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471 2015
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Acknowledgements
Safety Committee
Disclaimer
Whilst every effort has been made to ensure the accuracy of the information
contained in this publication, neither IOGP nor any of its Members past, present or
future warrants its accuracy or will, regardless of its or their negligence, assume
liability for any foreseeable or unforeseeable use made thereof, which liability is
hereby excluded. Consequently, such use is at the recipient’s own risk on the basis
that any use by the recipient constitutes agreement to the terms of this disclaimer.
The recipient is obliged to inform any subsequent recipient of such terms.
Copyright notice
The contents of these pages are © International Association of Oil & Gas Producers.
Permission is given to reproduce this report in whole or in part provided (i) that
the copyright of IOGP and (ii) the sources are acknowledged. All other rights are
reserved. Any other use requires the prior written permission of IOGP.
Revision history
1 Introduction 6
4 Equipment selection 18
4.1 Welding power source 18
4.2 Safety switch or circuit breaker 20
4.3 Burning leads or burning umbilical 23
4.4 Ground leads 26
4.5 Wire (Cable) splices, connectors, and terminations 27
4.6 Continuity check 28
4.7 Oxygen 28
4.8 Oxygen hose 28
4.9 Oxygen regulators 29
4.10 Oxygen pressure 30
4.11 Torches or electrode holders 30
5 Consumables 32
5.1 Tubular steel 32
5.2 Exothermic 33
6 Pre-job considerations 34
8 Proper venting 36
9 Diver’s PPE 38
Bibliography 82
Oxy-arc underwater cutting recommended practice 6
1 Introduction
Diver
Person who by qualification and experience is a
competent commercial diver
Oxy-arc underwater cutting recommended practice 7
2.1 Saws
Tubular members, pipelines and structural members can be readily cut
with various types of underwater saws. Many of these saws are ROV or
remotely operable.
Hydraulic ring saws are of particular value for cutting thick cross-sections.
Oxy-arc underwater cutting recommended practice 8
2.2 Shears
Shears have proven to be valuable tools for remotely cutting large
diameter components.
This method is particularly suited for small cross-sections, one inch thick
or less.
This method can be much slower than oxy-arc cutting and can also
produce hydrogen as a by-product of electrolysis.
Tungsten carbide cutters mill away the pipe from the inside and can be
used for cutting pilings on offshore structures.
Oxy-arc underwater cutting recommended practice 10
Hole saws are used to cut access holes for rigging underwater as well
as being a good choice for cutting first vent holes in an area where
burning is required.
Oxy-arc underwater cutting recommended practice 11
3.5 Divers
Divers participating in burning operations should be qualified in
accordance with this report.
Commercial dive: A logged dive carried out after training when the diver is employed as a
commercial diver
The diver should be able to identify a problem during the process, i.e.
torch malfunction, incomplete electrical circuit (poor burning), oxygen/
hydrogen build up (improper venting), etc.
4 Equipment selection
The two most widely used types of welding machines used in burning are
motor generators and electric inverter machines.
• The motor generators are pure DC current machines run with a
diesel engine, or electric motor, driving a DC generator.
(Newer machines may actually be AC rectified to DC.)
• The inverter machines are AC rectified to DC machines utilizing
220 V or 480 V.
Oxy-arc underwater cutting recommended practice 19
Some machines may be rated at 60% for maximum amperage and 100%
for amperages less than maximum. Machines rated at 60% duty cycle
should be regularly monitored during use for overheating and pauses in
the burning monitored. (A 60% duty cycle means that the machine can be
used at rated capacity for 6 minutes out of 10 minutes.)
Dive control
Least preferable set up is with a
twin pole knife switch
Handle hinge position lowest
Oxygen
Oxygen
Oxygen
–Ve
DC Welding Machine
+Ve
Dotted line would be the cable set up for ‘Single Pole’ switch
Dive control
Oxygen
Oxygen
–Ve
DC Welding Machine
+Ve
DC breaking contactor
The rocking motion of a dive vessel can affect the operation of some
breakers. These breakers should be selected on ‘fitness for purpose’
basis and the design should be carefully evaluated. Inverter type
machines are generally equipped to support remote contractor switching.
Generally, no wire smaller than 2/0 (9.26 mm) should be used for
burning in water depths to 100 fsw (30 m).
As a rule, for water depth over 200 fsw (60 m), the wire size should
increase one size per 100 fsw (30 m). 4/0 (11.7 mm) and greater wire
should be used for any burning in excess of 400 fsw (122 m). Doubling
the wire should be considered for extreme depths over 600 fsw (183 m).
