S0300-BB-MAN-010 0910-LP-111-3300 U.S. NAVY UNDERWATER CUTTING & WELDING MANUAL DISTRIBUTION STATEMENT A: THIS DOCUMENT HAS BEEN APPROVED FOR PUBLIC RELEASE AND SALE; ITS DISTRIBUTION IS UNLIMITED.
S0300-BB-MAN-010 LIST OF EFFECTIVE PAGES Date of Original Pages is: 1 April 1989 Date of Change A Pages is: 15 September 1995 Date of Change B Pages is: 1 June 2002 Page No.* Change No. Page No Title and A . . . . . . . . . . . . . . . . . . . . . . . . . . B Certification Sheet . . . . . . . . . . . . . . . . . . . . B blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O Change Record . . . . . . . . . . . . . . . . . . . . . . . O Change Record-2 blank . . . . . . . . . . . . . . . .
DEPARTMENT OF THE NAVY NAVAL SEA SYSTEMS COMMAND WASHINGTON, D.C. 20362 NAVSEA S0300-BB-MAN-010 U.S. NAVY UNDERWATER CUTTING & WELDING MANUAL 0910-LP-111-3301 CHANGE B 1 June 2002 PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND NAVSEA S0300-BB-MAN-010 is changed as follows: 1. Remove old pages and insert new pages as indicated in instruction below. Dispose of superseded pages in accordance with applicable regulations. 2.
S0300-BB-MAN-010 RECORD OF CHANGES CHANGE NO.
S0300-BB-MAN-010 FOREWORD Ship Salvage, Harbor Clearance and Wreck Removal oftentimes require extensive underwater cutting and welding. The lack of recent fleet experience in these areas dictates the need for a manual that incorporates state of the art equipment and tried and proven underwater cutting and welding techniques. The knowledge contained in this manual is a collection of fleet and commercial experience.
S0300-BB-MAN-010 TABLE OF CONTENTS Chapter/Paragraph Page FOREWARD ....................................................................................................................... i TABLE OF CONTENTS................................................................................................... iii LIST OF ILLUSTRATIONS............................................................................................. ix LIST OF TABLES.....................................................................
S0300-BB-MAN-010 2-3.6 2-3.6.1 2-3.6.2 2-3.6.3 2-3.7 2-3.7.1 2-3.7.2 2-3.7.3 2-3.8 2-4 2-4.1 2-4.2 2-4.3 2-4.4 2-4.5 2-4.6 2-4.7 2-4.8 2-4.9 2-4.10 2-4.11 2-4.12 2-4.13 2-4.14 2-5 2-5.1 2-5.2 2-5.3 2-5.4 2-5.5 2-6 Exothermic Cutting Technique .................................................................... 2-28 Exothermic Cutting Technique (Cast Iron, Stainless Steel and Non-Ferrous Metals)....................................................................................
S0300-BB-MAN-010 3-6 3-6.1 3-6.2 3-6.3 3-7 3-8 3-9 3-9.1 3-9.2 3-9.3 3-10 3-11 3-12 3-12.1 3-12.2 3-12.3 3-12.3.1 3-12.3.2 3-12.3.3 3-12.3.4 3-12.4 3-13 3-13.1 3-13.2 3-14 4 MATERIALS USED IN UNDERWATER SHIELDED METAL-ARC WELDING..................................................................................................... 3-6 Underwater Shielded Metal-Arc Welding Electrodes ................................... 3-6 Tong Test Ammeter .....................................................................
S0300-BB-MAN-010 4-2.4 4-2.5 4-2.6 4-2.7 4-3 4-3.1 4-4 Safety Switches............................................................................................ 4-16 Power Cables and Connectors ..................................................................... 4-16 Gas Manifolds.............................................................................................. 4-17 Underwater Oxygen-Arc Cutting Torches...................................................
S0300-BB-MAN-010 D-10 D-10.1 D-11 D-11.1 D-11.1.1 D-11.1.2 D-11.1.3 D-11.1.4 D-11.2 D-12 D-12.1 D-13 E FIRE AND EXPLOSION PREVENTION................................................... D-9 Major Causes .............................................................................................. D-10 COMPRESSED GAS SUPPLIES .............................................................. D-10 Use, Handling and Storage of Compressed Gases...................................... D-10 The Never List ..............
S0300-BB-MAN-010 E-4.6 E-4.6.1 E-4.6.2 E-4.7 E-4.8 E-4.8.1 E-4.8.2 E-4.8.3 E-5 E-5.1 E-5.2 E-6 E-7 E-7.1 E-7.2 E-7.3 E-7.3.1 Igniting the Torch Above Water..................................................................E-16 Preparation ...................................................................................................E-16 Ignition.........................................................................................................E-16 Lowering the Ignited Torch ........................
S0300-BB-MAN-010 LIST OF ILLUSTRATIONS Figure Title Page 2-1 Underwater Oxygen-Arc Cutting Electrodes................................................................... 2-3 2-2 Underwater Oxygen-Arc Electrode Designs ................................................................... 2-4 2-3 Drag Techniques for Cutting Steel with Steel-Tubular Electrodes ............................... 2-12 2-4 Technique for Cutting Steel Less Than 1/4 Inch with Steel-Tubular Electrodes ..........
S0300-BB-MAN-010 3-7 Feeding-In Technique for Underwater Shielded Metal Arc Welding of Fillet Welds in Wide-Gap Joints.................................................................................... 3-21 3-8 Repair Method for Cracks in Underwater Structures Using a Rectangular Patch......... 3-23 3-9 Repair Methods for Cracks in Underwater Structures Using a Circular Patch.............. 3-24 3-10 A Typical Underwater Welding Electrode Holder .......................................................
S0300-BB-MAN-010 LIST OF TABLES Table 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 3-1 3-2 3-3 4-1 4-2 4-3 4-4 A-1 E-1 E-2 E-3 E-4 E-5 E-6 E-7 Title Page Cutting Amperage Requirements for Steel-Tubular Electrodes ...................................... 2-6 Oxygen Regulator Settings for Oxygen-Arc Cutting Electrodes (Hose Lengths 50 Foot and 200 Foot)...................................................................................................... 2-7 Material Consumption using Steel-Tubular Electrodes........
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S0300-BB-MAN-010 STANDARD NAVY SYNTAX SUMMARY This manual utilizes standard Navy syntax as pertains to permissive, advisory, and mandatory language. The concept of word usage and intended meaning which as been adhered to in preparing this manual is as follows: “Shall” has been used only when application of a procedure is mandatory. “Should” has been used only when application of a procedure is recommended. “May” and “need not” have been used only when application of a procedure is discretionary.
S0300-BB-MAN-010 SAFETY SUMMARY This Safety Summary contains all specific WARNINGS and CAUTIONS appearing elsewhere in this manual. Should situations arise that are not covered by the general and specific safety precautions, the Commanding Officer or other authority will issue orders, as deemed necessary, to cover the situation. GUIDELINES Extensive guidelines for safety can be found in the OPNAV 5100 Series instruction manual, "Navy Safety Precautions.
S0300-BB-MAN-010 CAUTION A statement used to provoke notice, awareness, and attention from personnel regarding an action or procedural step which, if not followed, could result in possible injury or equipment malfunction. The following warning and caution statements appear in this manual and are repeated here for emphasis: WARNING Serious injury or death may result when adequate precautions are not followed during underwater cutting or welding operations.
S0300-BB-MAN-010 WARNING AC power shall not be used for underwater cutting and welding due to the extreme danger involved with AC current underwater. Electrical shock produced by AC current prevents voluntary relaxation of the muscles controlling the hand. Consequently, the diver may be unable to let go if his body or equipment accidentally enters the electrical circuit.
S0300-BB-MAN-010 WARNING Never get between the electrode holder and the striker plate (ground) when the switch is on. (page 2-31) WARNING Do NOT attempt to speed up the cutting by creating a fire or inferno deep inside the metal. Such a situation can lead to an explosion. (pages 2-33, D-1) WARNING The Kerie Cable WILL NOT cut rock or concrete either above or below water. To attempt to do so may create an explosion causing serious injury or death.
S0300-BB-MAN-010 WARNING Oxygen partial pressure increases with water depth, thereby creating a fire hazard in habitat environments. No habitat welding will be performed in an air environment at depths greater than 60 FSW. Habitats shall be filled with an inert gas at depths greater than 60 FSW. (page 3-2) WARNING A diver is at risk to severe electrical shock when performing a cutting or welding operation while only partially immersed in water.
