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The International Association of Oil & Gas Producers has access to a wealth of technical knowledge and experience with its members operating around the world in many different terrains. We collate and distil this valuable knowledge for the industry to use as guidelines for good practice by individual members.
Disclaimer
Whilst every effort has been made to ensure the accuracy of the information contained in this publication, neither the OGP 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 recipients 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. This document may provide guidance supplemental to the requirements of local legislation. Nothing herein, however, is intended to replace, amend, supersede or otherwise depart from such requirements. In the event of any conflict or contradiction between the provisions of this document and local legislation, applicable laws shall prevail.
Copyright notice
The contents of these pages are The International Association of Oil and Gas Producers. Permission is given to reproduce this report in whole or in part provided (i) that the copyright of OGP and (ii) the source are acknowledged. All other rights are reserved. Any other use requires the prior written permission of the OGP. These Terms and Conditions shall be governed by and construed in accordance with the laws of England and Wales. Disputes arising here from shall be exclusively subject to the jurisdiction of the courts of England and Wales.
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Acknowledgements
This Recommended Practice was produced by the OGP Oxy-Arc Underwater Cutting Task Force
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Table of contents
1 Glossary of terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4 Risk mitigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Alternative cutting methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1.1 Saws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 4.1.2 Shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9 4.1.10 4.1.11 Arc water gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Kerrie cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Thermal cutting techniques that use no oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Plasma arc cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Water jet cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Chain feed cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Orbital pipe cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Casing cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic hand tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Equipment selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Welding power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6.2 Safety switch or circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6.3 Burning leads or burning umbilical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 6.4 Ground leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 6.5 Wire splices, connectors and terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6.6 Continuity check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6.7 Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6.8 Oxygen hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6.9 Oxygen regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 6.10 Oxygen pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 6.11 Torches or electrode holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.1 Tubular steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7.2 Exothermic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7.3 Consumables in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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11 Training requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11.1 Specification for instructors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 11.2 Specification for diver training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11.2.1 11.2.2 Oxygen-arc cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Specification for diving supervisor training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12 Oxy-arc cutting risks & mitigation (a commentary section) . . . . . . . . . . . . . . . . . . . . . . 29 Appendix 1 Checklists for oxy-arc operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Client diving representative oxy-arc cutting checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Diving contractor oxy-arc prompt list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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1 Glossary of terms
ALARP As Low As Reasonably Practicable. Burning Underwater oxy-arc cutting. Commercial Dive A logged dive carried out after training when the diver is employed as a commercial diver. Diver Person who by qualification and experience is a competent commercial diver. DMT Diving Medical Technician. HAZID Hazard Identification. A process of defining all potential hazards on a job by task identification and then identifying all mitigations (barriers) to prevent an incident, as well as recovery efforts defined in the event the incident does occur. HP and LP High Pressure and Low Pressure. JSA Job Safety Analysis. Developed on-site; a group effort by the responsible crew about to perform a task; to define work roles, safety considerations, and mitigations, prior to a task being performed. O2 Clean Oxygen clean is the verifiable absence of particulate, fibre, oil, grease and other contaminants following appropriate industry guidance. Safe Work Plan Also known as a work scope or work plan. It outlines the work required to complete a project. It is not as detailed as a work procedure, but would allow procedures to be developed based on its detail. ROV Remotely Operated Vehicle. Tenders Newly-qualified divers or apprentice divers that are gaining the worksite commercial experience to be classed as a fully competent diver.
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2Introduction
Underwater oxy-arc cutting, also commonly referred to as burning, is the process of cutting materials (generally ferrous metals) with a tool that combines oxygen and heat to oxidize or melt the parent material, the method has been utilised extensively in the underwater diving environment. The frequency of diver fatalities, injuries, incidents, and asset damage occurring while using this process continues to be unacceptably high within the global diving industry. Divers engaged in burning need to be competent in the task. This competence is achieved through training, knowledge and experience. This Recommended Practice has been developed to assist with the management of this activity and provide control measures, guidance and processes to ensure the safe execution of this technique. Additional information can be obtained from the documents referenced below.
