Oxy-Arc Underwater Cutting Recommended Practice

REPORT
471
Oxy-arc underwater cutting

recommended practice
knowledge
experience
MARCH
2015
Acknowledgements
Safety Committee
Diving Operations Subcommittee
Photography used with permission courtesy of istockphoto/
think4photop and U.S. Navy (Front cover) U.S. Navy (Back cover)
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 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.
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REPORT
471
Oxy-arc underwater cutting

recommended practice
Revision history
VERSION
DATE
AMENDMENTS
2.0
March 2015
Version 2
1.0
June 2012
First release
MARCH
2015
Contents
1
Introduction 6
Mitigate risk by using alternative cutting methods
2.1 Saws
2.2 Shears
2.3
Arc water gouging
2.4
Kerie cable
2.5
Thermal cutting techniques that use no oxygen
2.6
Plasma arc cutting
2.7
Water jet cutting
2.8
Chain feed cutters
2.9
Orbital pipe cutters
2.10 Casing cutters

2.11 Hydraulic hand tools
9
10
Roles, responsibilities and

operational control
11
3.1
The client
11
3.2
The diving contractor
12
3.3
Client on-site representatives
13
3.4
Dive supervisor
13
3.5 Divers
15
3.6
Dive support crew
17
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
Pre-job considerations
34
On-site considerations and the burning operation
35
Proper venting
36
Divers PPE
38
10 Training and experience requirements
39
10.1 Training course providers
39
10.2 Course contents, material and facility requirements
39
10.3 Classes sizes
40
10.4 Specification for instructors
40
Level 1 and Refresher Training Instructor Qualifications
41
10.5 Specification for diver and supervisor training
42
10.5.1 Oxygen-arc cutting curriculum for Level 1 Beginner and Refresher Training Courses
42
10.5.2 Level 1 Beginner Oxy-arc Burning Course recommendations and suggested schedule
44
10.5.3 Refresher Training Course (top-up) recommendations and suggested schedule
45
10.5.4 Specification for diving supervisor training
46
10.6 Maintaining competency level and experience
47
10.7 Grandfathering and Recognition of Prior Experience (RPE)
47
10.8 Performance proficiency criteria
48
Level 1 Beginner Oxy-arc Burner
48
Level 2 Intermediate Oxy-arc Burner
49
Level 3 Advanced Oxy-arc Burner
49
11 Oxy-arc cutting risks and mitigation (a commentary section)
51
Appendix A: Checklists for oxy-arc operations
52
Client Diving Representative oxy-arc cutting checklist
53
Diving contractor oxy-arc checklist
54
Appendix B: Training course assessment checklist
63
Bibliography 82
Oxy-arc underwater cutting recommended practice
1 Introduction
Underwater oxy-arc cutting or 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 utilized
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. Competency
is achieved through training, knowledge and experience.
This recommended practice has been developed to assist with the
managing this activity and to provide control measures, guidance and
processes to ensure the safe execution of this technique.
No burning operation should be executed unless planned and managed in
accordance with this report.
Diver
Person who by qualification and experience is a
competent commercial diver
2 Mitigate risk by using

alternative cutting methods
A decision to use burning should always be considered against other
methods. Risks should be identified, assessed and controlled.
The choice to use a diver in an oxy-arc burning scenario should be balanced
with alternative methods. 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 Remote Operated Vehicles (ROVs)
with power operated saws can be considered. 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.
Alternative cutting methods follow. Other methods of cutting exist, many
using explosives, but are not reviewed in this report.
HSE (OTH 349) Evaluation, Selection, and Development

of Subsea Cutting Techniques has a comprehensive
list of alternatives.
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.
Guillotine saws use a reciprocating hacksaw blade to make a cut. Each
stroke sets the saw deeper in the cut. They can be diver or ROV deployed.
Diamond wire saws use a continuous loop of diamond-embedded wire
rotating around a guide-wheel frame to make a cut. They can be diver or
ROV deployed.
Hydraulic ring saws are of particular value for cutting thick cross-sections.
2.2 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, in general, shears. These devices use a
small low-powered explosive charge to operate the cutter as opposed to
hydraulics. They can be used to cut any shaped structural member that
will fit between the shear jaws. It can be deployed by an ROV.
2.3
Arc water gouging

