Underwater Welding Training CD
	In today’s job market it can be hard to find a job that will provide you with a stable, reliable income. Career paths that were once secure can suddenly disappear. For other people, the drudge work of sitting in a cubicle everyday has become mind numbingly boring. Wouldn’t it be great to have skills that are constantly in demand and would allow you to work when and where you choose? That is why the Underwater Welding Training CD is so valuable. This course can take you step by step through everything you need to know to learn this practical, in-demand trade!

Start Training For A Great New Career As An Underwater Welder Today!

Both The Government And The Private Sector
Are Looking For Underwater Welders!

Underwater welders perform a variety of tasks that are constantly in demand. When you learn this trade, you will be able to help private and public contractors with much needed salvage work. You will also be able to help repair hulls and other boat sections that need to remain underwater.

You could actually help save lives!

The best part of this exciting career is that few people have these much needed skills. It can cost hundreds of dollars and dozens of hours of classroom time to learn these skills - and that is not practical for most people!

Yet with this incredible course, you can learn these skills and train for an exciting new job on your own time - from the privacy of your own home!

Sample thumbnails taken from the collection. Click on image to view larger picture.

This Course Was Designed By The United States
Navy To Train Their Own Personnel To Handle Any
Underwater Emergency!

This incredible, easy to follow study course was designed by the United States Navy in order to train their personnel. As I am sure you know, the Navy has to train soldiers from a variety of educational backgrounds. Therefore they need to make sure their training documents can be understood by virtually anyone. Yet, because the Navy is responsible for our national security, they also have to make sure that when their men and women finish the course, they are true experts.

This Guide Is Broken Down Into Four
Easy To Follow Chapters!

This 200 page manual is divided into four chapters 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. Divers who perform underwater cutting and welding must have greater skill and stamina than those doing the same work topside.

The success and speed of operations depend upon the conditions under which the diver must work, because the underwater environment imposes numerous limitations and restrictions on the operator and equipment. The diver is often restricted to working for only a short time on the bottom, particularly at deeper depths. The use of correct technique and equipment becomes extremely important in terms of work accomplished per hour. Diving apparel, great depth, adverse currents, low temperature, lack of visibility and unstable footing are all factors which make underwater cutting and welding difficult.

Here is a complete list of what is covered in each section of this great course:

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

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

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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

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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

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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-2.5.1.2 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

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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

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