S0300-BB-MAN-010 WARNING This process produces large quantities of hydrogen gas. When combined with oxygen, these concentrations are highly explosive and will produce random explosions of some magnitude. Several divers engaged in salvage work have been killed using this process. (page E-5) WARNING Thermic Lances or Burn Bars are NOT to be used by divers while underwater or by topside personnel performing a cut below the waterline while a diver is in the water.
S0300-BB-MAN-010 CAUTION The hand should never be closer than 4 inches from the electrode tip. Therefore, as the electrode is consumed and becomes manageable, the pool que grip can be released. (page 2-14) CAUTION Pushing the electrode into the hole too fast will result in a shower of spatter, which may damage the diving equipment and/or result in a blow-back. (page 2-15) CAUTION It is important that the proper washer-collet combination is used.
S0300-BB-MAN-010 CAUTION When the electrode burns down to within 3 inches of the torch, call for SWITCH OFF. Release the trigger to extinguish the electrode, since it will continue to burn when the electrical power is off with oxygen still flowing. Do NOT attempt to use the last 3 inches of the electrode. To do so will subject the torch to unnecessary heat and possible damage. (page 2-27) CAUTION Burning the electrode shorter than the 3-inch minimum can damage the torch interior.
S0300-BB-MAN-010 CAUTION Arcing can damage welding machine switch contacts. DO NOT change the Range Switch position while welding or under load. Arcing causes pitting and will eventually render the contacts inoperative. (page 4-15) CAUTION When AC power is required for underwater lighting or operation of hand tools, the AC equipment must be protected by ground-fault detection (GFD) and/or groundfault interruption (GFI) devices. (page D-8) CAUTION It is extremely important to mount the switch correctly.
S0300-BB-MAN-010 CAUTION Keep all Thermic lance materials away from oil and/or grease.
S0300-BB-MAN-010 CHAPTER 1 INTRODUCTION 1-1 SCOPE This manual is intended to provide information on the use of conventional techniques for cutting and welding metals underwater. It is written for the U.S. Navy diver who specializes in ship salvage and harbor clearance operations. It is not a procedural guide for certifiable welding used in pre-planned underwater ship husbandry applications.
S0300-BB-MAN-010 the steel-tubular electrode. Of these, the exothermic is preferred because it will burn independently after an arc is struck and oxygen is flowing. Included in this manual is the Seeler Enterprises LU-001 Exothermic Cutting Tool (Kerie Cable), which operates on the same principal as the exothermic electrode. The second method of underwater cutting is the shielded metal-arc process in which the metal is cut by the intense heat of the arc without the use of oxygen.
S0300-BB-MAN-010 precautions, warnings and cautions. This information, which is based on knowledge and experience gained through many years of Naval and commercial operations, is presented in Appendix D and the Safety Summary. Strict adherence to the safety regulations is required. Before starting any new job, a thorough inspection of the situation must be made to determine hazards to personnel, equipment or ship that may exist. Appropriate action must be taken to eliminate or minimize noted hazards.
S0300-BB-MAN-010 1-4
S0300-BB-MAN-010 CHAPTER 2 UNDERWATER CUTTING WARNING Serious injury or death may result when adequate precautions are not followed during underwater cutting or welding operations. Supervisors shall ensure that all personnel become thoroughly familiar with the safety precautions covered in Appendix D. WARNING Under no circumstances shall compressed air be substituted for oxygen in underwater cutting operations due to the danger of contaminating oxygen regulators and hoses with oil residue (hydrocarbons).
S0300-BB-MAN-010 2-2 OXYGEN-ARC CUTTING There are two types of electrodes used for oxygen-arc (oxy-arc) cutting—steel-tubular (manufactured by Arcair) and the exothermic types (Arcair’s Sea-Jet and BROCO’s Ultrathermic - see Figure 2-1). These electrodes provide excellent cutting results and can be used with a constant current DC welding generator set on straight polarity (electrode negative) supplying current to the electrode. With the work grounded, the electrode will ignite as it touches the work.
S0300-BB-MAN-010 Figure 2-1.
S0300-BB-MAN-010 Figure 2-2. Underwater Oxygen-Arc Electrode Designs.
S0300-BB-MAN-010 c. It serves as an electrical insulator, even in wet conditions, thereby assisting in safeguarding the diver in the event of accidental body contact while cutting. d. It prevents arcing from the side of the electrode when working in confined quarters. 2-2.2.1 Advantages of the Steel-Tubular Electrodes. Steel-tubular electrodes have the following advantages: a. The cutting technique is simple and readily mastered. b. Metals up to 2 inches in thickness can be cut. c.
S0300-BB-MAN-010 Table 2-1. Cutting Amperage Requirements for Steel-Tubular Electrodes. Electrode Current in Amps Sea-Cut 300-400 Tuff Cote 300-400 The steel-tubular electrode requires 300-400 amps at the torch working depth. With proper power and oxygen pressure settings, satisfactory cutting results can be obtained. An amperage tong test ammeter is extremely useful in order to determine the exact amperage output of the welding generator.
S0300-BB-MAN-010 Table 2-2.
S0300-BB-MAN-010 Table 2-2.
S0300-BB-MAN-010 Table 2-2.
S0300-BB-MAN-010 Table 2-3. Material Consumption using Steel-Tubular Electrodes Unit Steel Plate cut in ft/box of electrodes 1/4-in. plate 1/2-in. plate 3/4-in. plate 1-in. plate 50-lb. Box of electrodes1 240 170 170 160 Oxygen cu.ft. per box of electrodes2 594 440 440 440 1. Each 50-pound box contains approximately 167 electrodes. 2. There are approximately 220 cubic feet of gas in a standard oxygen cylinder charged to 2000 psi.
S0300-BB-MAN-010 2-2.7 Oxygen Purity. The oxygen purity for all underwater oxygen cutting should be 99.5 percent or greater. As the oxygen purity is reduced, so is the cutting efficiency. A one percent decrease in oxygen purity will result with a 25 percent reduction in cutting speed. In addition, the quality of the cut decreases and the amount of slag adherence increases. At oxygen purities of 95 percent or less, the operation becomes one of melting and washing out rather than cutting.
S0300-BB-MAN-010 Figure 2-3.
S0300-BB-MAN-010 a. Insert the electrode into the collet opening until it bottoms out against the washer. Tighten the collet nut. To start the cut, hold the electrode perpendicular to the surface to be cut and hold the oxygen trigger down to get a steady flow. Place the tip of the electrode against the work and call for SWITCH ON. If necessary, withdraw the electrode slightly and tap it against the work to start the arc.
S0300-BB-MAN-010 CAUTION The hand should never be closer than 4 inches from the electrode tip. Therefore, as the electrode is consumed and becomes manageable, the pool que grip can be released. NOTE Before beginning the cut, the diver should visually check the oxygen flow while holding the electrode in a horizontal position. Holding the oxygen for approximately 20 seconds allows time for enough cutting-gas pressure to build up along the full length of the hose.
S0300-BB-MAN-010 2-2.10 Steel-Tubular Electrode Cutting Technique (Thin plate). When cutting steel plate which is 1/4-inch thick or less, use the following technique. This technique is slightly different from that used on thick plate. a. Instead of maintaining the electrode tip in the cut and pressing against the lip of the advancing cut, the tip should barely touch the plate surface as it advances along the line of cut. (See the technique illustrated in Figure 2-4.) b.
S0300-BB-MAN-010 Figure 2-4. Technique for Cutting Steel Less Than 1/4 Inch with Steel-Tubular Electrodes.
S0300-BB-MAN-010 Figure 2-5. Technique for Piercing Holes in Steel Plate using the Oxy-Arc Process with Steel Tubular Electrodes.
S0300-BB-MAN-010 2-2.12 Steel-Tubular Electrode Cutting Technique (cast iron and non-ferrous metals). Cast iron and non-ferrous metals do not oxidize; therefore, underwater cutting essentially becomes a melting process. There is no chemical reaction of the oxygen and the base metal. Therefore, the only benefit realized by the oxygen is the mechanical effect of blowing the molten metal away.