The circuit of the burning system starts and ends at the power source. All
leads to the safety switch from the power source should be considered in
the circuit length.
Usually the ground wire is married into the lead wire and oxygen hose to
form an umbilical but this is not always the case for surface supplied diving.
Therefore, the ground lead might be separate from the torch lead. The end
is coiled to allow the diver to place it in the immediate area of the cut.
The ground should have a brass or high copper alloy clamp arrangement
on the diver’s end to allow the ground to be securely attached to the work.
4.7 Oxygen
Oxygen used in a burning operation should be industrial quality (greater
than 99%). A percentage reduction in oxygen purity will result in a
reduction in cutting speed.
For depths greater than 200 ft, a ½ in (12.7 mm) hose inside diameter
might be required.
Oxy-arc underwater cutting recommended practice 29
5 Consumables
Each rod type has its inherent strong points and weaknesses. Both types
are commonly used and the equipment is the same for each type of rod,
with the exception of higher amperage machine requirements for tubular
steel electrodes. It is not uncommon to see both types of rod on a job and
being used for the same work.
Dispose of:
• rusted rods
• rods that have been in the water and returned
to the surface unused – they are unfit for
service.
The typical rod is a 5/16 in (7.9 mm) diameter tube with a concentric
through hole that is approximately 1/8 in (3.17 mm) in diameter. Tubular
steel rods can only be used for cutting when the electrical circuit is
energized (hot). Tubular steel rods require more amperage (~300 A) to
perform efficient cutting and work very well on clean steel of any shape
or design.
Oxy-arc underwater cutting recommended practice 33
Because of the need for electrical continuity, the tubular steel rods cannot
burn through heavy corrosion or marine growth efficiently. However
they can be more accurate and, because constant electrical contact
is required, when burning close to another member that must not be
damaged, rubber matting or insulation can guard against arc strike.
Typical rod travel during a cut is usually more than that of an exothermic
rod. Generally, tubular steel rods work better than exothermic rods on
steel thicknesses in excess of one inch (25.4 mm), making a cleaner cut
with less chance of an unburned section (hanger) being left behind.
Tubular steel rods produce a higher arc temperature than exothermic rods.
Arc temperature can be as high as 20,000°F, depending on amperage.
5.2 Exothermic
Exothermic rods are comprised of an insulated thin sheet steel
outer cover over several small diameter alloy wires used as fuel wire.
The small diameter wires are alloyed with materials that exhibit
exothermic properties.
The rod is typically 3/8 in (9.5 mm) in diameter and the inner wires are
arranged to form a hollow centre as an oxygen path. These rods require
much less amperage or no electrical current at all after ignition.
Once the rod is ignited, the electrical current can be shut off. The heat is
maintained by thermo-chemical reaction sustained by the exothermic
materials. Some burning might require a low amperage (~150 A)
boost, especially in thicker materials. Once the oxygen is shut off, the
reaction stops.
Oxygen must be shut off from the rod to stop the burning process once
started.
Oxy-arc underwater cutting recommended practice 34
6 Pre-job considerations
This will follow the contractors’ process and be in addition to the support
requirements for this process.
Only use divers and supervisors that follow the training and competence
guidance of this report.
Oxy-arc underwater cutting recommended practice 35
7 On-site considerations
and the burning operation
The metal in the cut area should be thoroughly cleaned before burning
begins. Metal should be cleaned of all corrosion scale, calcareous growth
(barnacle bases) and paint or coating. Cleaning should be done on both
sides of a cut when practical.
Any material other than carbon steel might not be easily cut with the
oxy-arc process. Non-ferrous metals are cut by melting not oxidation and
unsuited to the oxy-arc process.
8 Proper venting
The diver and supervisor must ensure that this gas is being removed from the area
and not building up in pockets. This gas path confirmation can be accomplished in
several ways:
• Vent holes can be drilled, or cut, above the intended cut line. If the content of
the void behind a cut is not known, drill or saw cut the holes into the material.
Vent holes made by drilling should be made with a drill using a reduced RPM
to prevent the cutting edge of the drill bit from creating enough heat to ignite a
combustible gas
• Circular saws and grinders with cutting blades can produce sparks and heat
which have been known to ignite combustible gas.
• Always assume hydrocarbon presence until proven otherwise.
• Once penetrative holes are drilled, windows should be enlarged to allow
adequate flow to vent properly.
• Prove the vent path by flowing secondary gas, such as from pneumofathometer.
• Consider and verify what is behind the cut before any vent holes are made.
