swordfish™ non exothermic cutting electrode user manual
Contents
1. May 2004 Swordfish Non Exothermic Cutting Electrode User Manual MAI NTENANCE GENERAL CARE After the equipment has been used the following procedures are recommended Wash all equipment that has been immersed in salt water with fresh water Cables The electric cables are to be washed in fresh water and dried before storing the cable ends and stinger can be coated in anti water dispersant Connections All cable connections should be stripped cleaned and re insulated If not being used again for extended periods all cables and hoses should be dusted with French chalk For surface cutting check the cables and associated equipment for damage burns and replace if necessary Equipment should be stored in an oil free environment Electrodes that have been exposed to salt water should be checked for damage and blown dry and stored to manufacturer s recommendations MECHANICAL SERVICING There is no mechanical servicing required with Swordfish however if the stinger or an alternative electrode holder is used the appropriate servicing procedure should be followed 90 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Chapter 5 5 1 5 2 Shell May 2004 Swordfish Non Exothermic Cutting Electrode User Manual TROUBLESHOOTING DENTI FYING THE FAULT If you cannot get an arc check the following o Is Open Circuit Voltage OCV available o Has the disconnecting saf2. o Adhere to the Safety Data Sheets that are supplied with the electrodes o During surface cutting ensure a well ventilated area is used whenever possible the user should use a ventilated welding visor and or extractor fans o There is no toxic gas risk during a dive except for the gasses that will rise to the surface therefore ensure all surface crews are aware of toxic gas hazards o Arc Rays can cause serious damage to eyes and skin o Always use Personal Protective Equipment PPE Eye protection and suitable clothing with rubber gloves When diving is taking place ensure that surgical gloves are worn under normal diving outer gloves and that the outer glove cuffs are taped o Always use an approved electrode holder Stinger with the electrode o Prior to the start of any underwater cutting it is good practice to consult and study any drawings and physical configurations of the work area Areas where cutting is to take place must be studied to determine areas voids that could contain or trap potentially explosive gasses These areas voids must be vented or made inert to prevent possible explosions To this end a cutting methodology should be adopted o When cutting hydrogen and Oxygen is disassociated from the water and will travel separately as bubbles These bubbles can collect in trapped or confined spaces overhead If hydrogen bubbles combine with oxygen bubbles which could come from the divers expelled gas they may igni
3. Description of Event Underwater Non exothermic Iron Oxide Electrode Cutting of Pipeline Personnel Conducting Assessment Specifically Named Project Manager Shell Representative Health and Safety Advisor Diving Supervisor Divers Risk Reduction Mitigation Measures Hazard Impact Effect Activity Event Consequence Uncompensated Risk Value Who When Residual Risk Action gt a o 2 gt p O SG o O JE L Consult plans and diagrams prior to Sup in o ee a operation plans Explosion Initial cut of target pipeline Cutting in wrong location plosio Conta vino harcamemaand aio Diver injury death diver prior to cutting Cutting area with increased spin 4 E e E bl Remove all corrosion wrappings and explosive gas content ap PIP lbs marine growth from area to be cut voids Diver injury death Provide ventilation gas escape Cutting area with no escape Gas methane Oxygen Structural asset damage points at top of area to be cut route for gas that is being entrapment in pipe hollows Explosion blow back Monitor gas release during the released from the process voids Diver injury death process Cut from highest point downwards Structural asset damage Shell May 2004 A OE QZ Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual Risk Reduction Mitigation Measures Hazard Impact Effect Activity
4. all connections shall be visually checked and rust free Operation of the holder shall be confirmed The operator is to ensure that the cutting electrode can be held securely and easily released by the jaws HEAD UW5001 WEAR PLUG UW5002 i SECURING FIN UW5003A MAIN BODY UW5003 CABLE CONNECTOR UW5005 WITH GRUB SCREWS CABLE RETAINER UW5004 Figure 6 Electrode Holder Suitable personal protective equipment PPE is to be made available and in good repair OM May 20040076 Of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Shell May 2004 Swordfish Non Exothermic Cutting Electrode User Manual o Welders coveralls smock for surface use o Protective gloves o Eye protection o Suitable head protection o Underwater visor for sub surface work o Gloves Neoprene diving gloves with latex under gloves for sub surface work Figure 7 Coveralls and Headgear Figure 8 Protective Gloves Figure 9 Head Protection Ensure a suitable Open Circuit Voltage OCV Is available from the machine 55 80 volts and check to ensure constant voltage is maintained If no metres are fitted to the equipment refer to the manufacturer s data plate The cutting process will be hampered if the welding generator is in a poor state of repair or fluctuates during the process 77 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swo
5. are adequately protected It is not sufficient to expect that the welding machine is earthed through its earth lead in the mains plug Although this will take care of any primary side problems it will not stop current leakage occurring on the secondary side of the circuit A secondary voltage shock can occur if the operator touches a part of the electrode circuit a bare spot on the cable for example while at the same time another part of his body comes into contact with another side of the welding circuit All personnel responsible for or engaged in underwater cutting welding should understand and be aware of the following 65 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual o Read and understand the safety and operating instructions of all involved equipment prior to use o Read and comprehend this manual o Know the capabilities of assigned equipment and strictly follow operational procedures o Use this manual in association with the equipment for ready reference o Follow all warnings printed on system components o Adhere to pre use use and post use routines o There are no hazardous substances used in the electrodes however the manufacturer s guidelines must be followed when cutting It is advisable for the operator to keep his or her head clear of the gas plume during surface use and employ Local Exhaust Ventilation where appropriate