S0300-BB-MAN-010 COLLET CHUCK COLLET RING ASSEMBLY BLOWBACK RETAINER SEA TORCH HANDLE FLASHBACK RESISTOR BALL CHECK VALVE WASHERS SET SCREW CABLE TIP INSULATOR WASHER OXYGEN VALVE CABLE ASSEMBLY VALVE LEVER ASSEMBLY PIN ADAPTER VALVE BOOT Figure 2-6a. Underwater Oxygen-Arc Cutting Torch Breakdown (Arcair).
S0300-BB-MAN-010 RIGHT SIDE HANDLE SCREWS ROD HEAD SCREEN FLASH ARRESTOR NEOPRENE WASHER COLLET HEAD LEFT SIDE HANDLE NEOPRONE WASHER HEAD NUT NUTS HOSE ASSEMBLY NUT LOCK VALVE HANDLE CABLE ASSEMBLY PISTON “O-RING” SCREW COPPER WASHER BLOW GUN NUT SPRING CONNECTOR NEOPRENE WASHER Figure 2-6b. Underwater Oxygen-Arc Cutting Torch Breakdown (BROCO).
S0300-BB-MAN-010 TORCH HEAD INSULATOR JACKET TORCH HEAD TORCH HEAD BASEPLATE FLASH ARRESTOR CARTRIDGE INLET NIPPLE LOCKNUT TORCH HANDLE CABLE BASE NIPPLE INSULATOR COUPLER TRIGGER VALVE ASSEMBLY VALVE MAY BE ROTATED TO ANY POSITION HANDLE SCREW INLET NIPPLE EXTERNAL WASHER INTERNAL WASHER COLLET LOCKNUT COLLET LOCKNUT COLLET Figure 2-6c. Underwater Oxygen-ARC Cutting Torch Breakdown (Craftsweld).
S0300-BB-MAN-010 2-3 EXOTHERMIC ELECTRODES WARNING It is not safe to operate the torch without the flashback arrestor installed. To do so may cause injury and/or destroy the torch. CAUTION It is important that the proper washer-collet combination is used. An oversize washer will allow the electrode to bottom on the flashback arrestor, creating electrolysis and possible arcing. An undersize washer will restrict the flow of oxygen to the larger bore electrodes, causing inefficient cutting.
S0300-BB-MAN-010 electrodes will continue to burn when the current is off, it is recommended that electrical current be used to provide more heat and enhance the cutting process on all conductive material. Table 2-4 lists recommended current settings for various cable lengths and sizes. NOTE The Sea-Jet electrode will operate on a wide range of amperage settings up to 400 amps.
S0300-BB-MAN-010 Table 2-4. Recommended Power Settings for Cable Length/Size for Ultrathermic Electrodes1 Length (Feet) 150 200 250 300 350 400 450 500 Amperage Setting for Cable Size Used 1/0 2/0 155 157 159 161 163 165 167 169 152 154 156 158 160 162 164 166 1. For greater cable lengths, add 2 amperes for each additional 50-foot length of power cable.
S0300-BB-MAN-010 2-3.2 Oxygen Requirements. Exothermic cutting consumes a large volume of oxygen; therefore, a 3/8-inch inside diameter oxygen hose is required to maintain sufficient volume. The hose size is important because it is the oxygen volume together with heat that does the cutting while the pressure blows the slag away. A high volume, high flow regulator capable of delivering 70 CFM is necessary. A two-stage regulator is recommended.
S0300-BB-MAN-010 Table 2-5. Exothermic Electrode Consumption Guide Electrode diameter Plate Thickness Range of cut per electrode1 1/4-in. 1/4-in. 1/2-in. 1/2-in. 1-in. 1 1/2-ins. 20-25-ins. 10-15-ins. 12-20-ins. 9-14-ins. 8-12-ins. 3/8-in. 1. Range of cut figures represent cuts made with and without power. The lower numbers were attained without power and the higher numbers with power.
S0300-BB-MAN-010 2-3.4.1 Disadvantages of Exothermic Electrodes. The following are disadvantages of exothermic electrodes. a. Larger volume of oxygen is required than with steel-tubular electrodes. b. Burning time of the electrode is short; 45 to 55 seconds. c. Contact with the work is not required to sustain ignition, thus electrode waste can occur.
S0300-BB-MAN-010 NOTE Thick, gauntlet-type rubber gloves in good condition, worn over a pair of playtex-type gloves afford the best protection against electrical shock. They should be secured at the wrist to prevent slag from getting inside the glove. When working in cold water, wetsuit gloves in good condition, worn over surgical gloves are equally effective. NOTE A striker plate attached to the positive (+) clamp is a good idea for a starting point for rod ignition.
S0300-BB-MAN-010 Figure 2-7. Technique for Cutting Steel Using Exothermic Electrode.
S0300-BB-MAN-010 b. To advance the cut, apply slight pressure to maintain electrode/work contact. Hold the electrode with the free hand as if holding a pool que, approximately 4 inches from the tip for a more stable cut. Move slowly at first, maintaining full penetration. Lack of penetration will be evident by back-spray, increased cutting noise and slag build-up. In such cases, stop advancement and go back and wash out all hangers to complete the cut.
S0300-BB-MAN-010 b. To cut thick, non-ferrous metals, create a puddle and keep the electrode tip slightly below the surface of the molten metal. Every few seconds, push the cutting electrode deeper into the molten pool to wash out and blow the molten metal through. Increase the oxygen pressure at the electrode tip to 110 psi for metals over 3 inches in thickness (see Table 2-2). 2-3.6.2 Exothermic Cutting Technique (Concrete, Rock and other Non-Conductive Materials).
S0300-BB-MAN-010 b. Electrode burns down in approximately 60 seconds of continuous use and cuts less than 12 inches of 1/2-inch plate. 2-3.7.2 Probable causes. The following are possible causes to an oxygen flow problem: a. Regulator incapable of delivering 70 cfm. b. Torch incapable of delivering sufficient flow. Older torches; those designed for 5/16inch electrodes will not flow sufficient oxygen volume. c.
S0300-BB-MAN-010 NOTE Washers for 5/16-inch electrodes and smaller will significantly obstruct the oxygen flow. e. Remove flashback arrestor and monel screen from torch and inspect. Replace as necessar y. Blow oxygen through the valve and torch to ensure a clear passage. This should complete the checkout of a low flow problem. Reassemble and recheck to ensure that the problem has been solved. 2-3.8 Post-Dive Maintenance. After each use, rinse the torch in fresh water and dry it.
S0300-BB-MAN-010 WARNING The equipment should not be used to cut non-ferrous metals underwater since they do not oxidize and have to be melted. Experience has shown that this can result in a violent explosion which could be fatal. A similar exothermic cutting method is the Seeler Enterprises LU-001 Exothermic Cutting Tool (Kerie Cable). Unlike a rigid electrode, the consumable electrode is a long flexible spiral cable with the center strand pulled out to allow for oxygen passage.
S0300-BB-MAN-010 tip of the Kerie Cable. The cable should ignite immediately. Lift the knife switch (switch off) when ignition takes place. Proceed to cut the metal, starting at the edge. Once in the water, the diver will quickly become accustomed to the feel, sound and use of the Kerie Cable. 2-4.2 Materials Required for Kerie Cable Cutting. The Seeler Enterprises LU-001 Exothermic Cutting Tool (Kerie Cable) is supplied with a surface control panel.
S0300-BB-MAN-010 Figure 2-8. Seeler Kerie Cable Control Panel.
S0300-BB-MAN-010 The Kerie Cable is manufactured in three sizes: 50-foot lengths of 9mm (0.36-inch) and 100-foot lengths of 12mm (0.48-inch) for cutting heavy plate wire and shackles, etc and 50-foot lengths of 6mm (0.24-inch) for cutting thinner plate, wire and shackles. The cable is the cutting electrode and is connected to the control panel via the extension lead, which supplies both power and oxygen to the cable.
S0300-BB-MAN-010 LP O2 HP O2 KNIFE SWITCH CONTROL PANEL + 12 VOLT + 12 VOLT - NEG AMP -NEG AMP LP O2 IN OUT OUT HP O2 IN HP MANIFOLD O2 O2 WORK INSULATING SLEEVE KEERIE CABLE Figure 2-9. Typical Kerie Cable Set Up.
S0300-BB-MAN-010 e. Connect a length of 100-, 200- or 250-foot extension lead to the control panel fitting marked LP CUTTING OXYGEN OUT. f. Open the knife switch. g. Connect a length of 100-, 200- or 250-foot electric lead to the control panel fitting marked NEG AMPS OUT. h. Place two fresh, 12-volt batteries of at least 20 ampere hours on a non-conductive surface (wooden plate, rubber mat etc). Connect the batteries in series. i. Connect the negative side of the batteries to the fitting marked NEG.
