oxygen specific health and safety D1.1 or ASME Section IX. The
are produced by the arc in wet plans, general risk assess- performed underwater welds
welding – precautions must be ments, job hazard analysis, are qualified on the basis of
visual and X-ray examination,
reduced section tension, all
weld-metal tension, 2T to 2-
1/3T bends, macro-etch, hard-
ness 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
Figure 6. Wet underwater welding result requirements representing a
ADVERT
WELDING
slightly lower level of quality,
but still resulting in an under-
water weld of predictable
strength. Class B underwater
welds are intended for less criti-
cal applications where reduced
ductility and increased porosity
can be tolerated. The main dif-
ference 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 under-
water welding and are intended
for applications where the load-
bearing function is not a primary
consideration. Class C underwa-
ter welding is usually performed
for temporary welds or minor
attachments to structures. The
qualification criteria basically
ensure that the primary structur-
al integrity is not impaired.
Underwater Welding Proce-
dure 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 per-
formed within a limiting depth
envelope. For instance, the qual-
ifications for a underwater weld-
ing operating with carbon steel
filler material designated at a
water depth of 10 metres should
be performed within a maxi-
mum 20-metre and minimum
two-metre envelope. Qualifica-
tion for underwater welding
with austenitic stainless steel
filler material at the same oper-
ating depth should be per-
formed within a maximum 13-
metre and minimum
▲
27
▲
WELDING
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 singe-
pass fillet weld is not qualified by
groove welds qualification. Joint
assembly tolerances for under-
water welding shall be devel-
oped during the welding proce-
dure 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 inspec-
tions 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
28
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 impor-
tant to recognise the wet weld-
ing quality limitations relating
to the joint configuration and
position (i.e try to avoid over-
head wet welding).
Secondarily, the wet welding
contractor qualifies a wet weld-
ing 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, div-
ing equipment used, water tem-
perature, and power supply. The
type of wet welding WPS for
which a company wants to qual-
ify 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 8. Completed repair
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 quali-
fy the needed number of
diver/welders for the job.
NOORDHOEK CAPABILITIES
The Subsea Repair Depart-
ment of the Noordhoek Off-
shore BV is recognised in the
offshore underwater repair seg-
ment and has extensive experi-
ence in operating in offshore
environments related to oil and
gas business. The Department
is specialised in turnkey execu-
tion 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 instal-
lation of 270 tonnes anodes
(7250 pieces) in the harbours of
Rotterdam, the Netherlands. In
2006, Noordhoek spent 450-
man 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 e-
mail: 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 war-
ranty and accepts no responsibility
for the accuracy or the completeness
of the material; no reliance should
be made by any user on this materi-
al. Noordhoek reserves the right at
any time to make changes, as it
deems appropriate.