Underwater Cutting and Welding Manual
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UNDERWATER
CUTTING & WELDING
MANUAL
S0300-BB-MAN-010
i (ii blank)
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 man-
ual that incorporates state of the art equipment and tried and proven underwater cutting and weld-
ing techniques. The knowledge contained in this manual is a collection of fleet and commercial
experience. It has been reviewed by technical experts with extensive salvage and underwater cut-
ting and welding experience.
This revision of the Underwater Cutting and Welding Manual has been prepared to provide the
most current information on equipment and procedures available. All of the equipment covered
may not be found on the Diving Equipment Authorized for Navy Use (ANU) list (NAVSEAINST
10560.2), but is included in this manual as an aid to the salvor who finds himself in a “must get
the job done” situation. Further guidance can be found in Appendix E.
Due to limited time allocation, there is a lack of realistic underwater cutting and welding training
in the Navy’s diving schools. Students are given only the basics in school and thereafter must
practice to become proficient and gain the experience necessary to become “qualified underwater
cutters and welders.” I therefore charge all diving officers, master divers and diving supervisors to
establish or maintain existing training programs for underwater cutting and welding. Practice,
practice, practice.
C.A. BARTHOLOMEW
Director of Ocean Engineering
Supervisor of Salvage and Diving, USN
S0300-BB-MAN-010
Change A iii
FOREWARD ....................................................................................................................... i
TABLE OF CONTENTS................................................................................................... iii
LIST OF ILLUSTRATIONS ............................................................................................. ix
LIST OF TABLES ............................................................................................................. xi
STANDARD NAVY SYNTAX SUMMARY ................................................................ xiii
SAFETY SUMMARY.......................................................................................................xv
1 INTRODUCTION
1-1 SCOPE ........................................................................................................... 1-1
1-2 UNDERWATER CUTTING OVERVIEW................................................... 1-1
1-3 UNDERWATER WELDING OVERVIEW ................................................. 1-2
2 UNDERWATER CUTTING
2-1 INTRODUCTION ......................................................................................... 2-1
2-2 OXYGEN-ARC CUTTING .......................................................................... 2-2
2-2.1 Principles of Operation .................................................................................. 2-2
2-2.2 Steel-Tubular Electrodes................................................................................ 2-2
2-2.2.1 Advantages of the Steel-Tubular Electrodes ................................................. 2-5
2-2.2.2 Disadvantages of the Steel-Tubular Electrode............................................... 2-5
2-2.3 Electrode Amperage Requirements ............................................................... 2-5
2-2.4 Oxygen Requirements.................................................................................... 2-6
2-2.5 Material Consumption ................................................................................... 2-6
2-2.6 Oxygen Pressure ............................................................................................ 2-6
2-2.7 Oxygen Purity .............................................................................................. 2-11
2-2.8 Grounding the Work .................................................................................... 2-11
2-2.9 Steel-Tubular Electrode Cutting Technique (Thick plate) .......................... 2-11
2-2.10 Steel-Tubular Electrode Cutting Technique (Thin plate) ............................ 2-15
2-2.11 Piercing Holes in Steel Plate ........................................................................ 2-15
2-2.12 Steel-Tubular Electrode Cutting Technique (Cast Iron and Non-Ferrous
Metals) ......................................................................................................... 2-18
2-2.13 Post-dive Maintenance ................................................................................. 2-18
2-3 EXOTHERMIC ELECTRODES................................................................. 2-22
2-3.1 Electrode Amperage Requirements ............................................................. 2-22
2-3.2 Oxygen Requirements.................................................................................. 2-25
2-3.3 Material Consumption ................................................................................. 2-25
2-3.4 Advantages and Disadvantages of the Exothermic Electrode Cutting
Process ......................................................................................................... 2-25
2-3.4.1 Disadvantages of Exothermic Electrodes .................................................... 2-27
2-3.5 Grounding the Work .................................................................................... 2-27
TABLE OF CONTENTS
Chapter/Paragraph Page
S0300-BB-MAN-010
iv Change B
2-3.6 Exothermic Cutting Technique .................................................................... 2-28
2-3.6.1 Exothermic Cutting Technique (Cast Iron, Stainless Steel and
Non-Ferrous Metals) .................................................................................... 2-30
2-3.6.2 Exothermic Cutting Technique (Concrete, Rock and other
Non-Conductive Materials) ......................................................................... 2-31
2-3.6.3 Exothermic Hole Piercing ............................................................................ 2-31
2-3.7 Trouble Shooting.......................................................................................... 2-31