6. of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual 3 4 UNPACKING SWORDFISH When unpacking Swordfish check the packaging for damage If any of the boxes are damaged the contents must be carefully checked and any damaged electrodes discarded If they arrive in damaged condition they should be returned to the manufacturer It is good practice to record batch numbers and use them sequentially This will assist in keeping cutting electrodes in prime condition 3 5 SWORDFISH AND ASSOCIATED EQUIPMENT SET UP User checks in accordance with manufacturer s guidelines on welding plant equipment must be followed The integrity of the welding leads must be inspected and damaged leads should not be used Figure 4 Good Lead Figure 5 Damaged Lead An appropriate earthing clamp is to be checked for wear and tear and the cable connection is positively secured as close to the cut as possible Shell May 2004005 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual The approved electrode holder Stinger has been marinised with resin compound and is CE marked in accordance with the use of underwater electrical equipment guidelines The electrode holder Stinger is recommended for use with Swordfish by the manufacturer If an alternative holder is employed it shall be fit for purpose
7. to avoid Products to avoid Hazardous decomposition products these cutting electrodes al normal ambient temperatures evolve no fumes or vapours but in use cutting fumes will be evolved see section 8 11 TOXICOLOGICAL INFORMATION Abn routes of entry Inhalation of welding fumes Symptomseffects Inhalation of excessive fume concentrations may result in following signs and symptoms Respiraiory tract irritation dizziness nausea andior metal fume fever iii to welding fumes can lead to lung diseases and affect pulmo 12 ECOLOGICAL INFORMATION WA 13 WASTE REMOVAL eg E OE TERO a Ao catan as vado 14 INFORMATION CONCERNING TRANSPORTATION Un mr N A IMDG N A RRID N A IATA N A 15 LABELLING i OTHER INFORMATION N A not applicable WD not determined NIVA no data available This information only refers to the described product and is based on actual knowledge and experience known by us because operating conditions are unknown to us and does not belong to our sphere of influence The product may not be used without written permission for a use other than mentioned in pt This information may not be taken nor as a guarantee nor as a quality indication of our product This material safety information describes the product in relation with safety rules and is not meant as a os fens od eae E ae A A laws and regulations Mame DJ Keats Date Now 2002 Shell May2004 00 AO FOR Evaluation Report
8. to the mating of cables to the power supply If 3 phase DC equipment is being used ensure all connections have been checked for damage prior to use If damaged do not use Figure 16 Switch Off the Welding Generator Shell May2004 BOO Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual Figure 17 Connect the Power Supply 17 The cable must be flaked out and the material to be cut must be suitably earthed Personal protective equipment PPE must be worn ready to cut this includes bystanders Safety point Arc rays can cause serious damage to eyes and skin 18 Ifa motorised generator is being used ensure fumes are down wind of any compressors 19 Material to be cut is free of loose particles and clean prior to cutting taking place 20 Carry out a visual check of the Swordfish cutting electrodes for damage prior to use and position the electrodes in vicinity of job for ease of use Figure 18 Check Cutting Electrodes for Damage Figure 19 Connect Electrode to Stinger 21 Connect the cutting electrode to the electrode holder Stinger ready for use 22 Turn the power switch on the welding generator to on Shell May2004 BOO Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E 3 1 Swordfish Non Exothermic Cutting Electrode User Manual 23 Close the disconnecting safety switc
9. touches the work 4 NC power can be used for surface cutting operations 3 8 1 Advantages o Cutting technique is simple and easily mastered with appropriate tuition o Metals up to 75mm in diameter can be cut o Cutting is accurate on most materials o Neat trim and narrow cuts are produced o Power required is between 200 400 Amps of welding power supply 3 8 2 Disadvantages o The burning time of the electrode is short approximately one minute o It produces a narrow gap which may be difficult to locate in poor visibility o A welding supply is required 3 8 3 Cutting Techniques DRAG The drag technique can be used for cutting thin gauge metal by dragging the electrode along the desired line of cut but ensuring the tip of the electrode is always in contact with the metal being cut 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 STEP FORWARD The step forward technique can be used for cutting heavy gauge metal by using the electrode in a sawing motion to push away the molten metal out of the far side of the cut Skilful application of this sawing technique makes the metal arc cutting process practical over a wide range of thicknesses When cutting non ferrous metal round stock a sawing motion should be used starting at the bottom and pushing through Z When using underwater p
