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Underwater cutting safety

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Example of underwater cutting system.

If you are inexperienced or unfamiliar with underwater cutting, the CD is an excellent resource for a general introduction to underwater cutting and welding. Although Magnum was not around when the manual was made, Magnum has subsequently distinguished itself in the field in having more commercial divers now trained on Magnum products than any other brand.

Underwater cutting (also called burning) produces hydrogen gas that can cause explosions. Always vent any object that can trap or confine gas bubbles. Ship hulls, cargo holds, double patches and double bottoms can contain explosive gases. Vent all areas prior to cutting. Always cut from the top down to allow natural venting of flammable, explosive gases. Hydro carbons can cause an explosion so be sure to inspect all sides of an area to ensure they are not present. Pipes and pipelines must be flooded with water prior to cutting. The U.S. Navy publishes a cutting manual that can be found online.

Never cut when a pressure difference exists. Your fingers, hands or flame particles can be sucked into a hole or opening. Objects can also be blown from openings. Always drill a hole in the top and allow pressures to equalize. This is critical on gantry legs or other objects and materials that can trap gases. Venting allows gases to escape. Since gases can become trapped in mud, remove mud from around the area to be cut. When encountering packed mud, ensure the tip of the cutting tube is pointed up while effecting the cut starting at the top and pulling it to the bottom to ensure gases are not driven into the mud ahead of the cut. The same process is used for concrete filled pipes.

Do not cut in a straight line around the circumference of a pipe. Cut one half of the pile. Go back to the starting point and cut the other half of the pile using the same technique. Start at the highest point and drag the cutting tube away from the kerf to prevent bubbles from being forced into voids. This process allows bubbles to naturally escape. Sufficient safety equipment is essential. For cutting, requirements include an insulated cutting torch, oxygen hose, 2 stage regulator, heavy duty ground lead with clamp, knife switch, and if not using a battery, a DC welder for ignition.

The knife switch is located on the tender platform so power can be turned on and off through commands given by the diver. On a single throw knife switch, the negative side of the DC welder is connected to the knife switch and cutting torch (straight polarity). The positive side of the DC welding machine is connected to the ground lead. An exception is the dual pole knife switch where both the negative and positive cable run through the knife switch. When open, all current stops. Because the dual pole stops all current when open, it is the safest switch to utilize.

Ensure all connections are tight and without gaps which could cause problems with arcing or current performance. Ensure the hoses are tight and located away from the burn zone. All equipment is to be free of oil, grease or any flammable material. Oxygen is adjusted per ocean depth (to be discussed later). Check for leaks prior to cutting. Although polarity is not important for ignition, it is essential for welding. An easy way to assess polarity is to submerge an unlit burning rod and the ground clamp into a plastic bucket filled with water keeping a 2" distance between the two. Close the knife switch (make hot). Reverse polarity will cause a stream of hydrogen bubbles to emanate from the tip of the burning rod.

Prior to cutting ensure the material to be cut is properly grounded. Clean the surface of the material to ensure the clamp is properly grounded. Ensure the clamp is close to the cut area yet in a strategic position to ensure the diver never comes between the ground clamp and the cutting torch. To initiate cutting the diver signals to have the knife switch closed (make it hot). The cutting tube is ignited by bringing it into contact with the grounded material to be cut. Always purge the torch head with a blast of oxygen to remove any residual hydrogen bubbles that can accumulate from the prior cut. The diver then signals to have the knife switch open (make it cold), so cutting can be effected without continuous current. The beauty of exothermic cutting is that is can be accomplished without current on once ignited.

Polarity effects the amount of heat going into the material. Straight polarity means most of the heat resides in the work piece. Underwater cutting is accomplished using straight polarity. Cutting without power is slower but safer. Cutting with continuous power is faster but not as safe as the diver must manage a continuous arc. For this reason, continuous current cutting is best left to seasoned professionals with extensive training and experience. Never leave a knife switch hot since hydrogen bubbles can explode. Leaving a knife switch on can also discharge the battery when a battery is used for ignition. In general, the cleaner the surface the faster the cut.

The purity of oxygen for all underwater cutting should be 99.5 percent or greater. Oxygen purity is related to performance. A one percent degrease in oxygen purity will result in a 25% reduction in cutting efficiency and an increase in slag inclusion. Commercially available oxygen should be 99.9 percent pure.

Amperage settings vary. Consider the following as a starting point when oxy-arc cutting:

Cutting 3/8" 200amps.

Cutting 3/4" 225 amps.

Cutting 1 1/4" 250 amps.

Cutting 2" and above 300 amps.

A 3/8" inner diameter hose is recommended.

Steel reinforced for deep dives.

Cable considerations:

Use the same size cable for all connections. Expect at lease a 2 amps drop per 50 foot of cable. Holes or defects in cable insulation generally show up as red because of the oxides. It is a good practice to test leads on land prior to underwater use. Running your hand along the cable will test for increased resistance demonstrated by a change in heat. Hot spots must be repaired with a splice or by changing the cable. Low or no voltage and high amperage as indicated by a meter indicates a cable that requires repairing or replacing.

A two stage regulator is required capable of producing 70 cfm flow. Oxygen cutting pressure is set at 90 psi over bottom pressure.

Hose length and regulator settings

Hose length 50 feet depth (FSW)	Regulator pressure settings (psi)
10	100
20	104
30	109
40	113
50	118
60	122
70	127
80	131
90	136
100	140

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Industrial Product Catalogues

High performance cutting, welding and safety products

Emergency Response and Tactical Cutting Systems

Underwater Cutting and Welding Systems

Repair, Maintenance and Salvage Cutting Systems

Hose length and regulator settings