S0300-BB-MAN-010 Upon reaching the work site, the diver, when ready, should call and wait for gas pressure to be increased. A delay of approximately 20 seconds is necessary between applying full cutting-gas pressure and closing the knife switch to allow time for the oxygen pressure to build up along the full length of the cable. The following procedure should be followed: a. The tender will increase the oxygen supply to the proper over bottom pressure.
S0300-BB-MAN-010 brushing motion and several passes to eliminate molten metal from the cut. 2-4.8 Cutting Thick Metals. When cutting thicker metal (2-1/2 inches and greater), use the 12mm (1/2-inch) cable and a brushing motion to allow the metal surrounding the cut to cool enough to prevent molten metal. Thick steel, such as propeller shafting, should be cut from the outside, working around the circumference, withdrawing the Kerie Cable every few seconds to allow water to enter the cut.
S0300-BB-MAN-010 Table 2-7. Kerie Cable Size/Metal to be Cut1 Cable size (mm) Metal Thickness (in.) 6 (0.24 in.) 9 (0.36 in.) 12 (0.48 in.) up to 1 1 to 2-1/2 over 2-1/2 1. Based on manufacturer’s data. Table 2-8. Kerie Cable Oxygen and Cable Consumption Ratio 2-42 Cable Size (mm) Average Cable Consumed (ft. per minute) Average Oxygen Consumed (psi per minute) 6 (0.24 in.) 9 (0.36 in.) 12 (0.48 in.) 2.1 2.2 2.4 13.9 35.5 40.
S0300-BB-MAN-010 2-4.9 Re-lighting Cable Underwater. After calling for GAS OFF, the diver should continue to rub the cable against the work to prevent the molten plastic coating from forming insulation over the inner wire core. This step is necessary to ensure reignition. When operations require reignition of the Kerie Cable for more than a second or third time, consideration should be given to the use of a DC welding machine due to limitations of the batteries. 2-4.10 Emergency Off Safety Procedures.
S0300-BB-MAN-010 2-5 SHIELDED METAL ARC CUTTING Underwater shielded metal-arc cutting is a simple process. It employs a stick-type electrode but can be accomplished with almost any waterproofed, mild steel electrode. Shielded metal arc has the following advantages over oxygen-arc cutting processes: a. It can cut corrosion and oxidation resistant steels and non-ferrous metals of all thicknesses. b. It can be used when no oxygen is available. 2-5.1 Principles of Operation.
S0300-BB-MAN-010 2-5.4 Underwater Shielded Metal-arc Cutting Techniques. The diver should understand that this process merely melts the metal and does not oxidize or consume the metal as in oxy-arc cutting. The molten metal will not run out of the cut on its own, but must be pushed out by manipulation of the electrode tip. By paying careful attention to the molten pool, the diver can master this process in a short period of time.
S0300-BB-MAN-010 2-5.5 Drag Technique. Steel plate can be cut simply by dragging the electrode along the desired line of cut. The drag technique can be used to cut 1/4-inch steel plates with 300 amperes of current. 3/8-inch plate requires using 400 amperes of current. This technique works more effectively using larger electrodes and higher currents. The diver may find that using the drag technique in a flat position is more effective than in other positions.
S0300-BB-MAN-010 Figure 2-10. Technique for Underwater Shielded Metal-Arc Cutting of Thick Plate and Round Stock.
S0300-BB-MAN-010 2-48
S0300-BB-MAN-010 CHAPTER 3 UNDERWATER WELDING WARNING Serious injury or death may result when adequate precautions are not followed during underwater cutting or welding operations. Supervisors shall ensure that all personnel become thoroughly familiar with all of the safety precautions covered in Appendix D. WARNING The position of the ground in relation to the diver must be such that at no time does the diver or his equipment get between the ground and the electrode.
S0300-BB-MAN-010 spent on the job can be reduced considerably. Historically, the Navy has performed most underwater welding for the purpose of making temporary repairs to waterborne ships. Specific wet and dry welding techniques applicable to underwater ship husbandry are properly addressed in the Underwater Ship Husbandry Manual. This manual addresses basic welding techniques and their application to salvage operations.
S0300-BB-MAN-010 techniques may be produced. In salvage, most underwater welding consists of joining fairly simple steel patches to hull plating. Therefore, wet welding may be acceptable for most patching applications. 3-3 SHIELDED METAL ARC WELDING Shielded metal arc welding is produced by heating with an electric arc created between a fluxcovered metal electrode and the work. The arc creates intense heat, 7,000°F to 11,000°F, concentrated in a very small area.
S0300-BB-MAN-010 a. Cut a small sample of the material to be welded and make a Tee fillet weld specimen similar to the one illustrated in Figure 3-1. b. Wet weld the specimen and break it with a sledgehammer. If it breaks easily after being welded with mild steel electrodes, it is more than likely that the steel is of a high carbon content and should be welded with austenitic electrodes.
S0300-BB-MAN-010 STOP AND RESTART WELD NEAR CENTER FILLET WELD 4" 8" 4" Figure 3-1. Test Specimen for Tee Fillet Weld.
S0300-BB-MAN-010 NOTE Very high strength steels, like HY-80, are not recommended for wet welding because of cracking problems stemming from the intense heat produced by the welding process followed by rapid cooling of the weld metal by the ambient water. For high strength steels, a stainless steel electrode gives better results. 3-6 MATERIALS USED IN UNDERWATER SHIELDED METAL ARC WELDING Equipment used for shielded metal arc welding is discussed in Chapter 4.
S0300-BB-MAN-010 Table 3-2. Electrodes for Underwater Shielded Metal-Arc Welding Size Description Specification Commercially Prepared Waterproof Electrodes 1/8” Andersen Easy1 Weld #1 Carbon Steel (E7014) -- 1/8” BROCO Sof-Touch1 Carbon Steel (E7014) -- Stainless Steel (E3XX) -- 1/8” BROCO SS 1. These electrodes have passed Navy qualification testing; larger sizes are available, but have not yet been tested by the Navy. Table 3-3.
S0300-BB-MAN-010 a. Manufacturer’s recommendations, particularly for stainless steel electrodes. b. Improved running characteristics of the electrode. c. Control of weld bead shape and penetration. d. Altered magnetic fields to reduce magnetic arc blow. 3-7 UNDERWATER WELDING ARCS The welding arc does not behave underwater as it does on the surface and the activity of the gas bubble is particularly important to successful completion of the underwater weld.
S0300-BB-MAN-010 Figure 3-2. The Underwater Welding Arc.
S0300-BB-MAN-010 c. Adverse currents, d. Low temperature, e. Where the metal thickness is less than 0.20 inch. f. Where the fit-up is poor. A 1/8-inch gap should be considered the maximum permissible for a quality wet weld using the self-consuming technique and 1/8-inch electrodes. g. As the depth increases, due to the increase in hydrostatic pressure. h. Where the visibility is extremely low and the diver has no groove to follow.
S0300-BB-MAN-010 Figure 3-3. Parts of a Weld.
S0300-BB-MAN-010 3-9.2 Fillet Weld. A fillet weld is a triangular weld used to join two surfaces that are at approximately right angles to each other. i.e., lap, tee and corner joints are normally welded with a fillet weld. A fillet weld should have a leg length equal to the plate thickness up to 3/8-inch plate. For plate thicknesses 3/8-inch and greater, a minimum of 3/8-inch leg length is required on all wet welds.
S0300-BB-MAN-010 3-11 JOINT FIT-UP Since most underwater tasks are more cumbersome than similar topside work, the proper positioning of large members or plates underwater for welding is also quite difficult. Positioning and fitting must be done with thoroughness and care to ensure a satisfactory weld. In underwater fillet welding, it is important that there be no gap at the root of the fillet before welding. When the gap cannot be eliminated entirely, it should be as small as the conditions will permit.
S0300-BB-MAN-010 needed. The open circuit voltage may also require adjustment. f. After the optimum settings are determined, welding can begin. g. The diving tender should always maintain a written record of the following: 1) The welding amperage as read from the tong meter. 2) Both open and closed-circuit voltage as read from the volt meter. 3) Electrode diameter, type, manufacturer and waterproofing material. 4) Electrical polarity. 5) Length of welding cable. 6) Depth of work site.