Carbon arc gouging utilizes a copper-coated carbon electrode that melts
the steel in a controllable puddle. A low pressure water jet sweeps the
molten metal from the cut area.
This method is particularly suited for small cross-sections, one 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 significantly
reduces the risk.
It also provides a very controllable cut depth. Thicker cross-sections can
be cut by first gouging a bevel before making the through cut.
This process also works well with non-ferrous metals.
2.4
Kerie cable
Kerie cable is a flexible exothermic cable suited to cutting large
components. This will require a dedicated additional training course
before use.
2.5
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.
2.6
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 oxy-arc cutting and can also
produce hydrogen as a by-product of electrolysis.
2.7
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.
2.8
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. The traveling cutter
is hydraulically-powered and a blade cuts the pipe as the machine travels
around the pipe on the chain.
2.9
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.
2.10 Casing cutters

These are 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.
10
2.11 Hydraulic hand tools

Tools such as hydraulic grinders with cutting discs may be used effectively
to cut underwater. Grinding should be considered hot work because
sparks and friction can 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 is required.
11
3 Roles, responsibilities and

operational control
Roles and responsibilities for diving-related projects are found at length in
the IOGP Report 411, Diving Recommended Practice.
The following guidance applies specifically to burning operations in
addition to the provisions of Report 411.
All personnel on a project have the right, authority,

and obligation to Stop Work if they consider anything
unsafe about the operation.
3.1
The client
The client should provide information to assist the contractor in planning
and preparing for an underwater cutting operation, including:
current drawings of work site and areas specific to the burning
operation, which include pipeline drawings, platform plan and
elevation drawings, P&ID drawings, detailed deck layout drawings
a detailed Scope of Work to allow the contractor to produce workscope procedures.
The burning operation should be executed according to this report.
Any changes to the approved burning procedure should be controlled by
a Management of Change (MOC) that is approved by client and contractor
representatives.
Concerned parties, or approvers, should be pre-determined and
documented a list generated and included in the diving project plan.
Approvers may include the client, project engineer, on-site rep, contractor
management, vessel master, diving superintendent and supervisors.
The clients authorized representative should participate in the
contractors project risk assessments.
A Permit to Work should be in place for control of this activity.
3.2
12
The diving contractor

The diving contractor is responsible for:
the Diving Project Plan detailing the operational work-scope and how
it will progress from start to finish
The HAZID and risk assessment being specific to underwater
burning (providing documentation of the trained and qualified divers
identified for the operation see section 10). The dive contractor
should have the dive supervisor and the divers safety delegate
present in the HAZID process.
providing equipment that is suitable for the burning operation
location-specific procedures for burning based on a review of all
drawings and inspection reports
location-specific risk assessment/Job Safety Analysis (JSA) developed
for the planned activities of that shift. If planned activities for that
shifts risk assessment change, or a shift change takes place during a
burning operation, additional risk assessments should be performed.
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.
Job Safety Analysis (JSA)

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.
3.3
13
Client on-site representatives