2-3.7.1 Symptoms .................................................................................................... 2-31
2-3.7.2 Probable Causes ........................................................................................... 2-32
2-3.7.3 Locating and Solving the Problem............................................................... 2-32
2-3.8 Post-Dive Maintenance ................................................................................ 2-33
2-4 SEELER ENTERPRISES LU-001 EXOTHERMIC
CUTTING TOOL (KERIE CABLE) ........................................................... 2-33
2-4.1 Advantages and Disadvantages of the of the Kerie Cable ........................... 2-34
2-4.2 Materials Required for Kerie Cable Cutting ................................................ 2-35
2-4.3 Equipment Set-up ........................................................................................ 2-37
2-4.4 Kerie Cable Preparation ............................................................................... 2-39
2-4.5 Cutting Underwater...................................................................................... 2-39
2-4.6 Cutting Technique ........................................................................................ 2-40
2-4.7 Cutting Thin Metals ..................................................................................... 2-40
2-4.8 Cutting Thick Metals ................................................................................... 2-41
2-4.9 Re-Lighting Cable Underwater .................................................................... 2-43
2-4.10 Emergency Off Safety Procedures ............................................................... 2-43
2-4.11 Loss of Communications ............................................................................. 2-43
2-4.12 Equipment Tender ........................................................................................ 2-43
2-4.13 Electrical Precautions .................................................................................. 2-43
2-4.14 Post-Dive Maintenance ................................................................................ 2-43
2-5 SHIELDED METAL ARC CUTTING........................................................ 2-44
2-5.1 Principles of Operation ................................................................................ 2-44
2-5.2 Materials ...................................................................................................... 2-44
2-5.3 Waterproofing Electrodes ............................................................................ 2-44
2-5.4 Underwater Shielded Metal-Arc Cutting Techniques .................................. 2-45
2-5.5 Drag Technique ............................................................................................ 2-46
2-6 CONCLUSION............................................................................................ 2-46
3 UNDERWATER WELDING
3-1 INTRODUCTION ......................................................................................... 3-1
3-2 MECHANICAL BARRIERS ........................................................................ 3-2
3-2.1 Cofferdams and Caissons ............................................................................... 3-2
3-2.2 Mini-Habitats ................................................................................................. 3-2
3-3 SHIELDED METAL-ARC WELDING ........................................................ 3-3
3-4 WET WELDING ........................................................................................... 3-3
3-5 SHIPBUILDING MATERIALS .................................................................... 3-3
S0300-BB-MAN-010
Change A v
3-6 MATERIALS USED IN UNDERWATER SHIELDED METAL-ARC
WELDING ..................................................................................................... 3-6
3-6.1 Underwater Shielded Metal-Arc Welding Electrodes ................................... 3-6
3-6.2 Tong Test Ammeter ....................................................................................... 3-6
3-6.3 Electrode Polarity .......................................................................................... 3-6
3-7 UNDERWATER WELDING ARCS ............................................................ 3-8
3-8 CONDITIONS ADVERSE TO UNDERWATER WELDING..................... 3-8
3-9 STRENGTH OF UNDERWATER FILLET WELDS ................................ 3-10
3-9.1 Parts of a Weld (Definitions) ....................................................................... 3-10
3-9.2 Fillet Weld ................................................................................................... 3-12
3-9.3 Trial Weld .................................................................................................... 3-12
3-10 SURFACE CLEANING .............................................................................. 3-12
3-11 JOINT FIT-UP ............................................................................................. 3-13
3-12 UNDERWATER SHIELDED METAL-ARC WELDING
TECHNIQUES ............................................................................................ 3-13
3-12.1 Welding Set-Up Procedures ......................................................................... 3-13
3-12.2 Self-Consuming Technique ......................................................................... 3-14
3-12.3 Fillet Welding in the Horizontal Position (Self-Consuming Technique) .... 3-14
3-12.3.1 Fillet Welding in the Vertical Position ........................................................ 3-17
3-12.3.2 Fillet Welding in the Overhead Position...................................................... 3-17
3-12.3.3 Self-Consuming and Manipulative Techniques ........................................... 3-20
3-12.3.4 Fillet Welding Where There is Poor Fit-Up ................................................ 3-20
3-12.4 Welding on Thin Plates................................................................................ 3-20
3-13 PROCEDURE FOR REPAIRING SMALL CRACKS ............................... 3-22