• Stored energy can shift the material being cut.
• Remove mud, grout, or other material built up behind a proposed cut. If it is
not possible to remove the background mud, use alternative cutting methods.
• Oxygen or other combustible gases can naturally rise away from the cut area and
be of no consequence. Verify this. Consider internal structural braces within a
structural member such as a tubular diagonal brace with internal stiffener rings
as a possible gas entrapment. If gas introduced into the member does not vent in
a predictable amount of time, consider it as blocked and make alternative venting
schemes considered.
• When burning on an incline or vertical position, do it from the top moving down to
reduce or eliminate the possibility of burning into a gas pocket. Make more than
one vent when burning in the horizontal directions
• Cutting into a tubular, tank or enclosed space vent holes will be needed
• Do not perform burning on a pipeline, vessel, storage tank, or anything having
previously contained a hydrocarbon product. Residual hydrocarbons in any
amount can become quite explosive when mixed with oxygen.
Oxy-arc underwater cutting recommended practice 37
• differential pressure
• residual forces in material causing load shifting
• internal structural bracing within a closed member, such as an internal ring
stiffener in a tubular member
• marine growth that can trap gases
• external coatings.
The process to verify flow path and identify any potential pockets should be in
three phases:
1. Identification
2. Mitigation
3. Verification, which includes continuous monitoring as the cut progresses or
locations changed.
Identify flow paths and investigate potential gas pockets using drawings, inspection
dives performed, and any other information available to project planning team.
Compose this team of personnel that have experience and competence in the type
of burning to be accomplished and knowledge of the structure being burned.
Mitigate the risk by establishing vent holes or windows to allow escape of explosive
gases, removing potential barriers to gas flow behind the cut and be aware of
trapped gases above vent windows that may ignite.
Warning:
Hot slag encased in an oxygen bubble can travel up several atmospheres in
the water column past the venting window and ignite gases or hydrocarbons
trapped above the vent location.
If burning operations are being conducted around a live structure, a water curtain
(deluge) should be used around the area that the gases are surfacing to break up
any bubbles that may have burning slag within the gas bubble.
Monitor and verify venting when conditions, location, divers and supervisors are
changed.
Oxy-arc underwater cutting recommended practice 38
9 Diver’s PPE
The following PPE should be worn by the diver for the burning operation in
addition to standard PPE required for all diving:
• non-conductive gloves. The diver’s gloves should not become
saturated with or entrap gas
• eye protection for arc flash in clear water with #4 shaded lens or darker.
• protective clothing to protect the diver and dive suit from damage or
burns from hot slag.
All training providers should plan and deliver courses following this
guidance as a minimum, but may elect to provide additional training to
accommodate advanced training, project specific training or national
standard training.
Where diving and diving related activities are a part of the training course,
that activity should be performed in accordance with IOGP Report 411,
Diving Recommended Practice.
The training course should have at least one instructor that is qualified
to plan and deliver the training course and to assess the trainee’s level
of competence. Qualified Competency Level 2 or 3 divers may assist the
instructor to help provide extra experience and skill where necessary. See
Table 1 (Diver competency levels).
Oxy-arc underwater cutting recommended practice 41
See IMCA C 007 Rev 1, Guidance on Assessor Training and IMCA C 016,
Guidance on Verifier Training for further information.
Oxy-arc underwater cutting recommended practice 42
The relevant parts of this report should be used as the basis for training
these points.
Principles of operation:
• alternative cutting
• theory of oxy-arc burning
• types of material: ferrous and non-ferrous
• oxygen systems
• circuit breakers
• safe consumables and their correct application
• venting
• grounding
• gas migration
• residual energy
• differential pressure
• hydrocarbons
• slag
• cutting on different structures (tubular, wire, solid, porous)
• confined space burning
• dredging and below mud line burning
• advantages of surface cleaning
• cutting in contaminated water
• tides, currents, splash zone
• electrical risks and considerations
• water depth effect on burning
• visibility effect on burning
• diver positioning during burning
• bell position, relative to burning operation
• burning and Simultaneous Operations (SimOps)
Oxy-arc underwater cutting recommended practice 43
Oxygen requirements:
• oxygen delivery pressure
• oxygen purity
• oxygen safety
• burning oxygen segregation from main gas stores.
Cutting technique:
• tubular steel electrode
• exothermic rod
• other rod options.
Troubleshooting:
• malfunction symptoms
• probable causes
• identification and problem solving.
Post-dive maintenance:
• electrode storage
• torch maintenance.