10. ANSPORTATION For storage and transportation each of the following must be understood and considered 1 Batch Number Swordfish electrodes should be stored in a dry environment in the manufacturer s containers Suitable conditions for storage would be for example 60 Humidity and a temp between 20 30 room temperature There are no hazards regarding the storage of Swordfish Electrodes should remain in their packaging until required Electrodes should be handled and stored in a manner that prevents any physical damage Any damage to the electrode coating may have a detrimental effect on cutting performance therefore caution must be exercised so as not to cause physical damage to the electrode coating Part used boxes can easily be resealed Tests in water have revealed that providing the cutting electrodes water proof coating has not been damaged they can be left immersed for long periods and used with no degradation in performance follow manufacturers recommendations It is recommended that electrodes are not taped together as this could cause damage to the protective waterproof coating Use of a suitable quiver is required Shelf Life There is no limitation specified however it is good practice to use batches in order which can be determined from the batch number as indicated in the illustration below 515616 amb GaP Rie GAO Ge DEPT z P A ee ee m aS Sa E E A H Ti T Se ee E
11. Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual Annex E Swordfish Non Exothermic Cutting Electrode User Manual Certain technical information contained within this document is copyright Mr David Keats 2004 and is reproduced with his kind permission Shell May2004 BF Of QB Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual Registered Trade Mark of Speciality Welds SWORDFISH NON EXOTHERMIC CUTTING ELECTRODE USER MANUAL Shell 2003 2004 This document is the property of Shell and the information contained herein is confidential This document either in whole or in part must not be reproduced or disclosed to others or used for purposes other than that for which it has been supplied without prior written permission from Shell or if any part hereof is furnished by virtue of a contract with a third party as expressly authorised under that contract Shell and Speciality Welds shall not be liable for any errors or omissions Swordfish User Manual Version 02 Shell May 2004 58 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual USER MANUAL CONTENTS Chapter L IMUA anna DA ernie neem een 61 Chapter2 General DESC OOM assa ssa da Sa tvataisyhcaeasan yatta seuacebaeauvetets
12. Event Consequence Hazard Severity Probability Uncompensated Risk Value Residual Risk Action Who When Confirm competence and currency of diver qualification in equipment Provide adequate information instruction training and supervision Allow time for proofing on test pieces Overhead Hot cut with ro vor Fan aaa dd Swordfish cutting electrode 19 g ia equipment housekeeping Diver to clean an area forward of the Electric shock cut and secure the earthing clamp Electricity Diver injury burns At no stage should diver position death himself between the work piece and earth clamp Ensure all plant and equipment is certified and maintained in Asset damage accordance with planned Diver injury death maintenance programme Conduct pre use and function tests orior to deployment Inexperience incompetence of diver for Swordfish cutting operations Asset damage Diver injury death Hot cut with Swordfish cutting electrode Hot cut with Swordfish cutting electrode Hot cut with Swordfish M cutting electrode Equipment failure 4 The above Risk Assessment is provided merely as a guide to possible format All cutting operations must be Risk Assessed employing the Assessment as a part of the overall Hazard Reduction Process Shell May 2004 AA Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual 3 3 STORAGE amp TR
13. Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Annex E Swordfish Non Exothermic Cutting Electrode User Manual LIST OF LLUSTRATIONS PUI A UV es COM DO santos a a ias 68 FUMEIEXTACIonN das 69 A A E a O 72 GOOG A salen eg US So A 75 Damaged Lead esrin ac PR ER POD RREO RR 15 Electrode Holdem RR OR RR POR RR RO OR RR RR RR 76 Coveralls and esla ocio tdcios 17 Protective GIOVES aiii rara iaa doo ates 17 ELO 5d 0 al 6 y CR IO cedar saeaie aise PD DART PROERD CR RR RR 17 AN A A Ap q 78 Rabe Capac a aos 79 AO 81 Negative Cable Connection ira ic iia 81 Positive CablerCoONne cOn da iaa id na 82 current Selecto AA O nha ee 82 Switch Off the Welding Generator ococcococcococccnocconoconnnnononnonnnnnnnnnncnnnnnonnnnonnnnnnnnnnrnnnrrnnnnnenos 82 Connect the POW El SUDOV daran aaa diario aaa 83 Check Cutting Electrodes for Damage siii 83 Connie CE Electrode to nda ada 83 PRED eG tO CUE raio a O 88 Figure 20 Shell May 2004 60 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual Chapter 1 INTRODUCTION O Shell May 2004 The function of this instruction manual is to provide information only It is subject to alteration without notice and does not represent a commitment on the part of Shell and Speciality Welds or their agents The success and speed o
14. akes and wasted bottom time may be avoided by simply taking an ammeter reading before the diver enters the water This step will eliminate any doubt as to the actual welding generator amperage output Excessive burning can be achieved by a diver who has assumed the welding machine was functioning properly when in fact it was delivering amperage far in excess of the dial setting On the other hand there have been many man hours wasted by divers trying to cut with too little amperage To determine the exact amperage output of the welding generator o Take a tong meter reading o Wait until the diver has established an arc and is cutting and simply encircle the welding lead with the tongs of the test ammeter and close them o A clear accurate reading will instantly register on the scale This will be the closed circuit reading It is recommended that you do not rely exclusively on the values indicated by the control panel knobs or installed meters The meters are not intended for exact current or voltage measurements The Tong Test Ammeter will read the actual current passing through the welding cable 3 6 PRE USE ROUTINE SURFACE For ease of demonstration 3 phase DC equipment has been the preferred power source However fundamentally all equipment checks are similar and should be carried out prior to use It is recommended that these measures are incorporated into local procedures Any deviation from these measures should be fully ju