3-13.1 Using a Rectangular Patch ........................................................................... 3-22
3-13.2 Using a Circular Patch ................................................................................. 3-22
3-14 POST-DIVE MAINTENANCE .................................................................. 3-25
4 UNDERWATER ARC CUTTING AND WELDING EQUIPMENT
4-1 INTRODUCTION ......................................................................................... 4-1
4-2 EQUIPMENT USED FOR UNDERWATER ARC CUTTING
AND WELDING ........................................................................................... 4-1
4-2.1 Oxygen-Arc and Shielded Metal-Arc Equipment ......................................... 4-1
4-2.2 Diving Equipment .......................................................................................... 4-1
4-2.2.1 Welding Shields ............................................................................................. 4-1
4-2.3 Power Supply Requirements .......................................................................... 4-9
4-2.3.1 Power Converters ........................................................................................... 4-9
4-2.3.2 Welding Generator, Pre-Setup Inspection ................................................... 4-11
4-2.3.3 Polarity ......................................................................................................... 4-11
4-2.3.4 Polarity test .................................................................................................. 4-11
4-2.3.5 Tong Test Ammeter ..................................................................................... 4-13
4-2.3.6 Amperage and Voltage ................................................................................ 4-13
4-2.3.7 Diesel Driven Welding Generator Amperage and Voltage Settings ........... 4-15
S0300-BB-MAN-010
vi Change A
4-2.4 Safety Switches ............................................................................................ 4-16
4-2.5 Power Cables and Connectors ..................................................................... 4-16
4-2.6 Gas Manifolds .............................................................................................. 4-17
4-2.7 Underwater Oxygen-Arc Cutting Torches ................................................... 4-17
4-3 EQUIPMENT FOR UNDERWATER SHIELDED METAL-ARC
WELDING .................................................................................................. 4-19
4-3.1 Electrode Holders ....................................................................................... 4-19
4-4 WELDING ACCESSORIES ....................................................................... 4-20
Appendix Page
A DOCUMENTATION MATRIX
A-1 PURPOSE ..................................................................................................... A-1
A-2 REFERENCE DOCUMENTS ...................................................................... A-1
B METRIC CONVERSION FACTORS
English and Metric Equivalents .......................................................................................B-1
Weights ...................................................................................................................B-2
Measures .................................................................................................................B-2
Pressure or Stress (Force/Area) .......................................................................................B-3
Temperature Conversion..................................................................................................B-3
Metric Prefixes .................................................................................................................B-3
Multiplication Factors ......................................................................................................B-3
C BIBLIOGRAPHY ..........................................................................................................C-1
D SAFETY IN UNDERWATER CUTTING AND WELDING
D-1 PURPOSE ..................................................................................................... D-1
D-2 GENERAL .................................................................................................... D-1
D-3 EXPLOSIVE GASES ................................................................................... D-1
D-3.1 General Information ...................................................................................... D-2
D-3.2 Specific Information ..................................................................................... D-2
D-4 ELECTRICITY UNDERWATER ................................................................ D-4
D-5 GENERAL PRECAUTIONS FOR UNDERWATER CUTTING AND
WELDING .................................................................................................... D-4
D-6 POWER SUPPLY......................................................................................... D-5
D-7 ELECTRODE HOLDERS AND CUTTING TORCHES ............................ D-6
D-8 POWER CABLES AND CONNECTORS ................................................... D-7
D-9 SAFETY SWITCH ....................................................................................... D-8
S0300-BB-MAN-010
Change A vii
D-10 FIRE AND EXPLOSION PREVENTION ................................................... D-9
D-10.1 Major Causes .............................................................................................. D-10
D-11 COMPRESSED GAS SUPPLIES .............................................................. D-10
D-11.1 Use, Handling and Storage of Compressed Gases ...................................... D-10
D-11.1.1 The Never List ............................................................................................ D-10
D-11.1.2 The Always List .......................................................................................... D-11
D-11.1.3 General Oxygen Precautions ...................................................................... D-12
D-11.1.4 General MAPP Gas Precautions ................................................................. D-12