Oxy-arc underwater cutting recommended practice 44
The proficiency criteria levels in this section may supplement the diver
competency levels in Table 1 (Diver competency levels).
Exothermic Rod
• Burn 6 inch dia. Schedule 80 pipe using no more than 4 rods.
No Hangers.
• Burn 1 inch thick clean steel for a distance of 18 inches using no more
than 6 rods. No Hangers.
• Burn 2 inch thick clean steel for a distance of 18 inches using no more
than 10 rods. No Hangers.
Exothermic rod
• Burn 6 inch dia. Schedule 80 pipe using no more than 3 rods. No
Hangers. 5 minute start to finish.
• Burn 1 inch thick clean steel for a distance of 18 inches using no more
than 5 rods. No Hangers. 15 minute start to finish.
• Burn 2 inch thick clean steel for a distance of 18 inches using no more
than 9 rods. No Hangers. 18 minutes start to finish.
Exothermic rod
• Burn 6 inch dia. Schedule 80 pipe using no more than 3 rods. No
Hangers. 4 minute start to finish.
• Burn 1 inch thick clean steel for a distance of 18 inches using no more
than 5 rods. No Hangers. 12 minute start to finish.
• Burn 2 inch thick clean steel for a distance of 18 inches using no more
than 9 rods. No Hangers. 15 minutes start to finish.
Grandfather and
Normal scheme Refresher scheme RPE scheme
Qualified Competency
Level 1 Diver Burner
Complete the
Qualified Competency Complete the
Performance Proficiency
Level 2 Diver Burner Performance Proficiency
Test equivalent to the
Test to the equivalent level of
competency level
assessment (1,2 or 3) that
requalifying for (1,2 or 3)
was conducted
after refresher training
Complete
Competency Level 3 –
Advanced criteria
Qualified Competency
Level 3 Diver Burner
Maintain
5-hrs burning Yes
practice in previous
12-months?
No
Many of these comments are included in the reference documents and are
important enough to be mentioned here.
Appendix A
Checklists for oxy-arc operations
Two checklists have been added for use and to give a quick reference as to what is
required both pre-operation and pre-dive.
The (pre-dive) Diving contractor oxy-arc checklist has been created as a reference to
assist the diving contractor in managing the operation.
Appendix A - Checklists 53
Equipment Yes No
Oxygen Marked according to IMCA
Cylinders
Oxygen warning signs in place
Equipment Yes No
Oxygen Manifold Fit for purpose
(on the Quad)
Integral with the quad
Fabricated from suitable materials rated for oxygen (see Swagelok
catalogue or similar).
• Should not be carbon steel, copper, or iron tube.
• Should not contain galvanized or cadmium coated fittings.
Pressure test certificate
Oxygen cleaned to an internationally recognised standard and certified by
a competent person.
Valves – must be rising stem type.
Valves – Fit for purpose – i.e. rated for oxygen use by the manufacturer
Valves – oxygen clean
Visual check metallic pig tails for: crush, crimp, twist, buckle, cracked
joints, in-appropriate fittings, excessively tight radius.
If the pig tails are silver soldered to a main tube – request a pressure test
certificate.
(Hydro test of pipe work is usually 1.5 × WP)
(200 bar WP requires a TP of 350 bar)
Visual check flexible hose pig tails for: crush, crimp, twist, buckle,
inappropriate fittings, and excessively tight radius.
If the pig tails are flexible – request a pressure test certificate.
(Hydro test of pipe work is usually 1.5 × WP)
(200 bar WP requires a TP of 350 bar)
Purpose-built oxygen distribution manifold should be:
• Designed to a recognized international standard
• Constructed from materials designed for oxygen use
• Capable of withstanding up stream pressure or a relief valve should
be fitted to protect LP components
• Certified by a competent person
• Oxygen cleaned and certified
• Pressure tested to and internationally recognized standards
Equipment Yes No
‘Burn back’
(automatic device designed to sever the connection between the
hose/regulator in the event of internal hose fire).
Relief valve fitted (downstream component protection)
Generally set at 90 psi over bottom, pressure reduced to 40 bar or less
at source
Oxygen Hose:
• From Quad regulator to the Top-Side Burning Umbilical connection
must not be wire-reinforced.
• Hoses constructed from non-conductive materials.
Hoses & Tube Oxygen hose is fit for purpose and designated for oxygen transport
runs by the manufacture.
Hydraulic Hose:
• From Hydraulic Power Pack to the Burning Umbilical Reel
connection must not be wire-reinforced.
• Hoses constructed from non-conductive materials.