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3References
OGP Report 411, Diving Recommended Practice OGP Report 431, Diving worksite representative roles, responsibilities and training U.S. Navy Underwater Cutting and Welding Manual, Doc. S0300-BB-MAN-010 IMCA D 045, R 015, Code of Practice for the Safe Use of Electricity Under Water IMCA D 003 Rev. 1, Guidelines for oxy-arc cutting IMCA D 031, Cleaning for Oxygen service HSE OTH 349, Evaluation, selection & development of subsea cutting techniques
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4 Risk mitigation
The decision to use burning should always be considered against other methods and the risks identified, assessed and controlled. Many alternative cutting methods are safer and, in some cases, faster and more cost effective than oxy-arc burning. The use of unmanned submersibles or ROVs with power-operated saws can be considered and the choice to use a diver in an oxy-arc burning scenario should be balanced with alternative methods. An ROV can also be used to assist in oxy-arc cutting by monitoring hoses, vent paths and the operation; this should be identified in the risk assessment.
4.1.2 Shears Shears have proven to be valuable tools for remotely cutting large diameter components. Where there is stored residual energy in the component to be cut this method creates a risk to the diver.
Pyro-mechanical systems are generally a shear and these devices use a small low-powered explosive charge to operate the cutter as opposed to hydraulics. It can be used to cut any shaped structural member that will fit between the shear jaws. It can be deployed by an ROV.
4.1.3 Arc water gouging Carbon arc gouging utilises a copper coated carbon electrode that melts the steel in a controllable puddle and a low pressure water jet sweeps the molten metal from the cut area. This method is particularly suited for small cross-sections, 1-inch thick or less. It does not completely eliminate the hydrogen gas build-up due to electrolysis, but the lack of pure oxygen in the process reduces the risk significantly. It also provides a very controllable cut depth and thicker cross-sections can be cut by first gouging a bevel before making the through cut. This process works well with non-ferrous metals as well. 4.1.4 Kerrie cable Kerrie cable is a flexible exothermic cable suited to cutting large components. This will require a dedicated additional training course before use. 4.1.5 Thermal cutting techniques that use no oxygen These are electrodes manufactured for cutting underwater that use no oxygen in the process. This method can be much slower than oxy-arc cutting and can also produce hydrogen as a by-product of electrolysis. 4.1.6 Plasma arc cutting A process whereby material is removed with heat from a high-energy plasma stream created in a hand held torch and usually propelled with an inert gas. This method can be much slower than oxyarc cutting and can also produce hydrogen as a by-product of electrolysis.
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4.1.7 Water Jet Cutting The cutting of metal is achieved by pumping high pressure water through a small diameter nozzle. This process is generally not a diver operated device and is used for inside or outside cuts made on tubular structural members where the cutting machine is set up and held in place on the member as it tracks around the member while cutting. An abrasive material is sometimes used in the high pressure water jet to aid in the cutting. 4.1.8 Chain feed cutters This machine tracks around a tubular member with the aid of a tensioned belly chain and guide wheels that encircle the tubular member. The traveling cutter is hydraulically powered and a blade cuts the pipe as the machine travels around the pipe on the chain. 4.1.9 Orbital pipe cutters These consist of a pipe clamp, guide ring and a pair of geared cutter heads. The cutters revolve around the clamp and each rotation sets the cutter deeper, automatically producing a finished cut on tubular members. These can either be hydraulic or air operated. 4.1.10 Casing cutters Generally used for cutting pipe or casing from the inside; these cutters are deployed hydraulically and have several cutters that revolve on an axis and open outward as the cutting is done. Tungsten carbide cutters mill away the pipe from the inside and can be used for cutting pilings on offshore structures. 4.1.11 Hydraulic hand tools Tools such as hydraulic grinders with cutting discs may be used to cut underwater effectively. Grinding should be considered hot work as sparks and friction may raise the metal temperature to the ignition point of any trapped flammable material. Hand-held reciprocating saws which use a reciprocating hacksaw blade can be used to make a cut. 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 will be required.