D-11.2 Additional Safety Precautions .................................................................... D-13
D-12 PERSONAL SAFETY IN DIVING ........................................................... D-14
D-12.1 Diving Dress ............................................................................................... D-14
D-13 CONCLUSION........................................................................................... D-14
E EXCEPTIONAL SITUATIONS
E-1 PURPOSE ...................................................................................................... E-1
E-1.1 Discussion ...................................................................................................... E-1
E-1.2 Authorization ................................................................................................. E-1
E-2 UNDERWATER CUTTING EQUIPMENT ................................................. E-1
E-2.1 Arcwater Cutting............................................................................................ E-1
E-2.2 Principles of Operation .................................................................................. E-2
E-2.3 Applications ................................................................................................... E-2
E-2.4 Necessary Equipment .................................................................................... E-2
E-2.4.1 Power ............................................................................................................. E-2
E.2.4.2 Water .............................................................................................................. E-2
E-2.4.3 Arcwater torch ............................................................................................... E-2
E-2.4.4 Electrodes....................................................................................................... E-2
E-2.5 Arcwater Electrode Cutting Technique ......................................................... E-4
E-2.5.1 Underwater Preparations................................................................................ E-4
E-2.5.1.1 Cutting ........................................................................................................... E-4
E-2.5.1.2 Gouging ......................................................................................................... E-4
E-2.6 Material Consumption ................................................................................... E-5
E-2.7 Post-Dive Maintenance .................................................................................. E-5
E-3 CUTTING UNDERWATER WITH THERMIC LANCE (BURN
BARS) ............................................................................................................ E-5
E-3.1 Material Description ...................................................................................... E-7
E-3.2 Required Equipment ...................................................................................... E-8
E-3.3 Set Up Procedure ........................................................................................... E-8
E-3.4 Material Consumption ................................................................................ E-10
E-4 MAPP GAS CUTTING ............................................................................... E-10
E-4.1 Principles of Operation ................................................................................ E-10
E-4.2 Equipment and Material............................................................................... E-11
E-4.3 Protective Clothing ...................................................................................... E-12
E-4.4 Cylinders and Regulators ............................................................................. E-12
E-4.4.1 Purging the Hoses ........................................................................................ E-12
E-4.5 Underwater MAPP Gas Cutting Torches..................................................... E-14
S0300-BB-MAN-010
viii Change A
E-4.6 Igniting the Torch Above Water .................................................................. E-16
E-4.6.1 Preparation ................................................................................................... E-16
E-4.6.2 Ignition ......................................................................................................... E-16
E-4.7 Lowering the Ignited Torch ......................................................................... E-18
E-4.8 Underwater Cutting...................................................................................... E-18
E-4.8.1 Starting the Cut at the Edge of a Plate ......................................................... E-18
E-4.8.2 Starting the Cut at the Central Portion of a Plate ......................................... E-18
E-4.8.3 Advancing the Cut ....................................................................................... E-21
E-5 UNDERWATER WELDING ...................................................................... E-22
E-5.1 Waterproofing Surface Electrodes ............................................................... E-22
E-5.2 Preparation for Underwater Shielded Metal Arc Welding .......................... E-24
E-6 LOSS OF VOICE COMMUNICATIONS .................................................. E-26
E-7 FRICTION STUD WELDER ...................................................................... E-26
E-7.1 Principle of Operation.................................................................................. E-26
E-7.2 Advantages................................................................................................... E-26
E-7.3 Equipment Requirements ............................................................................. E-27
E-7.3.1 Equipment Details........................................................................................ E-27
Glossary ............................................................................................. Glossary-1
Index ....................................................................................................... Index-1
S0300-BB-MAN-010
Change B ix
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 .......... 2-16
