The purpose of this study is to investigate the evolution of residual stress during designing a 89-pass narrow gap welding of nuclear rotor pipes. A two-dimensional finite element model is employed to calculate the residual stress in welding process and heat treatment process, and then the evolution of residual stress during the welding process was discussed in detail. The investigated results show that the overall trend of hoop stress on the inner surface decreases gradually before pass 30, while the trend remains unchanged after pass 30. The through wall axial residual stress at the weld centreline demonstrates a distribution of bending type before pass 38, while this bending type distribution turns into a clearly self-equilibrating type after pass 38.
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