Other methods of cutting are known to exist, many of them using explosives that will not be reviewed in this document. For a comprehensive list of alternatives, please refer to: HSE (OTH 349) Evaluation, selection & development of subsea cutting techniques.
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Verify that tools are available to assess electrical current and gas pressure/flow during the burning operation. Contractor shall provide these verification tools. Participate in the risk assessment process and ensure that mitigation measures are implemented during the operation.
5.5 Divers
Divers participating in burning operations shall be qualified in accordance with this Recommended Practice. Competence levels shall be demonstrated and based on the following levels:
Diver Competence Level Criteria Completed 30 logged commercial dives using oxy-arc as level 2. Plus a minimum of 150 commercial dives. For offshore this may be a combination of 100 offshore and 50 carried out inland. For inland diving only, this can be a minimum of 150 commercial inland dives. Restrictions Evaluate diver competence requirements as part of risk assessment for intended operation. No other restrictions.
1 Advanced
2 Intermediate
Completed 10 logged commercial dives using oxy-arc as level 1, plus 100 commercial dives.
Only perform cuts with no residual energy in the component to be cut. No potential for gas entrapment. No grout or mud behind the cut location. No depth limitation. Only cut component with less than 2 inches wall thickness. Only perform cuts with no residual energy in the component to be cut. Water visibility not less than 2 feet. No potential for gas entrapment. No grout or mud behind the cut location. Only cut component with less than 1.5 inches wall thickness.
3 Entry
Divers shall have a comprehensive knowledge of the burning equipment being used and the scope of work.
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The diver shall 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. Diver shall initially confirm the vent path using a secondary supply such as the pneumofathometer prior to commencing the cutting operation. Thereafter the diver shall continually verify the gas vent path and have proven to himself and the supervisor that a clear vent path exists and is maintained, and there is no potential for gas entrapment adjacent or above the work site. Shall have reviewed the HAZID, risk assessment, dive procedures and work plans or MOC, prior to making a dive to burn.
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6 Equipment selection
6.1 Welding Power Source
The power source used to supply electrical current shall be installed at the dive site, vessel or structure and brought into service within the restrictions and requirements of any relevant vessel classing society, such as ABS, DNV or Lloyds. Machine grounding issues shall be addressed prior to hook-up. 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 utilising 220V or 480V, 3-phase input. The following considerations should be noted before the use of any welding power source for underwater burning: DC output only machines shall be used. No machine that can be switched from DC to AC shall be used. No machine which has been modified in any way from manufacturers specification shall be allowed. Machine polarity shall be set to electrode negative or straight polarity (DCEN). During machine selection, failure path and consequences must be considered. Machines must be designed to fail in the open circuit mode. Machines used for burning should be isolated from other welding machines on the vessel (within the rules of vessel classification). On some vessels a common ground is used for all machines that can allow stray electrical current to enter the circuit specific to the burning. Any machine that is specifically designed for welding processes other than stick electrodes (GMAW, GTAW, etc.), should not be considered unless it is DC output only. Machines in constant use should be 400-600-amps or greater with a 100% duty cycle for the amperage setting being used. Some machines may be rated at 60% for max 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) On jobs requiring day to day burning activity, a 100% duty cycle machine is highly recommended. These machines are much more robust and fit for maximum usage. Exothermic electrodes require less amperage and a correspondingly lower amperage machine can be used for this type of application. If a combination of tubular steel, and exothermic electrodes, are planned for use, the machine should be rated for the higher amperage requirements of the tubular steel rods. Amperage control may be remote and controlled by the Supervisor in dive control. Amps/Volts may be remotely monitored by Supervisor from dive control. Amperage may be verified by calibrated instrumentation at or in the vicinity of the torch.