15. ask risk assessment is carried out prior to all sub surface cutting operations The Risk Assessment shall receive input from all concerned with the process including the diver 28 Check material to be cut for any types of coating or wrapping as this may hamper cutting or cause unknown gasses to be released If coatings are detected then the cutting operation may have to be delayed until any potential hazard has been identified and the subsequent risk has been eliminated or reduced to an acceptable level 29 Ifan electric generator is being used ensure that it is in a suitable position is earthed and does not interfere with diving or surface operations 30 All cables integrity have been checked flaked out suitably and the correct placement of the ground connection earth is made prior to cutting The manufacturers recommended distance from the cut line is 300mm 31 When working in deep water due to the weight it is sometimes beneficial if the cables can also be supported by rigging a strain relief to assist the diver 32 Itis recommended that the area to be cut is cleaned and free of marine growth as it is known that marine growth releases gases into the water and may have contributed to some explosions No work directly above the diver is to be carried out O Shell May 2004 33 The diver is to wear appropriate personal protective equipment prior to cutting 84 of 93 Evaluation Report of Swordfish Iron Oxide Cuttin
16. ctive Equipment available 1 To 2 _ Is the electrical power isolated to the torch prior to and during deployment to the diver TT 3 _ Is the diver established in the correct position and NOT between the return lead and the welding lead Is the diver s umbilical clear of the cutting operation 5 Has the diver checked above and around the cutting area to ensure there are no potential areas of gas entrapment 6 Has the area to be cut been cleaned of marine growth and corroded material pa A 7 Has the diver checked beneath the cutting area to ensure that any molten material will fall clear of equpments AAA EA ES E es i 8 Do vent holes need to be cut to release any trapped gas O S S S o _9 _ Isit safe to cut vent holes If required ensure the diver knows to cut from the top down _ _ Can the structure being cut fall on the diver or on his or her equipment Comments SUPEI Sr SIONA PP e oo E Piintea Name asus ET aa Ena it Shell May2004 B60f93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual 3 8 OPERATION SURFACE SUB SURFACE The Swordfish electrode provides an effective and efficient cutting result and is to 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
17. e flux coating USES o Mild Steel Plate Pipe Including Concrete Lined o Forged Steel o Cast Iron o Aluminium o Phosphorous Bronze o Stainless Steel Li MITATIONS o Swordfish requires a welding plant with an output of between 200 400 amps o Cutting can be hampered in poor visibility o Poor footing stage can hinder good cutting technique o Swordfish cutting electrodes are currently only available from the manufacturer 62 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Shell May 2004 Swordfish Non Exothermic Cutting Electrode User Manual DEPTH LIMITATIONS WATER o Cable lengths Providing the necessary current can be maintained there is no depth limitation o Double insulated cable with orange rubber butadiene nitrite cover OPERATING TEMPERATURES o Surface Sub surface Arc plasma will provide heat intensity of 5000 C OPERATING CURRENT o Surface A range between 200 350 for 4mm and 290 390 for 5mm o Sub Surface A range between 200 350 for 4mm and 290 390 for 5mm OPERATING VOLTAGE 2 TYPES o Open Circuit Voltage OCV which would typically be between 55 80 volts o Arc or Closed Circuit Voltage which would typically be between 25 40 volts DEPTH LIMITATIONS MATERIAL THICKNESS During testing and evaluation the maximum thickness cut was 50mm mild steel during a surface cutting exercise It is worth noting that the thickness of the ma
18. e path of slag from the cutting operation If cutting overhead is deemed unavoidable ensure appropriate Personal Protective Equipment PPE is worn The diver is not to be directly beneath any molten metal falling from the cutting procedure Divers should ensure cutting operations are carried out from one side of the area to be cut and not directly facing or beneath it This will ensure that should an explosion occur the blast energy is not channelled directly towards the diver The supervisor should remind the operator of this throughout the operation The diver shall ensure that while power is on hot the torch is never left unattended Only change the electrode when cold disconnecting safety switch When the electrode has been consumed to within 75mm 3 of the torch the diver is to stop cutting and signal for the torch to be made cold via the disconnecting safety switch knife switch before attempting to change electrodes Maintain the torch in the cutting position until the surface has confirmed the torch is cold The diver should tap the electrode twice to make sure the current is off When starting the cut the hand should never be closer than 100mm 4 from the electrode tip As the electrode is consumed and becomes more manageable a one handed grip can be used Never get between the electrode and the return lead Arcing can damage welding machine switch contacts Do not change the range switch position whilst weldi
19. ety switch knife switch connection been made o Are all connections tight and secure o Is the cutting electrode damaged o Check the earth clamp is secure and well attached o Is the power source turned on and set to the required ampage for the job o Is the electrode holder stinger fit for use ORDERING PARTS The Underwater Welding Stinger and Swordfish Cutting Electrodes can be ordered from Speciality Welds Office Suite 18 Moorlands Business Centre Balme Road Cleckheaton West Yorkshire BD19 4EW Tel 44 0 1274 879867 Fax 44 0 1274 855975 Email Sales Specialwelds com Website http www specialwelds com 91 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual Chapter 6 LIMITED WARRANTY If found to be defective providing the equipment has been used within the manufacturers guidelines the cutting electrodes will be replaced at no additional cost OShel May2000 O Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual Chapter 7 QUALITY CONTROL If at any time Swordfish becomes defective or results have deteriorated for unknown reasons then the manufacturer should be contacted for advice feedback Shell May2004 OO