Burning Umbilical: Oxygen hose fit for purpose and designated for oxygen
transport by the manufacture.
Oxygen hoses pressure tested and certified by a competent person.
Equipment Yes No
Oxygen hose to have a double block and bleed facility
Valves – Fit for purpose, i.e. rated for oxygen use by the manufacturer
Umbilical winch Slings & Shackles – fit for purpose and in date.
Equipment Yes No
Cutting Consider the fitting of ‘D’ rings as lift points or chain stops
Umbilical
Cable cross section should be commensurate with the length of cable
and the anticipated voltage drop. See a welding cable selection guide or
low voltage electrician
Cable insulation should be of a robust nature.
Consider sheathing in areas likely to sustain damage from structure or
marine growth.
It is likely that robust sheathing incurs a flexibility penalty.
Consider the last three to five meters be ‘extra’ flexible welding cable.
Cable and hose should be taped every meter.
Cable should show no visible defects – look for ‘blisters’, cuts and tears,
wire protrusion, ‘green’ staining (copper/salt residue)
The both cables should be resistance and continuity checked prior to
immersion.
Electrical tests may be problematic due to water salinity, salt build up on
the umbilical, water penetration of the cable sheath
Visual inspection is likely to be the best infield method of fault detection.
• If necessary lay the entire cable out and have it inspected.
• Whilst the cable is flaked out, set up for ‘Welding’. Test the cables
by having a number of welds run. If it is difficult to weld on deck
there are brakes in the copper wires and strands inside the cable
sheath. High resistance brakes may boil internal water generating
steam and ‘blisters’
Areas of high resistance (caused by copper wire cable thinning) will get
hot very quickly
The torch should be in good condition (see torch section)
Umbilical deployment method Pad Eyes – pull test and MPI in-date
Umbilical deployment method Slings & Shackles – fit for purpose and
in-date load test certificates.
Cable cross section should be commensurate with the length of cable and
the anticipated voltage drop. See a welding cable selection guide or low
voltage electrician
Fit for purpose
Appendix A - Checklists 59
Equipment Yes No
Cables Supported
Protected from dropped objects
Treat all styles with caution (Lenco style). Often they wear out due to internal
arcing eroding the contact faces.
If they get hot during operation then the joint may be high resistance.
Check the internal faces of the male and female unit for corrosion and
arc pitting also the grub screw that locks the copper wire in the connector
body. (Grub screw is likely to be low quality steel and subject to corrosion).
Cable Stab (Lenco style) connections should not go sub surface unless
connectors specifically designed to do be immersed in salt water.
Cutting & Amperage range to suit the type of rods being used
welding switch
Equipment Yes No
Planning Is the current burning work planned?
Is there a client document detailing the work scope?
Have the correct personnel been identified and represented at the risk
assessment?
Representatives may be (but not limited to):
Client Project team representation, Engineer, Diving Contractor Project team
representation, Client Diving Rep, OIM, Vessel Master, Vessel Chief engineer,
ROV, crane operators, Third party groups such as other asset owners in the
same field.
Has the contractor prepared generic burning risk assessments?
Sufficient oxygen
Regulator set
Equipment Yes No
Inspect the Torch for condition:
• Large rubber washer
• Rod rubber washer
• Flash arrestor
• Collet condition
• Collet contact face condition
• Condition and security of the extra flexible copper cable
• Collet Nut threads
• Collet Nut
Torch trigger leak and function tested
Generator on line and set to the amperage required
Generator polarity test. Electrode should ‘negative’.
• Bubble test can be made by immersion of a small plate attached to
the ground lead and a rod in the Torch (remove the insulation on the
test rod. Apply current – the larger bubble generation will occur at
the cable connected to the negative terminal.
Test the knife switch and torch with a ‘rod test’
• Note the amperage range
Visor in place on helmet
• Lens to suit water clarity – No. 4, 6 or 8
Quiver full and tied shut
Spare quiver full and tied shut
Spare collets and washer on a safety pin tied three meters back from
the torch
Diver has gauntlets and rubber gloves
Spare gloves tied back beside the collets
DDC checked
Cleaning equipment inspected and power equipment tested prior to
deployment:
• Water blaster
• Power or Hand wirebrush
• Grit Blaster
• Chipping hammers
• Scrapers
Small tools available:
• Hammers
• Dot punches
• Drills
• Hole saws
• Grinders
• Paint sticks and markers
• Tape measure
Oxy-arc underwater cutting recommended practice 62
Equipment Yes No
Dive check Diver confirms the conditions are as predicted, or Not
• Review of the dive plan may be required
Burning gear is deployed ‘Switch Open’ Generator ‘Cold’
Vent holes are cut and proven to the process identified in the HIRA.
