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This research proposes FEM analysis for Tandem welding process used in wind tower and predicts optimal welding process to improve the stability of welded structures. Three dimensional elasto-plastic analyses are employed to evaluate thermo-mechanical behavior of residual stress and deformation during Tandem welding for different distance between two touches. To confirm the thermal distribution, Goldak’s ellipse heat source model and the real size wind tower pipe model are utilized. Four different analyses are being performed, where in each case the distance between two electrode torches is being changed and residual stress and welding deformation are predicted. Depending on base material state, each case is divided into: Liquid (100mm), Austenite+Liquid (200mm), Austenite+Cementite (400mm), Pearlite+Cementite (800mm).