20. f an underwater cutting operation depends upon the conditions under which the diver must work The underwater environment imposes numerous limitations and restrictions on the operator and the equipment being used Diving equipment currents lack of visibility and poor footing are all factors that will make underwater cutting challenging Only competent persons should use the procedures and techniques contained within this manual Those wishing to use Swordfish without the necessary skills training and experience do so at their own risk Prior to delivery your Swordfish Cutting Equipment was in a dry and serviceable condition 61 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Chapter 2 2 1 2 2 2 3 Shell May 2004 Swordfish Non Exothermic Cutting Electrode User Manual GENERAL DESCRIPTION Swordfish is a non exothermic arc cutting electrode designed for the cutting of metallic objects surface and subsurface where gas entrapment from a conventional exothermic cutting process may present a safety issue It is not designed to replace normal open water cutting processes SPECI FI CATIONS Electrode Length 46cm Electrode Diameter 4 0mm 5 0mm Number in Box 4 0mm 60 electrodes By weight 5 0mm 41 electrodes By weight Power Range 4 0mm 200 350 Amps 270 300 Amps theoretical optimum 5 0mm 290 390 Amps 330 360 Amps theoretical optimum Composition A high tron oxid
21. g Electrode Annex E 34 35 36 37 38 39 40 41 42 43 44 45 46 Swordfish Non Exothermic Cutting Electrode User Manual HSE approved diving helmet with suitable welding visor fitted Neoprene gloves with latex under gloves gloves taped to the diving suit When making any connections ready for use always ensure the welding generator power switch is off and the disconnecting safety switch knife switch is open cold Follow the set up procedures for connecting cables as for the surface pre use routine above Ensure all connections of cable extensions are suitably insulated and water proofed to prevent electric shock Earthing clamp is securely attached to the material to be cut The diver must ensure that he or she is not between the return lead and the welding lead All umbilicals hoses are clear of the job Set the desired current on the selector dial of the welding generator Place cutting electrodes in a position where they are easily accessed for the job normally in a quiver Connect a cutting electrode to the electrode holder stinger ready for use Ensure suitable eye protection is worn or welding filters are provided when using Swordfish Welding generator has been powered up but the disconnecting safety switch knife switch is cold As the diver you inform the surface supervisor to make it hot the disconnecting safety switch knife switch will be closed making
22. h knife switch making the circuit Hot 24 When ready to cut it is advised to finally check that there is enough cable slack to prevent snagging on the job thus ensuring a smooth and unhindered cut You are now ready to commence cutting PRE USE ROUTINE SUB SURFACE It is recommended that these measures are also incorporated into local procedures Any deviation from these measures should be fully justified and recorded within the risk assessment For electrical welding generators follow pre use routine for surface cutting including the additional recommendations within this section Prior to the start of any underwater cutting it is good practice to consult and study any drawings and physical configurations of the work area Areas where cutting is to take place must be studied to determine areas voids that could contain or trap potentially explosive gasses These areas voids must be vented or made inert to prevent possible explosions 25 Careful examination of the target area and surrounding environment should be made before starting the cutting operation Particular attention should be made as to how the cut away piece or molten metal will fall and whether there are any projections wires or any other objects which may foul lines or Cause a piece to swing around in an unexpected manner 26 If available an ROV can be deployed to obtain images of the site and surrounding areas where cutting is to take place 27 Ensure a t
23. ing the electrode against the target When it becomes necessary to change electrodes underwater the diver is to inform the supervisor that he wishes to do so by giving the command MAKE IT COLD The supervisor will then break the circuit by opening the disconnecting safety switch knife switch and will return a report back to the 88 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual diver Cold when the disconnecting safety switch knife switch is in the open position It is important that the operator does not operate the switch unless specifically directed to do so by the diver Furthermore when directed to do so he should confirm each change to the diver Once electrodes have been changed the diver will inform the supervisor of this by stating Make it Hot the supervisor will close the disconnecting safety switch knife switch and inform the diver of this by stating Hot 3 8 5 Emergency Shut down If at any time a problem an emergency occurs the following procedure is to be followed J 6 7 8 Stop cutting Inform the surface Isolate the cutting circuit immediately Make it cold Turn the power Isolating switch to off Seek medical assistance if necessary Shell May 2004 89 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Chapter 4 4 1 4 2 Shell
24. lectrical current voltage and very high electrode tip temperatures It is impossible to anticipate all possible situations that may arise from underwater cutting consequently it cannot be assumed that safe operating conditions will exist simply by blindly following the guidelines laid out in this manual Nonetheless with a thorough knowledge of cutting fundamentals and electrical Safety combined with the use of suitable and sufficient control measures the procedures described within can be performed in maximum safety For sub surface operations only competent and certified divers are allowed to perform underwater cutting operations All diving operations shall be carried out in accordance with recognised national and international diving regulations Figure 2 Fume Extraction Follow all employees safety practices The guidelines as specified by the Association of Offshore Diving Contractors AODC Safe use of electricity underwater code of practice and the International Marine Contractors Association IMCA publication DOO3 RISK ASSESSMENT The following document is provided as an example of possible format to be used for the conduct of a risk assessment 69 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual RISK ASSESSMENT Assessment No PMT 023 Sh ABC Revision No Original Date 14 10 2003 Shell ABC 123 Location Defence Diving School