Umbilical clear.
Post-dive Electrolysis can adversely affect the integrity of the metallic parts,
checks especially on long burning campaigns. Frequency of Inspection of the
dive hat and burning equipment should be increased
Appendix B - Training course assessment checklist 63
Appendix B
IOGP oxy-arc cutting training course
assessment checklist
1 Purpose 64
3 Teaching Facilities 65
4 Administration 68
5 Fire Prevention 70
6 First-Aid 70
7 Training Plans 71
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
1 PURPOSE
This is a standardized checklist for assessing training facilities that provide instruction
in underwater oxy-arc cutting in accordance with the International Association of Oil and
Gas Producers (IOGP) Report 471, Underwater oxy-arc cutting recommended practice.
This checklist has been developed to assist the assessment team in interpreting the
recommended practice as it relates to its guidance on training.
portion of the course, risk assessment shall determine the minimum number of diving
supervisors and dive team size.
64
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
2.4 Instructor Training and Competence Assessment a) Formal training in leadership and
(10.4 Specification for instructors) communication skills
Instructors should have undergone training that teaches classroom b) Experience in teaching
communication, leadership and instruction techniques. Additionally the c) Trained in-house
instructor should have been trained on competence assessment techniques d) Gained expertise by experience only
such as the IMCA C 007 Guidance on Assessor Training. The instructor should
meet the minimum requirements defined in the training provider’s accreditation
requirements, where applicable.
2.5 Diving Safety and Oxy-Arc Practices and Procedures a) IMCA safety flashes regarding oxy-arc
Instructor staff should be familiar with industry references to oxy-arc cutting in cutting
diving, such as those listed the references of Report 471. Additionally instructors b) Oxy-arc equipment manufacture
should be familiar with equipment manufacturers, IMCA and ADCI technical and technical notes
safety alerts. c) IMCA D 003, IMCA D 031 and IMCA D
045
d) US Navy Underwater Cutting and
Welding Manual
The environmental conditions and ergonomic arrangements of the lecture rooms b) EHS policies and procedures
can affect the individual’s ability to absorb information during the lectures. The
65
Rooms should be illuminated and climate controlled/ventilated properly. Outside a) External noises noted during lectures
noise should not interfere with the training environment. b) Room temperature suitably controlled
c) Proper overhead lighting
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
Rooms should be clean and tidy and be maintained in a state of good repair a) Lecture rooms cleaned regularly.
b) Organized with good housekeeping
The area used to set-up and operate the oxy-arc cutting equipment should be a) Proper electrical supply and wiring
sufficiently constructed, located and equipped to allow for the electrical equipment b) Suitable ventilation
and compressed oxygen handling. c) Proper compressed oxygen storage
Proper fire prevention equipment should be immediately available at the cutting location. and handling equipment.
3.3 Dive Tank or Sheltered Water Location a) Tank engineered and built for purpose
(10.2 Course contents, material and facility requirements) b) Tank has cathodic protection
The dive tank should be of suitable design and construction to allow for safe and c) Lifting appliances are fit for purpose
Oxy-arc underwater cutting recommended practice
practical oxy-arc training. A dive tank can be substituted for a sheltered open water d) Proper ingress/egress equipment
location such as harbour, bay, etc. It should be large enough and deep enough to e) Visibility and conditions to allow
66
accommodate a diver and stand-by diver, and have sufficient room to allow for instructor view
inserting, cutting, and removing tubular and flat metal material. There should be
ample room to allow divers to position properly for cutting the largest material.