2-5 Technique for Piercing Holes in Steel Plate using the Oxy-Arc Process with
Steel Tubular Electrodes ................................................................................................ 2-17
2-6a Underwater Oxygen-Arc Cutting Torch Breakdown (Arcair) ....................................... 2-19
2-6b Underwater Oxygen-Arc Cutting Torch Breakdown (BROCO) ................................... 2-20
2-6c Underwater Oxygen-Arc Cutting Torch Breakdown (Craftsweld) ............................... 2-21
2-7 Technique for Cutting Steel Using Exothermic Electrode ............................................ 2-29
2-8 Seeler Kerie Cable Control Panel ................................................................................. 2-36
2-9 Typical Kerie Cable Set Up ........................................................................................... 2-38
2-10 Technique for Underwater Shielded Metal-Arc Cutting of Thick Plate and
Round Stock ................................................................................................................... 2-47
3-1 Test Specimen for Tee Fillet Weld .................................................................................. 3-5
3-2 The Underwater Welding Arc.......................................................................................... 3-9
3-3 Parts of a Weld ............................................................................................................... 3-11
3-4 Self-Consuming Technique for Underwater Shielded Metal Arc Welding
of Horizontal Fillet Welds ............................................................................................. 3-16
3-5 Self-Consuming Technique for Underwater Shielded Metal Arc Welding
of Vertical Fillet Welds.................................................................................................. 3-18
3-6 Technique for Underwater Shielded Metal Arc Welding of Overhead
Fillet Welds .................................................................................................................... 3-19
LIST OF ILLUSTRATIONS
Figure Title Page
S0300-BB-MAN-010
x
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 ........................................................ 3-26
4-1 Typical Arrangement of Underwater Arc Cutting Equipment ........................................ 4-2
4-2 MK12 SSDS Welding Shield .......................................................................................... 4-3
4-3 MK1, MOD 0 Mask and Lens Holder Assembly ............................................................ 4-4
4-4 Superlite-17B/NS Helmet and Lens Holder Assembly ................................................... 4-5
4-5 MK 12 Helmet Lens Holder Assembly with Parts Identification .................................... 4-6
4-6 Superlite-17B/NS Welding Lens Holder with Parts Identification ................................. 4-7
4-7 Typical Welding Generator and Power-Converter Control Panel ................................. 4-10
4-8 Equipment Arrangement for Welding and Cutting Straight Polarity ............................ 4-12
4-9 Tong Test Ammeter ....................................................................................................... 4-14
4-10 Voltage Drop in Welding Cables ................................................................................... 4-18
E-1 Arcwater Torch Assembly ............................................................................................... E-3
E-2 Thermic Lance Holder Assembly .................................................................................... E-9
E-3 Standard Thermic Lance Equipment Set Up ................................................................... E-9
E-4 Standard Surface Cutting Torch with Underwater Spacer Sleeve ................................. E-15
E-5 Starting the Cut at the Edge of a Plate ........................................................................... E-19
E-6 Starting a Cut in the Central Portion of a Plate.............................................................. E-20
E-7 Restarting the Cut .......................................................................................................... E-21
E-8 Friction Stud Welder ...................................................................................................... E-28
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This manual provides comprehensive information on conventional techniques for cutting and welding metals underwater, essential for ship salvage, harbor clearance, and wreck removal operations.
The knowledge compiled in this manual is a culmination of fleet and commercial experience, reviewed by technical experts with extensive salvage and underwater cutting and welding expertise.
CONTENTS:
- Introduction
- Underwater Cutting
- Oxygen arc cutting
- Exothermic electrodes
- Exothermic cutting tool
- Shielded metal arc cutting
- Underwater Welding
- Mechanical barriers
- Shielded metal arc welding
- Wet welding
- Shipbuilding materials
- Material used in underwater shielded metal arc welding
- Underwater welding arcs
- Conditions adverse to underwater welding
- Strength of underwater fillet welds
- Surface cleaning
- Joint fit-up
- Underwater shielded metal arc welding techniques
- Procedure for repairing small cracks
- Post-dive maintenance
- Underwater Arc Cutting and Welding Equipment
- Equipment used for underwater arc cutting and welding
- Equipment for underwater shielded metal arc welding
- Welding accessories
- Documentation Matrix
- Metric Conversion Factors
- Bibliography
- Safety Underwater Cutting and Welding
- Explosive gases
- Electricity underwater
- General precaution for underwater cutting and welding
- Power supply
- Electrode holders and cutting torches
- Power cables and connectors
- Safety switch
- Fire and explosion prevention
- Compressed gas supplies
- Personal safety in diving
- Exceptional Situations
- Underwater cutting equipment
- Cutting underwater with thermic lance
- Mapp gas cutting
- Underwater welding
- Loss of voice communications
- Friction stud welder
- Glossary
- Index
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