Knowledge and understanding is essential.
Client on-site representatives should:
be knowledgeable of burning operations, the primary risks, applicable
controls and the guidance in this report
be familiar with the worksite location, either through drawing review
or diver inspection and assessment
verify that tools are available to assess electrical current and gas
pressure/flow during the burning operation. The contractor should
provide these verification tools
participate in the risk assessment process and ensure that mitigation
measures are implemented during the operation.
3.4
Dive supervisor
A dive supervisor is responsible for divers overall
safety and ensures that all control measures
identified through the risk assessment process are
implemented.
Dive supervisors should:

be competent in the management of burning operations, including
knowledge of the primary risks, their controls and compliance with
this report
be familiar with the work site, through procedural review, diver
inspection and assessment.
maintain physical control of the dive, burning operation, and
management control over the knife switch or circuit breaker
controlling the electrical current to the burning torch.
14
It is essential that the circuit breaker/safety switch is

in easy reach of the dive supervisor.
participate in the risk assessment specific to the burning operation.
It is essential that the dive supervisor does not

take over or hand-over an operation to the next
shift supervisor without a thorough exchange of
information as entered in the operational log,
equipment status, and location of diver and
earthing/grounding point prior to leaving the radio
or assuming control of the diver.
The dive supervisor should only take over or handover cold equipment.
If a diving superintendent is present on the job, the diving superintendent

should also be involved in this hand-over and ensure that control
measures are being complied with.
The risk assessment process should determine whether a second diving
supervisor is required on each shift. If there is only one supervisor per
shift, no burning may be performed during shift handover.
15
3.5 Divers
Divers participating in burning operations should be qualified in
accordance with this report.
Competency levels should be demonstrated and based on Table 1
(Diver competency levels).
Diver
Competency
Level
Criteria
Restrictions
3 Advanced
Completed 30 logged commercial

dives using oxy arc as Level 2.
Evaluate diver competency

requirements as part of risk
assessment for intended
operation.
A minimum of 150 commercial

dives. For offshore, this may be a
combination of 100 offshore and 50
carried out inland.
No other restrictions.
For inland diving only, this may

be a minimum of 150 commercial
inland dives.
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.
1 Beginner
Passed training and assessment
Only perform cuts with no residual

energy in the component to be cut
Water visibility not less than 2feet.
No potential for gas entrapment.
No grout or mud behind the cut
location.
Only cut component with less than
1.5 inches wall thickness.
Commercial dive: A logged dive carried out after training when the diver is employed as a
commercial diver
Table 1: Diver competency levels
16
Divers should have a comprehensive knowledge of the burning equipment

being used and the scope of work.
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.
It is essential that the diver initially confirms the

vent path using a secondary supply such as the
pneumofathometer prior to commencing the
cutting operation. Thereafter, the diver continually
verifies the gas vent path and proves to themself
and the supervisor that a clear vent path exists, is
maintained, and that there is no potential for gas
entrapment adjacent or above the work site.
It is essential that the diver has reviewed the
HAZID, risk assessment, dive procedures and safe
work plans or MOC prior to making a dive to burn.
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 allows
procedures to be developed based on it.
3.6
17
Dive support crew

One experienced member of the crew should be designated by the dive
supervisor for burning equipment oversight and to monitor equipment
while in use.
The crew should be responsible for maintaining the burning equipment
during the operation.
They should monitor equipment during use to spot trouble, with
particular attention to welding leads and chaffing and to check for hot
spots in the wires, i.e. lead coating producing steam, smoke, or a slick
wetted appearance. Hot spots indicate possible conductor breakdown
within the lead.
They report equipment status to the dive supervisor.
The crew should have a sound knowledge of AC and DC sources and
principles.
It is essential that oxygen equipment is clean when

handled and operated.
18
4 Equipment selection
Oxy-arc cutting equipment is basically welding equipment with
oxygen added to the process. There are many suppliers of welding
equipment globally.
This guidance is to assist selection of equipment but

it is not an endorsement or recommendation for
any equipment or consumable. No endorsement is
intended or implied.
Any specific equipment here is for example only.
See IMCA D 045, R 015, Code of Practice for the Safe