Working deck/area around the tank or open water location is suitably constructed a) Injured diver removal from the tank
and is fit for diving and oxy-arc training tasks. It is organized and laid-out in a fashion b) Ample room for personnel to move and
that promotes a safe working and observation area for personnel and equipment. work
c) Hand railing, ladders, fall prevention,
slip prevention
d) Sufficient illumination
e) Electrical Ground Fault Interrupters
(GFI)
f) Cable trays
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
3.4 Teaching Aids (10.2 Course contents, material and facility requirements) a) PowerPoint Presentations
There should be a suitable and sufficient supply of teaching aids provided which b) Technique video Presentations
should be well maintained and relevant to the lecture being given. c) Cutting equipment
d) Diver cutting PPE
e) Cut coupons
f) Electrode samples
There should be a number of spare units or components readily available to a) Sufficient spares available for the
minimize interruptions should an equipment failure occur. equipment being used
Training aids should be easily visible from all parts of the lecture room and where a) Training facilities visible from all parts
practical equipment is used there should be a sufficient number of training aids of the lecture room
which should be easily accessible to all students b) Sufficient number of practical training
aids
Safety switch is of sufficient type and meets 4.2. a) Has sufficient pole disconnects
b) Electrical rating higher than source,
marked on the gear
c) Location and wiring configuration
Electrical cables, torch lead, ground lead, and splicing hardware meets 4.3, 4.4 and 4.5. a) Correct diameter and length
b) Proper connections and insulation
c) Condition and storage
Cutting rods of both types, exothermic and tubular steel should meet section 5. a) Rods are produced by an approved
manufacturer
b) Working condition of the rods
c) Storage and handling of the rods
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
Compressed oxygen equipment meets 4.7, 4.8 and 4.9. Care of maintenance and a) Hoses are manufacture approved for
handling meets oxygen cleaning practice, such as IMCA D031 Cleaning for Oxygen oxygen
Service or an equivalent practice. b) Oxygen compatible fitting
c) Oxygen compatible regulators
d) Oxygen cleanliness
e) Maintenance practice and storage
f) HP cylinder handling
There should be equipment set-up, testing and operation procedures in the vicinity a) Contractor Oxy-Arc Checklist in
of the operation area and made available to the instruction staff and students. Appendix A
b) Manufactures instructions
There should be PPE that is suitable for the Dry and Wet Cutting portions of the a) Protective over clothing
training. b) Shields, lenses, eye protection, etc.
c) Welding and nonconductive gloves
Oxy-arc underwater cutting recommended practice
d) Foot protection
68
A proper two person/two compartment decompression chamber is available within a) Chamber is verified available during
two-hours if diving shallower than 10 metres. A decompression chamber should be training
onsite if training dives are deeper than 10 metres. b) Transportation to chamber is
established
4 ADMINISTRATION
The training establishment should use good management practices to document
and control all stages of the training course. Accreditation of the course will
require comprehensive review of documentation regarding student information,
attendance recording, procedures, training material, teaching materials,
examinations, etc. This section will identify administrative requirements.
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
equipment information sheets that provides study aids to the student. Welding Manual
d) Manufacturer’s product manuals
69
There should be a written Training/Lesson Plan that lays out the steps and flow a) Lecture times
of the course. It should be broken down into timed modules based on subject, b) Enabling objectives
objective and application. c) Examples and application of the topics
There should be written or computer based tests that cover the theoretical a) Covers the theoretical sections
portions of the training course. These should be satisfied before practical b) Questions are representative of
assessment begins. material covered
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
There should be a method of documenting successful completion of the course. a) Certificate of completion
This should have the completion date, hours of instruction, level of proficiency and b) Logbook entries
electrode types.
5 FIRE PREVENTION
Provision should be made for students who are unfamiliar with the location so that
all reasonable precautions are in place to ensure the safety of all personnel who
attend the courses.
There should be suitable emergency arrangements in place for the evacuation of a) Emergency evacuation arrangements in
students from the building or work area in the event of a fire. place
There should be suitable emergency exits from all areas which should be clear of a) Emergency exits available from all
obstructions, clearly sign posted and can be opened from the inside. parts of the building
b) Fire doors and emergency exits free
from obstructions
c) Clearly marked
Fire extinguishers should be installed in all work areas/lecture halls/dive tank. a) Sufficient number of in date fire
Oxy-arc underwater cutting recommended practice
extinguishers
b) Fire Extinguishers suitable for electrical
70
fires
At the dive tank there should be a medical kit that meets the DMAC 15 standard, a) Last inspection
AED and a personnel litter suitable for transporting injured personnel. Staff should
be trained in the use of AED.
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
7 TRAINING PLANS
(10.2 Course contents, material and facility requirements)
Compliance with Objectives.
The training course should be planned and laid out in such a way that it is delivered
logically and effectively to the students. Instructors should have a written plan that
modulates and organizes the topics and objectives into deliverable units. Each unit
should be planned to allow a certain amount of lecture and/or practical hands-on time.
This will assist the training establishment with ensuring consistency of delivery.
The Lesson Plan should be laid out to clearly identify each lesson topic and the
associated elements that make up each topic.