S0300-BB-MAN-010 d. Hold the electrode against the plate at a work angle of 45° to the plate end surfaces as illustrated in Figure 3-4. Tilt the electrode to a lead angle of 45° ± 15° in the line of intended weld. The angle variance, depends on the size of electrode used and the skill and technique of the diver. e. Call for SWITCH ON. The arc should start when the tender (phone talker) closes the safety switch.
S0300-BB-MAN-010 LEAD ANGLE 45° A ELECTRODE ELECTRODE A END VIEW B TOP VIEW (SLANTED) ANGLE A = 45° 15° C A. POSITION THE ELECTRODE AT AN ANGLE OF APPROXIMATELY 30 DEGREES TO THE LINE OF WELD WITH THE ELECTRODE TIP IN CONTACT WITH THE WORK. B. CALL FOR SWITCH “ON.” TAP THE ELECTRODE MOMENTARILY, IF NECESSARY, TO START THE ARC. C. APPLY SUFFICIENT PRESSURE IN THE DIRECTION OF THE ARROW TO ALLOW THE ELECTRODE TO CONSUME ITSELF. Figure 3-4.
S0300-BB-MAN-010 f. When the electrode is consumed, break the arc, call for SWITCH OFF. Keep the electrode in welding position until the tender (phone talker) has confirmed switch off, then tap the electrode twice to make sure the switch is off. Only then proceed to change the electrode. g. Before starting to deposit a new weld, clean the previous weld thoroughly, especially the end where the arc was broken. Look for any visible pin holes or porosity which may affect the quality of the weld.
S0300-BB-MAN-010 Figure 3-5. Self-Consuming Technique for Underwater Shielded Metal Arc Welding of Vertical Fillet Welds.
S0300-BB-MAN-010 Figure 3-6. Self-Consuming Technique for Underwater Shielded Metal Arc Welding of Overhead Fillet Welds.
S0300-BB-MAN-010 3-12.3.3 Self-Consuming and Manipulative Techniques. The self-consuming technique is recommended for divers of average or less than average skill who have little time for practice. Naturally, the self-consuming technique does not produce as strong a weld as does one laid down by a skilled underwater welder using the manipulative technique. However, for salvage purposes, sound welds made using the self-consuming technique are considered acceptable.
S0300-BB-MAN-010 Figure 3-7. Feeding-In Technique for Underwater Shielded Metal Arc Welding of Fillet Welds in Wide-Gap Joints.
S0300-BB-MAN-010 g. The arc should always be broken by pulling back on the previously deposited metal. h. It is always good practice to establish proper heat and travel speed on practice material of thickness equivalent to the base metal of the intended weld and under similar conditions. 3-13 PROCEDURE FOR REPAIRING SMALL CRACKS Preparation is the key to stopping crack propagation.
S0300-BB-MAN-010 Figure 3-8. Repair Method for Cracks in Underwater Structures Using a Rectangular Patch.
S0300-BB-MAN-010 A. TACK AT 12 O'CLOCK AND 6 O'CLOCK POSITION. B. WELD FROM 12 O'CLOCK TO 6 O'CLOCK, CLOCKWISE. C. MOVE 3 INCHES AWAY FROM 12 O'CLOCK POSITION; WELD FROM 12 O'CLOCK TO 6 O'CLOCK, COUNTER-CLOCKWISE. D. WELD UP 3-INCH HOLE Figure 3-9. Repair Methods for Cracks in Underwater Structures Using a Circular Patch.
S0300-BB-MAN-010 a. Tack the patch on at the 12 o’clock position, tap it down and tack it on at the 6 o’clock position. Then tack at the 3 and 9 o’clock positions. b. Clean the slag from the tacks and grind all tack ends to a feather edge. c. Begin welding downhill at the 12 o’clock position. Weld clockwise to and including the tack at the 6 o’clock position. d. Return to the 12 o’clock position and move approximately 3 inches away from the previous weld.
S0300-BB-MAN-010 Figure 3-10. A Typical Underwater Welding Electrode Holder.
S0300-BB-MAN-010 CHAPTER 4 UNDERWATER ARC CUTTING AND WELDING EQUIPMENT 4-1 INTRODUCTION This chapter presents information concerning underwater cutting and welding technology and the equipment necessary to conduct such operations. Included are discussions on the required equipment and equipment set up procedures. This information will be particularly useful during the planning and staging phase of an operation. Because no two underwater operations are exactly the same, each must be regarded as unique.
S0300-BB-MAN-010 Figure 4-1. Typical Arrangement of Underwater Arc Cutting Equipment.
S0300-BB-MAN-010 Figure 4-2. MK12 SSDS Welding Shield.
S0300-BB-MAN-010 Figure 4-3. MK1, MOD 0 Mask and Lens Holder Assembly.
S0300-BB-MAN-010 Figure 4-4. Superlite-17B/NS Helmet and Lens Holder Assembly.
S0300-BB-MAN-010 Figure 4-5. MK 12 Helmet Lens Holder Assembly with Parts Identification.
S0300-BB-MAN-010 Figure 4-6. Superlite-17B/NS Welding Lens Holder with Parts Identification.
S0300-BB-MAN-010 Table 4-1.
S0300-BB-MAN-010 Specific technical information necessary to operate diving equipment is addressed in the appropriate surface supported diving system technical manual. WARNING AC power shall not be used for underwater cutting or welding due to the extreme danger involved with AC current underwater. Electrical shock produced by AC current prevents voluntary relaxation of the muscles controlling the hand.
S0300-BB-MAN-010 Figure 4-7. Typical Welding Generator and Power-Converter Control Panel.
S0300-BB-MAN-010 4-2.3.2 Welding Generator, Pre-Setup Inspection. Successful underwater welding and cutting is highly dependent on the efficient running of the power supply unit. Before any underwater work takes place, the welding power source should be fully inspected by qualified personnel. The commutators on motor-generators should be clean. Brushes must not be excessively short or worn. Slack brush rigging springs must be replaced.
S0300-BB-MAN-010 Figure 4-8. Equipment Arrangement for Welding and Cutting Straight Polarity.
S0300-BB-MAN-010 2) If bubbles appear from the plate, switch off the current and change the lead connections to the opposite terminals. Repeat test and label the machine terminals for future reference. f. Once the correct polarity is determined, the ground clamp should then be bolted to the POSITIVE (+) lead and the electrode holder attached to the NEGATIVE (-) lead. 4-2.3.5 Tong Test Ammeter.
S0300-BB-MAN-010 Figure 4-9. Tong Test Ammeter.
S0300-BB-MAN-010 machine with no current flowing in the circuit. This is known as the open circuit voltage and is higher than arc voltage when current is flowing (closed circuit voltage, also referred to as arc voltage). Resistance is a restriction to current flow in an electrical circuit. Every component in the circuit, including the conductor, (welding and ground leads) offers resistance to current flow. Current flows through some conductors easier than others.
S0300-BB-MAN-010 EXAMPLE: Setting up a Typical Welding Generator. With the Amperage Range set at the 100 to 220 position and the Fine Adjustment set at 0 percent, the welding generator would produce 100 amps and 24 to 26 closed-circuit volts. By moving the Fine Adjustment to the 35 percent position, the generator would produce 140 amps and 28 to 30 closed-circuit volts.
S0300-BB-MAN-010 Each additional length of cable and its connectors produce a voltage drop. To prevent excessive voltage-drop in the welding or cutting leads, it is desirable to have various lengths of continuous lead on hand. Welding lead procured in lengths of 50, 100, 200 or 300 feet will prevent considerable current-loss at connections. Excess cable should be laid out in straight lines or large “U”s because coiling sets up an electrical field and reduces cutting or welding efficiency.
S0300-BB-MAN-010 Figure 4-10. Voltage Drop in Welding Cables.
S0300-BB-MAN-010 device which will make the changing electrodes underwater a relatively simple task. Only torches which have been designed specifically for underwater cutting shall be used. The torches must also have a sufficient capacity for the maximum current required by the electrodes with which the torch is to be used. The elements of an oxygen arc cutting torch are: a. Collet or grip which holds tubular cutting electrodes and provides for entry of oxygen into the cutting electrode bore. b.