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Dive control Least preferable set up is with a twin pole knife switch Handle hinge position lowest
DC Welding Machine
Dotted line would be the cable set up for Single Pole switch
Oxygen
Oxygen
DC Welding Machine
DC breaking contactor
Oxygen
Oxygen
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In addition: The switch must be rated greater than the maximum amperage of the welding machine powering the burning. The knife switch shall be mounted to a non-conducting stand. The knife switch shall not be mounted in an area where oxygen could accumulate, such as an enclosed, non-ventilated dive van. Mounted in such a way that if the knife blade should fall it would fall to the open position and not close the circuit. The switch shall be covered with a non-conductive housing to safeguard the operator from electrical shock for reasons as described in the warning below. Local governmental or client requirements of explosion proof equipment may be required on offshore platforms, refinery loading docks or chemical plant docks where ignitable concentrations of flammable gases, vapours or liquids are present within the atmosphere during normal operating conditions. Warning: a manual knife switch produces a large arc when being connected or disconnected. This arc carries high energy and can cause electrical burn or shock. It is also a large ignition source. The preferred mode of circuit interruption is through a remote circuit breaker that is housed in its own breaker box and operated through an on/off switch in the dive control. There are breakers specifically designed for use in burning operations and feature remote switching from the operator location. This type of switch is typically permanently mounted in a safe location outside the dive control van. These breakers shall always fail to the open circuit. It should be noted that the rocking motion of a dive vessel can affect the operation of some breakers and these breakers should be selected on fitness for purpose basis and the design carefully evaluated. Inverter type machines are generally equipped to support remote contractor switching.
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The position of the ground in relation to the diver must be such that at no time does the diver or his equipment become positioned between the ground and the electrode. The diver must avoid becoming part of the electrical circuit.
6.7 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. Oxygen pressure and flow requirements should be based on the manufacturers recommendations for the material thickness to be cut.
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The hose shall be routinely maintained for oxygen use (O2 clean is the verifiable absence of particulate, fibre, oil, grease and other contaminants). Restrictions through hose fittings shall be minimised where possible. Full bore valves and full port regulators should be used for burning applications. In the cutting of non-ferrous materials air is sometimes used as a medium to move the molten metal from the cut. If air is used in an oxygen hose then the hose must be cleaned prior to returning to oxygen service. Air from HP cylinders is preferred to minimise or eliminate the oil contamination that can occur with LP or HP air produced by a compressor.
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The welding cable or torch lead should be inspected at the connection to the torch body. Electrolysis will result in this connection becoming loose over time. It should be re-tensioned according to manufacturers specification. Warning: electrolysis can produce hydrogen as a by-product of the process. This hydrogen may build up in the torch head voids if dead space exists. Check for work hardened areas in the welding cable adjacent to the torch handle. Work hardened cable may indicate the presence of broken conductor strands inside the insulation.
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7Consumables
In oxy-arc cutting there are two basic electrode (rod) designs, Tubular Steel Electrode and Exothermic Rod. Each rod type has its inherent strong points and also its 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. A brief definition of each rod is as follows:
7.2 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 (9.5mm) 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 may require a low amperage (~150-amp) boost, especially in thicker materials. Once the oxygen is shut off the reaction stops. Note: exact amperage requirements should be established by testing. Examples given only suggest a range for use. Oxygen must be shut off from the rod to stop the burning process once started.
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8 Pre-job considerations
All burning operations shall be risk assessed. This will follow the contractors process and in addition to the support requirements for this process. Only divers and supervisors that comply with the training and competence requirements of this document should be used.