25. nds on the metal that is cut and the surface condition from it Cutting of stainless steel will develop fumes containing chromium and nickel compounds These values pertain to use of this product in air Shell May2004 OO Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual Respiration protection use fume respirator of air supplied respirator when welding cutting in confined space or in general work area when local exhaust does not keep exposure below TLV Eyes Wear shaded filter lens The choice of appropriate light filtration will be based on visual acuity and may vary from one individual to another particularly under different current densities materials and electrode diameter suggested filter shade number for shielded metal arc welding is 9 12 Hande Wear protective gloves to prevent injuries from radiation sparks and electrical shock Wear protective clothing to prevent injunes from radiation sparks and electrical shock Welder ermit live paris or electrodes to make contact with skin q PHYSICAL AND CHEMICAL DATA Physical form solid coated metallic rod Explosion limits Odour odourless LEL lower WA Colour purple black VEL upper N A pH Vapour pressure N A Boiling point Ni Specific gravity WA Melting point grees Solubility in H O Nill Flash port 10 STABILITY AND REACTIVITY Stability Conditions
26. nfa red heat rays can injure eyes and skin Electric shock can kill 4 FIRST AID INSTRUCTIONS Inhalation bring affected person to fresh air if breathing is difficult administer oxygen In case of burning flush with plenty of cold water for several minutes at least 5 10 minutes In case of are bum call a physician In case of eve contact flush open eyelid with water for several minutes 5 FIRE FIGTING INFORMATION The product is non flammable N A Extinguishing media N A Extinguishing media to bj special fire fighting procedures N A Hazardous decompositi MA 6 PRECAUCTIONS TO BE TAKEN IN CASE MATERIAL IS RELEASED Personal protection N A Cleaning methods N A Waste disposal method N A 7 HANDLING STORAGE Handling fume extraction needed if cutting fumes may be released when cutting on the surface Storing N A 8 PROTECTION OF PERSONNEL Technical precautions during welding the necessary precautions have to be taken Use enough and adequate ventilation and local exhaust to keep fumes and gases from the welders breathing zone and the general area Train the welder to keep his head out of the fumes Wear protective clothing and welder protection equipment TLV values UK list 2002 KB 11 03 02 CEE91 322 CASnr TLV Cutting fume 5 mgm Iron oxide fume 1309 37 1 5ma m 4 methy soluble compounds 108 10 208 mg m Xylene 1330 20 7 440 mgm 2 butaone 78 93 3 599 mg m The cutting fume evolved during cutting operations depe
27. ng or under load arcing causes pitting and will eventually render the contacts inoperative 67 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Shell May 2004 Swordfish Non Exothermic Cutting Electrode User Manual A diver is at risk to severe electrical shock when performing a cutting or welding operation if only partially immersed in water Hence the splash zone is the most hazardous location in which a diver can be placed Never enter a diving bell with Swordfish when the welding generator Is still running AC power shall not be used for underwater cutting using Swordfish 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 not be able to let go if his or her body or equipment accidentally enters the electrical circuit AC power is however acceptable in a surface air environment When conducting a risk assessment consider the following The material being cut Any coatings on in or around the material to be cut The content of the material being cut i e old gas fuel pipe Local and surface environment Type of sea bed e g rotting vegetation gives off gas Methane Conducting an initial survey with an ROV Only use DC welding power which should be set up by competent experienced personnel and that all electrical co
28. nnections are securely made before operations commence In particular the correct polarity should be selected Figure 1 Piranha Combo Ensure a positive operating disconnecting safety switch Fig 1 normally rated at 400 Amps is in the welding circuit The diver will then be fully isolated from electric current when the disconnecting safety switch knife switch is open and can safely change electrodes in this state All cables that are intended to be submerged shall be double insulated and watertight Cables should be checked at regular maintenance intervals as part of a planned preventative maintenance programme for integrity When working in deep water a strain relief should be used to provide support for the additional cable weight 68 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E 3 2 Shell May 2004 Swordfish Non Exothermic Cutting Electrode User Manual o If joining lengths of cable together use connectors which have a current carrying capacity that is equivalent to the cable being used and are appropriately insulated o The position of the return lead in relation to the diver must be such that at no time does the diver or equipment become positioned between the ground and the electrode The diver must avoid becoming part of the electrical circuit due to electrolysis An underwater cutting operation with Swordfish involves several hazards including potentially harmful e