S0300-BB-MAN-010 welding and most experienced divers prefer the light-weight underwater “stinger” as it is most often called. Electrode holders are designed for welding and should only be used for that purpose and never as scrapers or hammers. A number of electrode holders specifically designed for underwater use are commercially available. 4-4 WELDING ACCESSORIES In addition to the basic equipment, the following accessories are necessary for underwater shielded metal arc welding. a.
S0300-BB-MAN-010 Table 4-4 is divided into 4 columns and lists: • Item and description alphabetically • Military Specification Number. • Federal Stock Code.
S0300-BB-MAN-010 Table 4-2. Equipment Load-out for Wet Cutting/Welding Operations Quantity Unit Description WELDING/CUTTING 2 Each a. Checked for operation prior to load-out b. Fuel and oil source, if required, prior to load-out 3 Each Knife switches: 400 amp/250 volt minimum 3 Each Sets of welding leads: 2/0 size or larger. Each set to consist of: a.
S0300-BB-MAN-010 Table 4-2.
S0300-BB-MAN-010 Table 4-2.
S0300-BB-MAN-010 Table 4-2.
S0300-BB-MAN-010 Table 4-3. List of Manufacturer’s Manufacturer Code No. N/A 4-26 Manufacturer Andersen Wet Weld P.O. Box 1529 New York, NY 10116-1529 09867 Arcair Company P.O. Box 406 Lancaster, OH 43130 (614) 653-5618 59491 BROCO Incorporated 2824 North Locust Avenue Rialto, CA 92376-1749 (714) 350-4701 N/A Columbia Electric Mfg. Co. 4519 Hamilton Avenue N.E. Cleveland, Ohio 44114-3881 (216) 361-8060 94449 Craftsweld Equipment Corp. 26-26 Jackson Avenue Long Island City, N.Y.
S0300-BB-MAN-010 Table 4-3. List of Manufacturer’s Manufacturer Code No. 37775 Manufacturer Platex Ltd. 6363 Northam Drive Mississauga, Ontario Canada L4V N/A Proline Paint Company 2646 Main Street San Diego, California 92113 06023 Rego Company 4201 West Peterson Avenue Chicago, Illinois 60646-6020 94747 Seeler Enterprises 2046 Waverly Street Napa, California 94558-4637 (707) 252-8956 55681 TESCOM Corp.
S0300-BB-MAN-010 Table 4-4.
S0300-BB-MAN-010 Table 4-4. Parts Information Military Specification Number Federal Stock Group/Class Manufacturer’s Part Number N/A N/A N/A 3818-UW 1418-UW 3836-UW 3493 3493 3493 3493 3493 3493 3493 3493 3493 3493 N/A AWSAS.
S0300-BB-MAN-010 Table 4-4. Parts Information Military Specification Number Federal Stock Group/Class Manufacturer’s Part Number Kerie Cable Control Panel N/A LU-027 10-ft H.P.
S0300-BB-MAN-010 Table 4-4.
S0300-BB-MAN-010 4-32
S0300-BB-MAN-010 APPENDIX A DOCUMENTATION MATRIX A-1 PURPOSE. The purpose of this matrix is to provide the user of this manual with a listing of additional reference documentation. This is given by reference manual and topic area. A-2 REFERENCE DOCUMENTS. The following manuals/publications are referenced on the matrix (Table A-1): • SAFETY MANUAL - U.S. NAVY Ship Salvage Safety Manual (S0400-AA-SAF010) • SALVAGE MANUAL - U.S.
S0300-BB-MAN-010 Table A-1. Salvage Documentation Matrix.
S0300-BB-MAN-010 APPENDIX B METRIC CONVERSION FACTORS METRIC TO ENGLISH kilograms x 2.2046 kilograms ÷ 907.2 = pounds (lb) = tons (2000 lb) millimeters x 0.03937 or millimeters ÷ 25.4 = inches (in) = inches (in) meters x 39.37 meters x 3.281 meters x 1.094 = inches (in) = feet (ft) = yards (yd) sq millimeters x 0.00155 or sq millimeters ÷ 645.16 = sq inches (in2) = sq inches (in2) ENGLISH TO METRIC pounds ÷ 2.2046 tons (2000 lb) x 907.2 = kilograms (kg) = kilograms (kg) inches ÷ 0.
S0300-BB-MAN-010 WEIGHTS 1 pound (lb) = 453.6 grams, or 0.4536 kilograms (kg) 1 pound per foot (lb/ft) = 1.4882 kilograms per meter (kg/m) 1 net ton (2000 lb) 1 gross ton (2240 lb) = 907.18 kilograms (kg) = 1016 kilograms or 1,0160 metric tons 1 ounce per sq foot = 305.15 grams, or 0.30515 kilograms per sq meter (kg/m2) 1 kilogram (kg) 1 kilogram per meter = 2.2046 lb = 0.67197 lb/foot = 2204.6 lb 1 metric ton (1000 kg) = 1.10231 net tons = 0.98421 gross ton MEASURES B-2 1 inch (in.
S0300-BB-MAN-010 PRESSURE OR STRESS (FORCE/AREA) pascal (Pa) pound-force/sq inch (psi) x 6894.757 m Pa Thousand force per sq inch (ksi) x 6.894757 = newton/meter2(N/m2) = Pa = MN/m2 = M Pa TEMPERATURE CONVERSION Celsius (formerly known as centigrade) tc = temperature (Celsius) in degrees tf = temperature (fahrenheit) in degrees t f - 32 t c = ----------------1.8 tf = 1.8 t c + 32 METRIC PREFIXES Multiplication Factors 1,000,000,000,000 1,000,000,000 1,000,000 1,000 100 10 0.1 0.01 0.001 0.000001 0.
S0300-BB-MAN-010 B-4
S0300-BB-MAN-010 APPENDIX C BIBLIOGRAPHY ANSI/AWS D3.6, “Specification for Underwater Welding,” American Welding Society, 1980. AWS “Welding Terms and Definitions,” American Welding Society, 1980. AWS F4.1, “Recommended Safe Practices for the Preparation of Welding and Cutting of Containers and Piping that Have Held Hazardous Substances,” American Welding Society, 1980. Commercial Diving Manual, Richard Larn and Rex Whistler, David & Charles publishers. Second Printing 1986.
S0300-BB-MAN-010 C-2
S0300-BB-MAN-010 APPENDIX D SAFETY IN UNDERWATER CUTTING AND WELDING D-1 PURPOSE This appendix is intended to cover safety precautions to be followed while preparing for and conducting underwater cutting or welding operations. All personnel should read and comprehend the safety precautions listed in this section and the safety summary contained in the front section of this manual.
S0300-BB-MAN-010 WARNING A diver is at risk to severe electrical shock when performing a cutting or welding operation while only partially immersed in water. Hence, the splash zone is the most hazardous location in which a diver can be placed. WARNING NEVER bring a cutting torch into a bell with the oxygen on or with the welding generator running. D-3.1 General Information. Gases produced by underwater cutting are rich in oxygen and hydrogen and will explode if trapped and ignited.
S0300-BB-MAN-010 trap explosive gases. These areas and voids must be vented or made inert in accordance with Naval Ships Technical Manual NAVSEA 59086-CH-STM-030/CH-074 Vol 3 to prevent possible explosions. Care should also be taken when cutting or welding on enclosures that are on or above river beds, especially in mud, because trapped methane gas in the proper concentrations can explode.
S0300-BB-MAN-010 D-4 ELECTRICITY UNDERWATER WARNING AC power shall not be used for underwater cutting or welding due to the extreme danger involved with AC current underwater. Electrical shock produced by AC current prevents voluntary relaxation of the muscles controlling the hand. Consequently, the diver may be unable to let go if his body or equipment accidentally enters the electrical circuit.
S0300-BB-MAN-010 The following precautions must be observed: a. Careful examination should be made before starting the cut to learn how the cut-away pieces will fall and whether there are any projections, wires or other objects which may foul lines or cause a piece to swing around in an unexpected manner. b. Be extremely careful when cutting tightly-bound wire rope e.g., wire wrapped in a ship’s propeller. When severed, the wire can back-lash with spring-like force. c.
S0300-BB-MAN-010 d. Stand on dry wood, rubber matting or similar insulating material and not on grounded metal. e. Wear dry rubber or rubberized-canvas gloves that are in good condition when handling energized holders, torches, cables or welding machines. f. Keep the welding machine commutators clean to prevent excessive flashing. g. Keep the welding machine clean and operable, free of oil and grease and (in electrical parts) free of metallic particles that can cause short circuits.