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Mud, grout or other material built up behind a proposed cut shall be removed. If it is not possible to remove the background mud, alternative cutting methods shall be used. Oxygen or other combustible gases may naturally rise away from the cut area and be of no consequence. This shall be verified. Internal structural braces within a structural member such as a tubular diagonal brace with internal stiffener rings shall be considered a possible gas entrapment. If gas introduced into the member does not vent in a predictable amount of time, it shall be considered as blocked and alternate venting schemes considered. Burning on an incline or vertical position should be done from the top moving down to reduce or eliminate the possibility of burning into a gas pocket. More than one vent should be made when burning in the horizontal directions. When cutting into a tubular tank or enclosed space vent holes will be needed. Burning on a pipeline, vessel, storage tank, or anything having previously contained a hydrocarbon product shall not be performed. Residual hydrocarbons in any amount can become quite explosive when mixed with oxygen. Other hazards to consider when establishing a vent hole are: 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: Identification. Mitigation. Verification which includes continuous monitoring as the cut progresses or locations changed. Identification of flow paths and potential gas pockets shall be investigated using drawings, inspection dives performed, and any other information available to the project planning team. This team should be composed of personnel that have experience and competence in the type of burning to be accomplished and knowledge of the structure being burned. Mitigation of 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. Caution: 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. Verification of venting to prove it is adequate shall be accomplished. One recognised method is to introduce a burst of air/inert gas into a drilled hole at the potential cut location and record the time elapsed until it exits the vent window. Venting should be monitored and also verified when conditions, location, or when divers or supervisors are changed.
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11 Training requirements
11.1 Specification for instructors
Instructors shall be trained to the requirements of this RP, experienced to Level 3, with 10 years commercial diving experience. The instructor should be able to demonstrate the process in the training tank, or have a diver qualified to level 3 available who can perform this task.
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Differential pressure Hydrocarbons Visibility SimOps Types of material, ferrous and non-ferrous Configuration (tubular, wire, structural) Slag Bell position Gas migration Confined space burning Dredging and below mudlines Surface cleaning Contaminated water Tides, currents, splash zone Electrical risks Alternative cutting Water depth Diver position Diver stance Underwater Cutting Rods Tubular steel electrodes Exothermic rods Cutting rod amperage requirements Tubular steel electrode amperage Exothermic rod amperage Other rod options 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 Symptoms Probable causes Identification and problem solving Post-Dive Maintenance
Training schedule each diver Classroom instruction and assessment 3 days. Practical equipment setup 1 day. Dry burning 0.5 days. Student will practice the necessary techniques with each type rod. Wet tank training 2 days. Each student will burn 50 rods of each type.
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Level 1 will be required to satisfactorily demonstrate safe and successful burning technique as follows: Exothermic rod Burn 6 inch Schedule 80 pipe using no more than 3 rods. No Hangers. 4 minutes start to finish. Burn 1 inch clean steel for a distance of 18 inches using no more than 5 rods. 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. Tubular steel electrode Burn inch clean steel for a distance of 18 inches using no more than 3 rods. No Hangers. 4 minutes start to finish. Burn 1 inch clean steel for a distance of 18 inches using no more than 5 rods. No Hangers. 6 minutes start to finish. Burn 2 inch clean steel for a distance of 18 inches using no more than 9 rods. No Hangers. 10 minutes start to finish.
The diver should maintain competence by using oxy-arc for 5 hours in water per annum. Where this is not achieved, tank top-up training should be considered by the client.