29. r cutting operations Supervisors shall ensure that all personnel become thoroughly familiar with the information contained within this manual Deviation from established standards are of course potentially dangerous however the most serious aspect of disregarding safety rules may not be the initial deviation but the tendency to treat other rules just as casually Safety must be the paramount consideration throughout every operation and the more safety conscious each team member becomes the safer each diving operation will be Electrical Safety POSSIBLE SHOCK HAZARDS The electric shock hazard associated with arc welding may be divided into two categories o Primary Voltage Shock i e 240 415 440 volts o Secondary Voltage Shock i e 60 100 volts The primary voltage shock is extremely hazardous and on no account should any unqualified person interfere with a primary supply Personnel can receive a shock from the primary input voltage by touching a lead inside the machine with the power on whilst touching the machines case or other grounded metal The case must be earthed so that if a problem develops inside the machine the fuse will blow Other factors to be considered include o Adequate duty cycle of the machine o Isolation switches are readily accessible o All mains and secondary cables terminals and cable connectors are of adequate size and construction for the maximum welding current o Terminals and live components
30. rations are usually performed with DC electrode negative i e Direct Current Straight Polarity DCSP but may also be used with Direct Current Reverse Polarity DCRP However greater care needs to be exercised as electrolysis may cause discomfort shock potential o The cable from the electrode holder is connected to the negative terminal of the DC power supply o The positive or ground cable is connected to the work The majority of the electrode manufacturers call for a DC electrode negative set up Occasionally there may be a requirement for a reverse polarity sometimes referred to as Direct Current Reverse Polarity DCRP electrode positive for a particular electrode or for improved cutting This will normally be at the recommendation of the electrode manufacturer and will be printed on the electrode box or included in accompanying literature Final piece here dependant on gas analysis O Shell May 2004 79 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual 3 5 3 Tong Test Ammeter The Tong Test Ammeter is a portable instrument that will measure current flowing in a circuit without making electrical connections to it It is a most important tool to have on hand while setting up for and during underwater cutting operations This is especially true when there is uncertainty as to the output of a particular welding machine Costly mist
31. rdfish Non Exothermic Cutting Electrode User Manual Figure 10 Check Voltage 3 5 1 Welding Generator Pre Set up Inspection Successful underwater cutting is highly dependent on the efficient running of the power supply unit and the integrity of the secondary welding circuit Before any underwater work takes place conduct the following o The cutting power source should be fully inspected by qualified personnel o The commutators on motor generators should be clean Brushes must not be excessively short or worn Slack brush rigging springs must be replaced o All welding machinery and secondary circuit must only operate within its duty cycle rating o All power sources should be checked for confirmation of rated capacity before use by use of the manufacturer s data plate as shown in the following illustration Shell May 2004008 Of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Manufacture Swordfish Non Exothermic Cutting Electrode User Manual Grademark NORWELD AS OSLO NORWAY LNW Homer source symbol amp type of cooling Standard amp Year CO CNAN BS 638 1979 TYPE NL 401 125467 20 WELDING 10 ar 20 V 400 A 36V Yo s 50 60 TZ n r min Speed Rotation Y Kw BS 5490 Protection Gore Figure 11 Rated Capacity Arc welding and plant equipment is addressed within BS EN 60974 1 1998 Polarity Underwater cutting and welding ope
32. rior to cutting if not already done so it may be necessary to cut gas escape holes Shell May2004 0 BF OE QB Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual 3 8 4 Getting Ready to Cut Shell May 2004 The Electrode should be held between 45 90 to the work thicker the target the steeper the angle should be Figure 20 Preparing to Cut To commence cutting Lightly remove the waterproof coating from the end of the electrode by rubbing it against a file Put welding visor into position Place the electrode exactly where you wish to start the cut When diving Is taking place inform the supervisor to Make it Hot One of two things may now occur a The Arc is struck but sticks to the work If the electrode sticks simply rub the electrode gently up and down until the arc is struck a slight twisting action may aid this process b Nothing happens at all If nothing happens the waterproof coating is still preventing electrical contact Continue to remove the waterproof coating With the power still hot scrape the electrode along some scrap metal as if striking a match until the exposed core wire is level with the flux coating again When cutting maintain a firm pressure to keep the electrode against the work while steadily moving along the line of cut To achieve an efficient cut pressure must be maintained in keep
33. s eee vans cin isa DO aaa dd 62 2 SCE Ceres E 62 DP MUCOSA acuta ad eda anaes een na aaa ned tae ania 62 23 MIA ON SAA io 62 24 2GIOSSAFY Or ADDrEVIAUON Sarean aaa a ls 64 Chapters System Operas ir AA 65 O eee Ra 65 3 1 1 FCCC Alt Saeta A adas 65 Bee RISK ASS eso iN Ne rt a e ato l 69 33 Storage amp Transportation a iuausandia ini aa a 72 Be UNPACKING SWOLGHSI a a ad 75 3 5 Swordfish and Associated Equipment Set Up cccccececceceeeeceeeeeeeeeceeeeeeeeaeseeeeeeseeeteeaeeeeags 75 3 5 1 Welding Generator Pre Set up INSPECtION ccccceccecececeeeeceeeeeeeeeeeseeaeseeaeseeeeseseeaenaeags 78 3 5 2 A AO 79 3 5 3 LONG Test AM cin copo cion coat 80 360 Presse ROUTING A SUTTACE es sema ipi saias tomas idad 80 3 4 Pre USe ROUTING SUD SUNM ACE recontra ppp eed 84 do Operation Surface SUD SUCRE 87 Bo O A ee 87 3 8 2 Disadvantages daa 87 3 8 3 CUTTING Fechas iodo 87 So Betina Ready to CU aaa ida 88 3 8 5 Emergency SUE CO Wasi da ii ii cada 89 CHROUST AS IMaltenan Cernuda 90 Ads E EA A PP E 90 42 MechanicalsServi a is 90 Chapter Se TrOuUDIESNOOUNO diiseni rica iio 91 Dik dentina Ne II sca a d a A TA 91 DZ Ordering Pa io a E a e EE A E 91 Chapters Limited Warranty sasinen cinta 92 Chapters OUE ONTO eaaa sua act ao conocia 93 Shell May2004 BQ Of QB Evaluation Report of Swordfish Iron Oxide Cutting Electrode Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8