S0300-BB-MAN-010 j. Never allow any metallic part of the diving dress to touch the work. D-8 POWER CABLES AND CONNECTORS The following are power cable and connector safety precautions that should be observed: a. All parts of the cables that are intended to be submerged shall be fully insulated and watertight. This can not be overstated. b. Inspect cables and cable connections for damaged insulation before starting operations.
S0300-BB-MAN-010 h. Secure the ground clamp as close to the work-site as possible, preferably in the forward line of vision. The diver must face the ground when welding or cutting. A good rule-of-thumb to remember is: NEVER TURN YOUR BACK TO THE GROUND WHEN THE POWER IS ON. i. Keep additional power cables such as underwater light cables and welding leads separated.
S0300-BB-MAN-010 Both double-pole and single-pole safety switches are authorized, however a double-pole is the most often used because both the working and ground lead are opened or closed simultaneously (see Figure 4-8). To ensure safety switch effectiveness, the following guidelines must be followed: a. When using a single-pole knife switch, it should be located in the welding-lead side of the electric circuit and should be able to handle the maximum welding current. b.
S0300-BB-MAN-010 D-10.1 Major Causes. The major causes of fire and explosion are listed as follows: • combustibles reached by the arc, • flying sparks, • hot slag, • misuse of compressed gases and cylinders and • short circuits. It is necessary for the diving supervisor be aware of topside work being conducted in the vicinity of the diving station. Do not allow welding or cutting in an area where there are combustibles. Sparks and slag can fly up to 35 feet.
S0300-BB-MAN-010 g. Never tamper with safety plugs (safety relief valves). h. Never connect a regulator to a cylinder containing a gas other than that for which the regulator was designed. i. Never, under any circumstances, tap an electrode against a cylinder or any other pressure vessel to strike an arc. It creates a brittle area that can cause a violent rupture or can lead to such a rupture under rough handling. D-11.1.2 The Always List a.
S0300-BB-MAN-010 b. Avoid storing cylinders in heavy traffic areas, such as near access or gangways of vessels. c. Do not store cylinders in unventilated enclosures. d. Secure all cylinders that are not actually in use in designated storage racks. e. Protect hoses from damage due to sharp edges, sparks, slag and open flame. f. Examine hoses regularly for leaks, wear and loose connections. Use non-ionic soap suds or a proper liquid leak detector. g.
S0300-BB-MAN-010 a. During set-up procedures, point the MAPP gas valve outlet away from the oxygen cylinder before cracking to clear the valve connections. b. When MAPP gas lines are being purged, do not permit open lights or other sources of ignition in the vicinity of uncapped openings. c. Do not use copper connections or fittings with MAPP gas. There is a slight possibility that MAPP gas may react with copper to produce explosive acetylides when the gas is under high pressure. d.
S0300-BB-MAN-010 do this can result in the accumulation of an explosive mixture. This is a serious explosive hazard. d. Metal tools (even the “sparkless” type) shall be used with caution to avoid making a spark. Such a spark could cause an explosion if the proper mixture is present. D-12 PERSONAL SAFETY IN DIVING D-12.1 Diving Dress. It is extremely important that the diving attire afford maximum protection against electric shock and eye injury from electric arcs. The U.S.
S0300-BB-MAN-010 APPENDIX E EXCEPTIONAL SITUATIONS E-1 PURPOSE This appendix is intended to cover cutting and welding procedures and equipment which may be used during exceptional situations. Normally, the procedures covered in Chapters 2 and 3 will be followed, using authorized equipment tabulated in Table 4-4. However, when authorized equipment is not available and a situation requiring immediate action is at hand, alternate equipment and/or procedures will likely be necessary.
S0300-BB-MAN-010 E-2.2 Principles of Operation. The process consists of striking an arc underwater between a carbon-graphite, copper-coated and waterproofed electrode and the workpiece. The metal is instantly transformed into a molten state and is blown away by a high-pressure jet of water which exits the torch through an orifice located directly below the electrode opening in the torch. E-2.3 Applications. This process can be used for the following applications: a.
S0300-BB-MAN-010 Figure E-1. Arcwater Torch Assembly.
S0300-BB-MAN-010 WARNING The position of the ground in relation to the diver must be such that at no time does the diver or his equipment get between the ground and the electrode. The diver must avoid becoming part of the electrical circuit. NOTE Thick, gauntlet-type rubber gloves in good condition, worn over a pair of Playtex-type gloves afford the best protection against electrical shock. They should be secured at the wrist to prevent slag from getting inside the gloves.
S0300-BB-MAN-010 should be held at a 40° angle to the work with the water jet under the electrode. The torch should be moved forward at a speed sufficient to maintain the arc and the desired groove depth. The diver should not cut deeper than 1/4" in a single pass. This will prevent molten metal from being blown back at the diver. WARNING When the arcwater electrode has been consumed to within 1.5 inches of the torch, stop the cut and signal for SWITCH and water OFF before changing the electrode.
S0300-BB-MAN-010 WARNING Thermic Lances or Burn Bars are NOT to be used by divers while underwater or by topside personnel performing a cut below the waterline while a diver is in the water. However, during situations where it would be impossible to place a diver in position for cutting and where the cutting can be accomplished from the surface, the Thermic Lance may be used with EXTREME CAUTION! Table E-1.
S0300-BB-MAN-010 WARNING Always wear protective clothing when using the Thermic lance: full protective suit, leather gloves, tinted face shield and a hard hat. CAUTION Keep all Thermic lance materials away from oil and/or grease. Frequently, during a salvage operation, conditions prevent safely placing a diver in position for cutting.
S0300-BB-MAN-010 E-3.2 Required Equipment. The following is a list of required equipment: a. Thermic lance. b. Thermic lance holder/ball valve assembly. c. Oxygen (One burn bar requires 60 cubic feet of oxygen). d. 25 to 50 feet of 3/8 or 1/2-inch oxygen hose (Hose with smaller than 3/8-inch diameter will not deliver sufficient oxygen). e. A two-stage, high volume regulator. f. Ignition equipment. (oxy-acetylene torch). E-3.3 Set Up Procedure. The following is the recommended set up procedure: a.
S0300-BB-MAN-010 Figure E-2. Thermic Lance Holder Assembly. Figure E-3. Standard Thermic Lance Equipment Set Up.
S0300-BB-MAN-010 E-3.4 Material Consumption.1 One Thermic lance will penetrate 24-inches of reinforced concrete producing a hole 2-1/2 inches in diameter using 60 cubic feet of oxygen in 5 minutes. E-4 MAPP GAS CUTTING WARNING Acetylene is very unstable at pressures above 15 psi and is NOT used for underwater cutting. MAPP Gas cutting is the only oxygen-fuel underwater cutting process approved for use by the Navy.
S0300-BB-MAN-010 E-4.2 Equipment and Material. The equipment generally required for underwater MAPP gas cutting is listed in Table E-2. Only approved equipment shall be used. Prior to use, it shall be examined, tested and determined to operate properly. The entire assembly, from cylinders to torch is essentially one complete functioning unit. The condition of internal cleanliness and repair of regulators, gauges, manifolds torch and hoses will govern the overall operating efficiency.
S0300-BB-MAN-010 E-4.3 Protective Clothing. MAPP gas cutting may be conducted underwater without special protective clothing or devices. E-4.4 Cylinders and Regulators. Eight to ten 220 cubic feet cylinders of oxygen is required for each M-70 cylinder of MAPP gas. All cylinders must be secured in an upright position. When operating in extremely cold weather, it may become necessary to warm the MAPP gas bottles to maintain vapor pressure and proper gas flow.
S0300-BB-MAN-010 Table E-3. Regulator Gauge Settings1 Depth Minimum Water Temperature Minimum Bottle Pressure when using Hydrogen Double Stage Regulators Minimum Bottle Pressure when using Acetylene Single Stage Regulators (fsw) °F (psig) (psig) 10 28 34 19 20 28 39 24 30 28 43 28 40 28 47 32 50 28 52 37 60 28 56 41 70 30 60 45 80 35 65 50 90 38 69 54 1002 40 73 58 125 50 84 69 150 60 95 80 175 66 106 91 200 75 117 102 1.
S0300-BB-MAN-010 E-4.5 Underwater MAPP Gas Cutting Torches. A standard oxy-acetylene oxygen cutting torch can be used for cutting with MAPP gas underwater. Figure E-4 shows a standard surface cutting torch with the underwater spacer sleeve, controls for oxygen and MAPP gas, the cutting oxygen control and the FS or stinger cutting tip.