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
• Crane and Lift bag use when cutting d) Explain why venting should be
• Hydrocarbon hazards when cutting performed with a ‘cold cut’ technique
72
• Bell position during cutting operations Terminal objectives that are a measure of
• Confined space burning theoretical knowledge may be demonstrated
• Dredging and below mud lines with written or computer based examinations
• Contaminated water or interview type discussion
• Tides, currents, splash zone
• Alternative cutting methods
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
7.10 Lesson: Practice Burning in Dry Conditions (10.5.2 Level 1 Beginner Oxy-arc Terminal Objective Examples:
Burning Course recommendations and suggested schedule) a) Should be able to complete a cut 24”
This module may be substituted for in-water training when circumstances don’t allow long on flat plate material
for dry training. b) Should be able to cut a section off a
coupon of 6” pipe
The time taken for this lesson should be a minimum of a half day. Personnel
should practice the burning techniques of each rod type in dry conditions, as Enabling Objective Examples:
closely resembling the set up for in-water as possible. a) Should demonstrate how to locate and
This exercise should employ roll play between the diver and supervisor so that remove a coupon hanger
proper communication and terminology is practiced before entering the water. b) Should demonstrate proper placement
A JSA and Hot Work permit should be issued for this lesson. Additional personnel of hands and head while burning
may need to be present for the role of Fire Watch. c) Should demonstrate proper
communication and terminology
Instructors should closely observe the student for proper:
during the cutting process.
• body positioning
• holding of the torch
• Initiating the cut
• drag or push rate
• ending the cut
Oxy-arc underwater cutting recommended practice
• Hanger inspection
• Hanger removal
• Communication between diver and supervisor
76
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
During the wet tank practical training module the diving supervisor ensures and a) Review JSA and Permit to Work
observes that proper diving procedures, checks and operations are conducted b) Monitoring the diving
Appendix B - Training course assessment checklist
• Pre-dive briefing
• Top-side crew using proper PPE
• Diver proper wearing of apparatus and cutting PPE
• Proper umbilical tending
• Proper monitoring diver’s gas manifold
• Tracking dive profile and time
• Dive record sheets
• Post dive checks
• Post dive briefing
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
rods. No Hangers.
78
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
Students should perform safe and effective cutting technique on a variety of Exothermic rod
materials in times evolutions. • Burn 6 inch Schedule 80 pipe using
no more than 3 rods. No Hangers. 4
Students should utilize and be tested on both exothermic and tubular steel cutting
minutes start to finish.
rods.
• Burn 1 inch clean steel for a distance
In accordance with Table 1, students should have provided evidence of Level 2 of 18 inches using no more than 5 rods.
qualification to the training establishment in order to qualify to test for Level 3. No Hangers. 12 minutes start to finish.
• Burn 2 inch clean steel for a distance
of 18 inches using no more than 9 rods.
No Hangers. 15 minutes start to finish.
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Yes/ COMMENTS
ITEM DESCRIPTION CHECKS/PROMPTS
No (1), (2), (3), (4)
oxy-arc technique
d) Describe techniques used to ensure
venting flow paths are established
Explanatory Notes:
(1) Poor Does not follow guidance in IOGP Report 471. A degree of improvement is needed before achieving IOGP Member recognition
(2) Fair Follows some of IOGP Report 471 but not to the degree needed to become IOGP Member recognized
(3) Good Follows IOGP Report 471 to the degree needed to become IOGP Member recognized
(4) Excellent Exceeds the guidance in IOGP Report 471 beyond what is needed for IOGP Member recognition
Oxy-arc underwater cutting recommended practice 82
Bibliography
HEALTH & SAFETY EXECUTIVE (HSE) [UK]. OTH 349. Evaluation, selection, and development of subsea
cutting techniques. Croydon, 1997.
INNOVATION AND BUSINESS SKILLS AUSTRALIA. TAE40110. Certificate IV in Training & Assessment.
May 2014. http://training.gov.au
INTERNATIONAL MARINE CONTRACTORS ASSOCIATION. IMCA D 003. Rev. 1. Guidelines for Oxy-Arc
Cutting. London, September 2011.
INTERNATIONAL MARINE CONTRACTORS ASSOCIATION. IMCA D 031. Cleaning for Oxygen service.
Setting Up Facilities and Procedures. London, May 2003.
INTERNATIONAL MARINE CONTRACTORS ASSOCIATION. IMCA D 045, R 015, Code of Practice for the
Safe Use of Electricity Under Water. London, October 2011.
IOGP. Report 431. Diving worksite representative roles, responsibilities and training. London, November
2009.
UNITED STATES. U.S. Navy Underwater Cutting and Welding Manual. S0300-BB-MAN-010.
Washington DC, April 1989. Change B revised June 2002.
Oxy-arc underwater cutting recommended practice 83
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