Orbital Welding and Subsea Applications

Orbital welding is a computer based welding process which is typically used to generate high quality, repeatable welds.  Welding specifications are completely programmed into the machine before welding begins, and once it does, there is minimal interference required by the operator, reducing the risk of human error.

As orbital welding is a computer controlled process, welds generated via an orbital welding procedure are both repeatable and consistent.  This is due to the operator’s ability to program specific parameters into the machine, including an alarm or ‘cease welding procedure’ should these parameters not be met.  Welding programs can be set in such a way that very strict tolerances are automatically monitored and adhered to, which allows the operator to meet essential welding variables with ease.  This process is particularly effective when working with thin wall and small diameter tubing, from which subsea hydraulic lines are predominantly fabricated.

There are two different types of orbital welding machines: autogenous, which does not use filler wire, and non-autogenous, which does.  When using an autogenous machine the operator gains the ability to better control the internal weld bead profile as there is no wire being used.  This eliminates the risk of internal bore reduction as required in hydraulic & control line tubing systems.  The risk of external weld contamination is also reduced due to the closed head welding environment.  For this reason, the majority of orbital welding performed by Diverse Welding Services is done so using an autogenous welding process.

Diverse Welding Services have both types of machines available, with qualified personnel & procedures for use of both systems on super duplex, duplex, inconel 625 and 316 stainless steel.  These materials are widely used for subsea applications as they combine high corrosion resistance and high mechanical strength with excellent resistance to seawater and marine environments.  For these reasons they are particularly well-suited for applications exposed to high stress in aggressive chloride-rich environments.

When fabricating or repairing subsea piping systems, orbital welding is preferred over manual welding as the welds produced are of an extremely high quality and have an exceptionally low failure rate when tested via 100% radiographic testing regimes.  Corrosion resistance rates are also maximised in the ‘as welded’ condition, proven by DWS, when samples tested under the G48 Method A – Pitting Resistance Test resulted in weight loss to be less than 0.36g/m2 for stainless steel. 

Orbital welding has many advantages.  The machine controls heat input, and so material quality and integrity is easily maintained.  The machine also features a recording data log which enables the user to track weld processes and guarantee consistency.  Due to the enclosed structure of the weld head, gas is kept inside the head and as such is effective when welding in confined spaces and challenging environmental conditions.  This feature decreases the amount of gas required and is therefore more economical than standard manual welding.  Inspection procedures are also simplified as the orbital welding machine prints a docket listing the parameters which have been adhered to whilst welding has taken place, meaning the operator does not have to be supervised to ensure the welding performed meets the welding procedures and standards required.  Welds are also generated in a faster weld time when compared to manual tig welding.

As the development of new energy reserves increases, so does the need for subsea infrastructure.  The ability to supply high quality, internationally competitive subsea fabrication is crucial to the ongoing growth & success of the Australian oil and gas industry.  There are currently a large number of unprecedented technical challenges involved with subsea oil and gas development and orbital welding is playing an increasingly vital role.

Oil & Gas Australia Publishes Article on Diverse Welding Services Pty Ltd

Diverse Welding Services is proud of its involvement in the Wheatstone project, and was happy to provide Oil & Gas Australia journalists details on our work history for their October 2015 publication.

Follow our link to read the article.

Oil & Gas Australia

Swagelok Tube Fitting Installation & Bending Training

Our General Manager John Lipscombe & Operations Manager Terry Mallinder, as well as four of our valued fabricators have successfully completed the Swagelok Tube Fitting Installation & Bending course.  Throughout the course they learnt how to select the correct fittings, install fittings to the manufacturer's installation specifications, and general good installation practices.

As we use Swagelok fittings in a variety of applications, it is crucial that our staff are correctly trained in their specifications to ensure our products are manufactured to the highest possible standard.  As customer satisfaction is what we strive for, it is imperative to us that we continue to upskill our staff and as a result will be enrolling remaining staff into this course over the coming months.

DWS Manufactures MQC Deployment Frame for Technip

DWS has recently completed an MQC Outboard Test Plate & two Female Test Plates for Technip Oceania.  This included the manufacture of an MQC Protection Panel, Half Shell Bracket & a Deployment Frame.  These have been manufactured as part of the Chevron/Technip Wheatstone Project and will be temporarily installed underwater to be used for testing purposes.  Once testing has been completed, they will be removed and the SSIV's (which our our MQC Plates have been installed onto) will be permanently installed into place.  Please see our Projects page for more photos!


Technip MQC Test Plate/Deployment Frame

DWS is Expanding!!

We at DWS are proud to announce that we have taken over the block next door at 14 Arvida Street and now have two workshops!  We are currently making a few alterations to the new workshop and adjoining it to our original building so that there is internal access between the two.  We also have plans to install a new 12.5 tonne overhead gantry crane at no.14, which will further expand our on site capabilities.

DWS Ongoing Plant Upgrades at Perrigo Laboratories

DWS is in the process of assisting Perrigo Laboratories with a pharmaceutical plant upgrade which will allow for increased alcohol mixing and storage facilities.  This project includes:

  • Supply & installation of pipework & process piping
  • Supply & installation of drain & transfer lines
  • Supply & installation of a CIP cleaning skid and associated pipework
  • Supply & installation of access platforms
  • Modifications to existing systems
  • UV steriliser relocation (2)
  • Pipe supports and gantry's
  • Pressure testing, passivation and documentation

We are proud to be working with such a reputable company and honoured that they have chosen to trust us to perform this work.


Chemical Manufacturing Equipment Upgrades at Bayer CropScience

For the past 6 months, DWS has been undertaking a variety of works at Bayer CropScience in Kwinana to allow them to mix a greater volume (and new varieties) of chemicals.  These works include, but are not limited to:

  • Installation of new mixing vessel
  • Installation of new dust & fume extraction system throughout the entire facility
  • Refurbishment of all existing vessels

DWS Time Lapse

October 2014 to Febuary 2015 was an extremely busy period of time for Diverse Welding Services.  During this time we completed many projects, including the Technip MQC Plates & Small Bore Instrument Tubing Package for the Wheatstone Project, which we captured in a time lapse video.  At the completion of FAT's the MQC plates were packaged & shipped to Batum, Indonesia in preparation for permanent installation to their subsea manifolds.  Thankyou to Technip & Chevron for allowing DWS the opportunity to complete this manufacturing package within Australia.  We hope you enjoy the video!!

Website launch!!

We are proud to announce that our website has gone live!  We look forward to being able to keep our vast client and supplier network up-to-date with our projects and general news.