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If the issues are analyzed, there is no valid reason not to consider underwater
welding, especially if production losses due to outage for repairs is punitive. Sunsea
welding generally needs specialized welding knowledge combined with diving skills,
which is more demanding than run-of-the-mill commercial divers can offer. Subsea
welding covers areas of repairing pipelines, offshore oil platforms and ships.
Subsea welding also reduces the cost for the company by directly carrying out the
welding work on location, saving time lost in production to the company.
Furthermore, because of the offshore exploration, drilling, and recovery of gas and oil
in deeper waters today, it is necessary to have the capability to repair pipelines and
the portion of drill rigs and production platforms which are deep underwater.
When subsea welding is completed, both the welder and the structures being welded
are at risk. The welder has to be very careful to avoid receiving an electric shock. For
this, adequate precaution is taken by insulating the welder and limiting the voltage of
welding sets. Continuous control of hydrogen and oxygen build-up is managed by
removal and kept away from the arc to minimise any potential explosion.
Lastly, the welders time under water is controlled by using saturation diving
chambers and regular rest periods in between. Inspection of an underwater weld is
very difficult and complicated when compared to surface welding, but as it is the only
controlling process of the quality of the weld, it is always done. The weld is inspected
very carefully to confirm that no defects remain.
There are many underwater welding schools located in different parts of the world,
including Australia, to train commercial divers. Historically, underwater welding was
restricted to salvage operations and emergency repair work with limited depths of
less than 9 m.
Because of the poor quality and difficulty in the process of welding underwater in the
past, welding in the wet environment was used primarily for emergency repairs in
shallow water. For example, to weld a patch for short duration until a complete repair
could be performed in dry docks. With more experience and the advent of special
welding rods and the persistence of some ambitious individuals and companies
improved results were achieved, which has made wet welding a common occurrence.
Todays underwater arc welding is accomplished in much the same manner as
ordinary arc welding the only variations being that the electrode holder and cable is
well-insulated to eliminate any possible current leakage and electrolysis of the
surrounding water and the coated water-proof electrodes are used so that the
electrodes do not get wet.
The most commonly used wet welding technique is shielded metal arc welding,
informally known as stick welding. The main differences in wet welding equipment
versus onshore welding equipment is that wet welding uses DC current only.
AC is not used as it can electrocute the diver and it is difficult to maintain a welding
arc underwater with AC. The inclusion of a single or dual circuit breaker switch and
the use of double-insulated cables protect the diver from electrocution. The power
source should be a direct current machine rated at 300 or 400 amperes. Motor
generator welding machines are most suitable for underwater welding.
The pipe itself represents the key member of the repair assembly with consequential
limitations such as, but not limited to, pipe wall strength, surface irregularities, and
deviations in shape. Fittings for sub-sea repair must be installed with caution to
reduce the likelihood of damage. Coupling strength should be sufficient in resisting
stresses from all relevant loads, within a factor of safety as defined in the standard.