34. stified and recorded within the risk assessment 9 A task risk assessment is carried out prior to any surface operation 10 Surrounding areas are checked and clear of combustible materials such as fuel stowage s etc 11 Electric generator is in a suitable position is grounded and does not interfere with surface operations 12 When preparing an electrical generator for use the following procedure is recommended a Ensure power isolating switch is in the off position b The disconnecting safety switch knife switch is in the open cold position breaking the circuit Shell May 200 BNO Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual NEGATIVE POLARITY DCSP ELECTRODE HOLDER ae WELDING LEAD KNIFE SWITCH Figure 12 Safety Switch 13 Connect the Negative cable bayonet connection to its appropriate port on the generator Figure 13 Negative Cable Connection 14 Connect the Positive cable bayonet connection to its appropriate port on the generator Shell Maya BL of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual Figure 14 Positive Cable Connection 15 Set desired current on selector dial of the welding generator Figure 15 current Selection 16 Ensure the welding generator power switch is in the off position prior
35. te Causing a popping sound If this occurs cutting should cease and the cause must be investigated immediately o Care should also be taken when cutting in or around dead or rotting marine growth leaves foliage or mud because trapped methane gas given the appropriate concentrations can explode OShel May2000 AO Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Shell May 2004 Swordfish Non Exothermic Cutting Electrode User Manual Explosive gasses may be produced by one or any of the following Corrosion The electrode itself Decaying or vegetable or animal matter Epoxies solvents or adhesives Paint mediums such as linseed oil or thinners Petroleum products fuel oil or greases To reduce the risk of explosions from trapped gasses do the following Gasses may be vented to the surface via a vent tube flexible hose secured in place from the high point whereby gasses would collect to a position above the water line if practicable Start cutting at the highest point and work downwards allowing gasses to vent as the cut is progressing When cutting vent holes if flammable gas is suspected use cold cutting techniques If cutting overhead beware of falling or rolling away of cutaway pieces or molten metal if in close proximity Take care if cutting tightly bound wire rope Prior to cutting ensure umbilical and any diving equipment is clear and will not be in th
36. terial that can be cut is only limited by the electrode length and the cutting angle required ANGLE LIMITATIONS Angles for cutting should be between 45 90 degrees In the unlikely event that an area for cutting is difficult to reach the electrode can be bent however the manufacturer does not recommend this procedure If the water proofing was to crack water could be absorbed which could affect performance and gas producing elements If absolutely necessary to bend the cutting electrode it would be best achieved where it joins the neck of electrode holder 63 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual 2 4 GLOSSARY OF ABBREVIATIONS Shell May 2004 AODC Association of Offshore Diving Contractors CCV Close Circuit Voltage DCRP Direct Current Reverse Polarity DCSP Direct Current Straight Polarity HSE Health amp Safety Executive International Marine Contractors Association 64 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Chapter 3 3 1 Jdel Shell May 2004 Swordfish Non Exothermic Cutting Electrode User Manual SYSTEM OPERATION SAFETY This chapter is intended to cover the safety precautions to be followed while preparing for and conducting underwater cutting operations with Swordfish Serious injury or death may result when protocols are not followed during underwate
37. the circuit The supervisor will then inform the diver that the circuit is hot When ready to cut it is advised to finally check that there is enough cable slack to prevent snagging on the job thus ensuring a smooth and unhindered cut You are now ready to commence cutting The following Check List is provided to aid supervisors and contribute to the management of a safe and comprehensive procedure It is emphasised that the Supervisor s Check List illustrated overleaf is provided for guidance only It should be used in conjunction with this User Manual and local procedures being adapted to meet the specific circumstances of each cutting operation Shell May 2004 85 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual Swordfish Iron Oxide Cutting Electrode Supervisor s Check List The following checks are to be conducted Surface Preparation an fod E 4 Has the equipment been function tested prior to sub surface deployment SSCS 5 Are all cables free to run and clear of sharp edges or snag hazardas 6 Has the target area been confirmed with e client 7 Have potential gas entrapment areas been identified 8 Has the diver been included in the risk assessment process and briefed by the supervisor JO Comments Sub Surface Preparation Yes No 1 _ Does the diver have the correct Personal Prote
38. y A te ia R AA ee r e A eee E r rr A E mm 010031 de e i E L A KS SKA he se ew a A e e Ad ae q Figure 3 Batch Number Electrodes can be taken directly from the packaging into the water Transportation There are no transportation restrictions with the electrodes They can be transported safely and easily by Road Rail Sea or Air however it is good practice to make the Data Sheets available to drivers and loading personnel The following pages illustrate Safety Data Sheets O Shell May 2004 72 of 93 Evaluation Report of Swordfish Iron Oxide Cutting Electrode Annex E Swordfish Non Exothermic Cutting Electrode User Manual Speciality Weld MATERIALS HEALTH SAFETY ENVIRONMENTAL DATA SHEET CEE 91 1545 FOR SWORDFISH CUTTING ELECTRODE IDENTIFICATION OF PRODUCT amp COMPANY 1 1 Product Identification Trade Name Swordfish Application Underwater cutting burning of steels 1 2 Manufacture Supplier Name Speciality Welds Address Unit 3 Moorlands Business Centre Beane Rond Cleckheaton West Yorkshire BDI9 4EW UK y 0 14 0 1274 879867 Fax 44 0 1274 355975 2 COMPOSITION amp INFORMATION ABOUT CONSISTUENTS Core wire carbon steel dedo coming high i iron 1 onde coating p Electric are may create ong or more of the following hazards Cutting fumes and gases may be dangerous to health Arc rays UV can injure eves and bum exposed skin I
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