Training and assessment in the hazards and controls of conducting oxy-arc cutting: Risk assessment and MOC Hazards Mitigation Controls Principles of Operation Theory of burning Oxygen system Safe materials and their correct application Venting Grounding Circuit breakers Lifting Rigging Dropped objects Lift bag use Residual energy Differential pressure Hydrocarbons Visibility SimOps Types of material, ferrous and non-ferrous Configuration (tubular, wire, structural) Slag Bell position Gas migration
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Confined space burning Dredging and below mudlines Surface cleaning Contaminated water Tides, currents, splash zone Electrical risks Alternative cutting Water depth Diver position Underwater Cutting Rods Tubular steel electrodes Exothermic rods Cutting rod amperage requirements Tubular steel electrode amperage Exothermic rod amperage Other rod options 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 Symptoms Probable causes Identification and problem solving Post-Dive Maintenance
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3 4 5 6 7 8 9 10 11 12 13 14
OGP
31
32
OGP
YES Equipment (continued ) Oxygen manifold (on the quad) (continued) Purpose-built oxygen distribution manifold shall be: Designed to a recognised international standard Constructed from materials designed for oxygen use Capable of withstanding upstream pressure or a relief valve shall be fitted to protect LP components Certified by a competent person Oxygen cleaned and tested Pressure tested to an internationally recognised standard Fit for purpose (high pressure & high flow) Oxygen cleaned HP & LP gauges fitted and operational (scale appropriated) HP filter in place Protected from dropped objects Bull nose is the correct type for the cylinder Pressure relief valve - to protect downstream components 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 Hoses & tube runs Oxygen hose: From quad regulator to the top-side burning umbilical connection must not be wire reinforced Such hoses shall be constructed from non-conductive materials Oxygen hose shall be fit for purpose and designated for oxygen transport by the manufacturer Hydraulic hose: From hydraulic power pack to the burning umbilical reel connection must not be wire reinforced Such hoses shall be constructed from non-conductive materials Burning umbilical: oxygen hose shall be fit for purpose and designated for oxygen transport by the manufacturer Oxygen hoses shall be pressure tested and certified by a competent person Oxygen cleaned to an internationally recognised standard & certified by a competent person Whip checks shall be used where required Oxygen carrying hose/tube specifically related to thermal cutting operations shall not be bundled with life support gas, electrical, communications or other services critical to the diver, bell or DDCs life support functions Oxygen carrying hose/tube shall not pass through machinery spaces or other areas that contain flammable substances or may promote or enhance combustion (such as hydraulic power pack rooms etc.) Umbilical winch Designated SWL must be marked on the frame Securely sea-fastened Load tested and deck tie-down joint ND inspected Primary brake - should be automatic when the lever returns to neutral Secondary brake - may be manual Maximum heave force to be entered in the risk assessment Oxygen hose connection should be on the opposite side from the hydraulic connections Oxygen hose to have a double block and bleed facility Valves - should be rising stem type Valves - fit for purpose - i.e. rated for oxygen use by the manufacturer
NO
Regulator
OGP
33
YES Equipment (continued ) Umbilical winch (continued) Valves - oxygen clean Electrical connections must be designed for the application intended and fit for purpose Umbilical winch lifting pad eyes in pull test & MPI date Umbilical winch slings & shackles - fit for purpose & in-date Must be electrically grounded to the vessel with heavy duty cable Welding machine AC welding current output machines are unacceptable Only Direct Current (DC) output machines shall be used DC negative to the torch is the industry norm 400 to 600 amp range Duty cycle 60 to 90 per cent depending on the type of rods used The machine must be certified as fit for purpose by a competent electrical technician Safety devices such as ground fault detection systems must be operational The machine shall be electrically grounded to the vessel hull Remote voltage and amperage read out is an advantage (in dive control) Remote amperage control is an advantage (in dive control) Test the output current is as indicated (Tong test or amp clamp) Warning signs and barriers Fire monitoring & suppression should be considered Consider engine exhaust location Welding machine lifting pad eyes - pull test & MPI in-date Welding machine slings and shackles - fit for purpose & in-date load certificates Cutting umbilical Should, at a minimum, contain a positive and negative cable with an oxygen hose Consider a strength element of non-stretch rope such as Spectra Consider the fitting of D rings as lift points or chain stops 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) Both cables should be resistance & 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) The ground clamp should be in good condition
