UseofUnderwaterDry

WeldingforInSitu
RepairtoOffshore
Structures

ElleftheriaDeligeorges;JaiTulsi
engineering@neptunems.com
11/03/2015
InSituWelding

SteelStructures

SuitabilityofRepairMethods

MobileOffshoreUnits
DryDockingSchedule(Inspectionand
Repair)
UnderwaterInspectionInLieuofDry
Dock(UWILD)

FixedOffshoreUnits

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DifficultiesinWelding

WeldingChallenges

DiverandOperationalChallenges

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WeldingChallenges

Water
RapidCoolingRates
Hydrogen
Cracking

AmbientPressure
Porosity

Material
Highercarboncontent(Older) NoShieldingGasonSteel.[Online].[Accessed23February2015].
Availablefrom:http://www.millerwelds.com
AlloyedSteels

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OperationalChallenges

WelderChallenges
Environment
Seastateandcurrent
Visibility
WeldLocation
AccesstoWeldArea
Fatigue
Technique

RepairTimeChallenges
Divingweatherwindow
Depthlimiteddivetime

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WeldingCodes

WeldingProcedureSpecification

ClassificationBodyCodes
DNVGL
ABS
LloydsRegister
BureauVeritas

AWSD3.6 UnderwaterWeldingCode(2010)
WeldClassification
ClassA suitableforcomparableapplicationstosurfacewelding
ClassB suitableforlesscriticalapplicationsandfitnessforpurpose
ClassO meetadditionalcodeorstandardrequirements

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WeldingProcedureSpecification

Adocumentwhichoutlinesthestepstobe
followedtoproduceaweldwiththerequired
properties.

SomeEssentialVariables:
Depth
AmbientPressure
Steelchemicalcomposition(Carbonand
CarbonEquivalent)
Hardenability(350HV10)
Weldingconsumables
Pre andPost Heating

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WeldClasses
Class A ClassB
VisualInspection / Novisiblecracks,porosity,or Novisiblecracks
SurfaceInspection inclusions
Maximumundercut1.5mm Maximum undercut3mm
Material Properties Weldmetalyieldandtensile Weldmetaltensilestrengthto
strengthtomeetor exceedbase meetor exceedbasematerial
materialspecification specification
Hardnessbelow325HV10 Hardnessbelow375HV10
Forspecified tensilestrength Forspecified tensilestrength
below485MPa,averageimpactof below485MPa,averageimpactof
27J(minimum14J) 20J(minimum14J)
NonDestructive Radiographic Testing RadiographicTesting
Testing UltrasonicTesting
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MethodsofUnderwaterWelding
WetWelding DrySpotWelding HyperbaricWelding
Weldingarcand NEPSYS Weldisseparatedfrom
weldisnot Weldisseparatedfromthe thewater
separatedfromthe water Diverisnotseparated
water Diverisseparatedfromthe fromtheweld
weld

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WeldingMethodComparison
Wet DrySpot(NEPSYS) Hyperbaric
TypicalQuality Class B ClassA ClassA
RepairDepth Achievedupto100m Achievedupto 60m Achievedupto400m
CarbonContent<0.1%, Restrictions comparable Restrictionscomparable
andCarbonEquivalent tosurfacewelding tosurfacewelding
RepairMaterials <0.37%
Limitedwetwelding Varietyofelectrodes Varietyofelectrodes
specificelectrodes maybeused maybeused
Almostnilrestrictions Somerestrictionsdue Restrictions dueto
Application toweldareageometry tohabitatsizeandweld chambersizeandweld
areageometry areageometry
Weldermobility Weldermobility SeparationofWelder
Safety SeparationofWelder and water
andweld
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TypicalCommercialComparison
Wet DrySpot(NEPSYS) Hyperbaric
WeldandWelderqualification
Qualification
andSetUp Smallhabitatdesign/ Largechamberdesign/
fabrication fabrication
Personnel
Divingspread
Project
Mobilisation Weldingequipment Welding/habitat Welding /chamber
andconsumables equipmentand equipmentand
consumables consumables
Vessel/personnel
Weldingspeed Habitat setup/removal Chambersetup/removal
Operations comparableto bydivers byvesselcrane
surfacewelding ReducedWeldingSpeed Weldingspeedcomparable
to surfacewelding
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TypicalCommercialComparison
Wet DrySpot(NEPSYS) Hyperbaric
Qualification Days toWeeks WeekstoMonths Months
andSetUp LowCost MediumCost HighCost
Project DaystoWeeks DaystoWeeks Weeks
Mobilisation LowCost LowtoMediumCost HighCost
Operations SmallVessel SmallVessel LargerVesselincluding
crane
Lownumberofdives Mediumnumberofdives Lownumber ofdives

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CaseStudy NEPSYSSystem

Habitatwhichisolatestheweldareais
designed.
Accommodatesthegeometryofthearea
surroundingtheweld
Incorporateswindowsforvisibilityand
accesstotheweld
Heatedgasdisplacesthewater,creatinga
dry,protectedenvironmentforwelding
WeldingRodsarecoatedandhermetically
sealedtoprotectfromtheenvironment
beforebeingusedinwelding

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CaseStudy

1.5mdiameterrakedpile
Approximately25%ofthecircumferencewas
damagedat17mLAT
Damagetotheundersideofthepile
ContactedbyclientinAugust
GroutingofpilesinOctober

Optionsforrepair:
RemovalandRepiling
Clamp
RepairPatchviawetweld
ReinstatementofMaterialviadrywelding

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WeldingQualification

BaseSteelhadhighCarbonContent
0.18%(CE0.44%)
InitialHardnessTesting Maximum
276HV10

Weldpreparationdesignedtominimise
weldingtime
ProcedurequalificationintheVertical
andOverheadpositionsoverthreeweeks
QualificationinPerthwitnessedbythird
party
Multiplewelderqualification

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InsertPlateandHabitatDesign

Insertplatedesignadaptedfor
damageprofile,weldingprocedure
Habitatdesignadaptedforinsert
plateprofile
Habitatfabrication(oneweek)

Removalofdamagedareaviawater
jettingwhichleftedgessuitablefor
welding
Insertplateinstallationallowed
progressionofgroutingworks

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Operations

MobilisationfromPerthtoQueenslandof
NEPSYSequipmentandpersonnel
Operationsconductedwithlocaldivespread
Divingfromthebackofa15mworkboat
Nitroxmixtureusedtoensurelongerdive
timesattherepairdepth
Fourqualifiedwelders
Approximately45hoursofwelding
2800mmofweldin16mmplate

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Results

Weldgroundflushtothepile
NosurfacedefectsfoundviaMagnetic
ParticleInspectionorCreepWave
UltrasonicTesting
NosubsurfacedefectsfoundviaShear
WaveUltrasonicTestingorTimeofFlight
Diffraction
Damagedareafullyremovedfromthepile
andreinstated
Designstrengthofthepilerestored

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Conclusion

Insiturepairoptions

SuitabilityofWeldingMethods

Questions?

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