S0300-BB-MAN-010 Figure E-4. Standard Surface Cutting Torch with Underwater Spacer Sleeve.
S0300-BB-MAN-010 Torch Igniter. A hand mechanical igniter should be used for lighting the torch. This simple tool is safer than an electrical igniter and is equally effective. After the steel has been pierced, cutting can proceed at approximately the same speed as it does above water. If loud popping sounds are heard, other than those made by hot slag forming in the water, add a small amount of preheat oxygen to the flame. This same procedure also applies to edge starts.
S0300-BB-MAN-010 Table E-5. Recommended Pressure Settings and Hose Size Selection Chart WATER MAPP GAS Depth Pressure (FSW) (psi) 10 20 30 40 50 60 70 80 90 100 4.5 9.0 13.5 18.0 22.5 27.0 31.0 35.5 40.0 45.
S0300-BB-MAN-010 E-4.7 Lowering the Ignited Torch. The ignited torch may be lowered to the working location in one of two ways: a. Carrying the Torch Below - In moderate or shallow depths and easily accessible locations, the ignited torch may be carried below by hand. The diver should be prepared to make adjustments to the flame to compensate for increased hydrostatic pressure during descent. b.
S0300-BB-MAN-010 Figure E-5. Starting the Cut at the Edge of a Plate.
S0300-BB-MAN-010 Figure E-6. Starting a Cut in the Central Portion of a Plate.
S0300-BB-MAN-010 E-4.8.3 Advancing the cut. The cut is advanced by moving the torch at a steady, uniform rate of speed along the line of cut, fast enough to keep the cut going, but slow enough to cut completely through the metal. When the torch is advanced too slowly, the steel will cool below the ignition temperature and the cutting action will stop. The diver has “lost the cut” and will have to restart the cutting action.
S0300-BB-MAN-010 E-5 UNDERWATER WELDING CAUTION Due to the flammability and toxicity of fumes from the waterproofing compounds, waterproofing must be conducted in a well ventilated space, clear of any open flames or spark-producing machinery. When commercially produced waterproofed wet welding electrodes are not available, surface welding electrodes can be used if waterproofed. Some above-water electrodes will give satisfactory performance underwater if properly prepared and deposited by a skilled diver.
S0300-BB-MAN-010 Table E-6. Surface Welding Electrodes Suitable for Wet Welding 1/8”, 5/32” & 3/16” E6013, E7014, E7016 & E7018 Carbon steel American Welding Society, AWS A5.1 1/8”, 5/32” & 3/16” E309, E310 & E312 Stainless steel American Welding Society, AWS A5.4 1/8” & 5/32” ENiCrFe-2, ENiCrFe-3 & ENiCrMo-3 High nickel American Welding Society, AWS A5.
S0300-BB-MAN-010 E-5.2 Preparation for Underwater Shielded Metal Arc Welding. Standard electrode holders designed for surface use may be used when underwater holders are not available, but only in an extreme emergency situation. It must be realized that these holders were never intended to be used underwater and therefore are not adequately insulated. The importance of fully insulating all current-carrying parts cannot be overemphasized. See Table E-7 for amperage settings to depths of 50 FSW.
S0300-BB-MAN-010 Table E-7.
S0300-BB-MAN-010 l. Waterproofing compounds drying times vary from minutes to several days. m. Never, under any circumstances, put a waterproofed electrode into a warm oven. The coating process should produce a hard, uniform surface without lumps or blisters. The coating should not dissolve or deteriorate when exposed to salt water. If this occurs, the cause is usually incorrect waterproofing technique.
S0300-BB-MAN-010 e. There are considerable metallurgical advantages with the use of this method. Defects normally associated with weld metal, such as porosity, slag inclusions, cracking arising from arc irregularities are not possible therefore rapid solidification can occur. E-7.3 Equipment Requirements. The term, hand-held, as used to describe this unit, is a somewhat misleading as the unit is merely carried to the job site by hand.
S0300-BB-MAN-010 Figure E-8. Friction Stud Welder.
S0300-BB-MAN-010 GLOSSARY NOTE The following Glossary of Terms is intended to aid the reader in understanding the materials, tools and processes involved in underwater welding and cutting. Most of the definitions were obtained from the approved list of definitions published by the American Welding Society (AWS). Alternating current (AC). Electricity which reverses its direction periodically.
S0300-BB-MAN-010 Cutting Tip. That part of an oxygen cutting torch from which the gases issue. Cutting Torch. A device used in oxygen cutting for controlling and directing the gases used for preheating and the oxygen used for cutting the metal. Direct Current (DC). Electric current which flows only in one direction. It is measured with an ammeter. Electrode Holder. A device used for mechanically holding the electrode and conducting current to it. Electrode Lead.
S0300-BB-MAN-010 Kerf. The width of the cut produced during a cutting process. Kerie Cable. A flexible spiral cable with a hollow core enclosed in plastic. Consumable metal strands of the cable have a high carbon content which burns more slowly than mild steel. Supplied in 50 and 100-foot lengths and gives 45 minutes of non-stop cutting at very high speeds. Manufactured in 3 different diameters. Manipulative Technique.
S0300-BB-MAN-010 Puddle. See preferred term Molten Weld Pool. Self-Consuming Technique. A method of arc welding in which the electrode is dragged across the work with significant amount of pressure. Shielded Metal Arc Cutting. A metal arc cutting process in which metals are severed by melting them with the heat of an arc between a covered metal electrode and the base metal. Shielded Metal Arc Welding.
S0300-BB-MAN-010 INDEX AC power ................................................................................................................................... D-4 Adapter cutting torches...................................................................................................................... 2-21 Advantages and Disadvantages exothermic process ...................................................................................................... 2-5, 2-25 kerie cable .......................
S0300-BB-MAN-010 Cutting and welding “C”-type ground clamps ....................................................................................................... 4-8 equipment ............................................................................................................................ 4-21 Leak Detector ........................................................................................................................ 4-8 tong meter ......................................................
S0300-BB-MAN-010 Electrodes Andersen Easy Weld ............................................................................................................. 3-7 Broco Sof-Touch ................................................................................................................... 3-7 Broco SS ............................................................................................................................... 3-7 E6013 ....................................................................
S0300-BB-MAN-010 Growth-encrusted metal (see Note) ............................................................................................................................ 2-11 Hole Piercing exothermic process ............................................................................................................. 2-31 steel-tubular ........................................................................................................................ 2-15 Hose care during storage ..................
S0300-BB-MAN-010 Operating principles Shielded Metal-Arc (SMA) ................................................................................................ 2-44 Oxygen Safety precautions .............................................................................................................. D-12 Oxygen-Arc Cutting Torches .................................................................................................... 4-17 Oxygen-Arc Cutting .......................................
S0300-BB-MAN-010 Resistance ................................................................................................................................. 4-13 Safety in Underwater Cutting and Welding ............................................................................... D-1 Safety Switches ................................................................................................................. 4-16, D-7 knife switch .......................................................................
S0300-BB-MAN-010 Underwater Cutting ................................ 1-1, 1-2, 2-1, 2-3, 2-6, 2-14, 2-21, 2-25, 2-27, 2-41, 2-43 methods ................................................................................................................................. 2-1 overview ................................................................................................................................ 1-1 Underwater Cutting and Welding difficulties .......................................................
Ref: NAVSEAINST 4160.1A NAVSEA S0005-AA-GYD-030/TMMP (Insert Classification of TMDER Here) CLASSIFICATION: NAVSEA/SPAWAR TECHNICAL MANUAL DEFICIENCY/EVALUATION REPORT (TMDER) INSTRUCTION: Continue on 8 1/2" x 11" paper if additional space is needed. 1. USE THIS REPORT TO INDICATE DEFICIENCIES, PROBLEMS, AND RECOMMENDATIONS RELATING TO PUBLICATION. 2.
FOLD HERE DEPARTMENT OF THE NAVY PLACE POSTAGE HERE Official Business COMMANDER PORT HUENEME DIVISION CODE 5B00 NAVAL SURFACE WARFARE CENTER 4363 MISSLE WAY PORT HUENEME, CA 93043-4307 FOLD HERE DERIVED FROM NAVSEA 4160/1 (REV 5-95) BACK