NO
34
OGP
YES Equipment (continued ) Cutting umbilical (continued) Cables Umbilical deployment method - pad eyes - pull test & MPI in-date Umbilical deployment method - slings and shackles - fit for purpose & 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 Shall be supported Shall be protected from dropped objects Ground (positive) shall not be through the vessel hull Cables shall not pass through areas that contain flammable substances Cable connectors Treat all styles with caution (Lenco style). They often 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 & 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.) Stab (Lenco style) connections should not go subsurface unless specifically designed to be immersed in salt water Joints should be waterproofed using approved materials and process Cutting & welding switch Direct Current (DC) rated Twin pole - solenoid operated Amperage range to suit the type of rods being used Should be located as close to the welding machine as possible Remote activation by the diving supervisor is preferred mode of operation Certified fit for purpose by a competent person Contained in a box that prevents arc flash Should not be in a location that is subject to elevated concentrations of oxygen or combustible gases or vapours (hydrocarbon, acetylene) Knife switch style (in dive control) Mounted in a box (arc flash suppression) Handle down to open the circuit Twin pole Oxygen analyser in dive control if Rich Mix is being used Consider positive ventilation of dive control Rated for the current loading of the rods being used Dive control must be grounded with a cable equal to the size of the welding cable Welding Cable Bulkhead cable connectors shall be mounted on a non-conducting board (such as Paxolin) FMEA electrical welding ground faults: considerations may be, but not limited to: Metallic/conducting pipe work with life support functions Electrical equipment overload (analysers) Fire Oxygen rich atmospheres Planning Is the current burning work planned? Is there a client document detailing the work scope? Has the contractor prepared a burning procedure? Has a risk assessment been conducted using the procedure as a guide?
NO
OGP
35
YES Equipment (continued ) Planning (continued ) 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? Do the generic RA adequately cover the work scope? Have the documents been reviewed? What is the current document revision status? Has the project plan been issued for construction? Have the divers undergone training for the specific job? Level 1 HIRA (onsite) to review findings of Level 2 HIRA? Do the conditions remain the same? Can variations to the HIRA be managed onsite? Are variations managed by the contractor MOC process? Execution Pre-dive checks Hot work permit in place for vessel Hot work permit in place for platform Supervisor or engineer drafts a dive plan Divers & others have read the dive plan Tool box talk - includes divers & others Knife switch open Sufficient oxygen Regulator set Oxygen hose pre-charged - pressure noted 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 & function tested Generator online 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 & 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 & 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 & washer on a safety pin tied 3 meters back from the torch Diver has gauntlets and rubber gloves Spare gloves tied back beside the collets DDC checked
NO
36
OGP
YES Execution (continued) Pre-dive checks (continued) Cleaning equipment inspected & 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 & markers Tape measure 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 Work cut site is cleaned & marked out Clean to a bright surface offers the best cutting quality & speed Clean the back side of the cut if possible Vent hole location(s) verified prior to cutting Vent holes are cut & proven to the process identified in the HIRA Ground clamp is connected at a location safe for the diver Diver is not to be between the ground clamp and the cutting face Set oxygen flow by adjusting the oxygen jet from the rod to about 150mm horizontal flow Do not place hands in front of the rod to test oxygen pressure Do not energise cutting torch before flowing oxygen through to purge any possible hydrogen build up Test cut is made on a dummy plate Supervisor verifies the current settings are within normal limits Do not burn the rod shorter than 75mm Do not allow oxygen pressure to drop below 90 psi over bottom Hose burn back may occur at low oxygen pressure Check load is supported Safety of diver and asset is identified in the direction of cut Assess retained energy - inspect for distortion, buckling, twisting etc. Umbilical clear Post-dive checks Electrolysis can adversely affect the integrity of the metallic parts, especially on long burning campaigns. Frequency of inspection of the dive hat & burning equipment should be increased.
NO
OGP
37
38
OGP
www.ogp.org.uk
209-215 Blackfriars Road London SE1 8NL United Kingdom Telephone: +44 (0)20 7633 0272 Fax: +44 (0)20 7633 2350 165 Bd du Souverain 4th Floor B-1160 Brussels, Belgium Telephone: +32 (0)2 566 9150 Fax: +32 (0)2 566 9159 Internet site: www.ogp.org.uk e-mail: reception@ogp.org.uk