Use of Electricity Under Water.
4.1

It is essential that the power source used to supply
electrical current is 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.
It is essential that machine grounding issues are
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 utilizing
220V or 480 V.
19
Before the use of any welding power source for

underwater burning:
Only DC output only machines may be used.
No machine that can be switched from DC to
AC may be used.
No machine that has been modified in any
way from manufacturers specification may
be used.
It is essential that machine polarity is set
to electrode negative or straight polarity
(DCEN).
During machine selection, consider failure
path and consequences.
It is essential that machines are designed
to fail in the open circuit mode.
Isolate machines used for burning 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 (e.g. GMAW and GTAW) may
not be used unless it is DC output only.
Machines in constant use should be 400 600 A or greater, with a 100%

duty cycle for the amperage setting being used.
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.)
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.
20
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 from
dive control.
Amps/Volts may be remotely monitored by the supervisor from dive control.
Amperage may be verified by calibrated instrumentation at or in the
vicinity of the torch.
4.2
Safety switch or circuit breaker

A circuit breaker such as a knife switch is the power disconnect switch
in the electrical circuit going to the diver. It is used to prevent electrical
shock when the diver is not actually cutting.
A manual knife switch, or single pole/single throw electrical switch, is not
recommended for diving operations.
The preferred form of safety switch is a remote electrical contactor. It
should be a double pole/single throw switch or two single pole/single
throw switches wired in parallel that interrupts the current flow through
both the torch lead and the ground lead.
21
Dive control
Least preferable set up is with a
twin pole knife switch
Handle hinge position lowest
Oxygen
+Ve
Oxygen
Oxygen
Ve
DC Welding Machine
Dotted line would be the cable set up for Single Pole switch
Figure 1: Basic oxy-arc cutting system
Dive control
Remote control of weld machine
DC Welding Machine
DC breaking contactor
Figure 2: Preferred circuit breaker arrangement
Oxygen
+Ve
Oxygen
Oxygen
Ve
22
It is essential that the switch is rated greater than

the maximum amperage of the welding machine
powering the burning.
It is essential that the knife switch is:
mounted to a non-conducting stand
not mounted in an area where oxygen could
accumulate, such as an enclosed, nonventilated dive van
mounted in such a way that, if it fell, the
knife blade would fall to the open position
and not close the circuit
covered with a non-conductive housing
to safeguard the operator from electrical
shock for reasons as described in the
warning below.
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.
Local governmental or client requirements of explosion-proof equipment

may be required on offshore platforms or 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.
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.
23
It is essential that these breakers always fail to the

open circuit.
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.
4.3
Burning leads or burning umbilical
It is essential that all cables providing a current

path in the burning system are copper and are
sized in accordance with Figure 3 (Voltage drop
over distance).
It is essential that all cables, including in-line
connectors that are exposed to the water or a wet
environment, are fully insulated and watertight.
Wet mate-able connectors of the proper size may
be used only with their locking caps secured and a
strength member installed to prevent separation.
24
Generally, no wire smaller than 2/0 (9.26 mm) should be used for
burning in water depths to 100 fsw (30 m).
1/0 (8.25 mm) wire is shown in Figure 3 to show amperage/voltage loss
over distance as example only.
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).
Figure 3: Voltage drop over distance
It is essential that all leads are copper and properly

sized for the application.
25
Due consideration should be taken that the burning umbilical loses

efficiency and voltage when coiled and heat is generated. The leads or
umbilical should be laid out across a deck to prevent the formation of an
electromagnetic coil.
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.
If large size (4/0 or 11.7 mm) wire is unavailable, an alternative means
of carrying high amperage is to double the leads throughout the circuit
(power and ground).
A strength member (synthetic and non-conductive rope) should be
incorporated into the umbilical to reduce strain on the leads. The leads
are not manufactured to hold their own weight over any length greater
than ~50 ft (15.24 m).
Cable construction should be considered when procuring the leads.
Cables with insufficient thickness of insulation can chaff and the
insulation could become compromised.
A tougher, more durable option is double-insulated wires with PVC as the
inner core cover and neoprene over the PVC. Insulation coating is critical
to safe burning. Water ingress into the wire core creates resistance and
electrolysis will corrode the wires severely in a short time. Welding cable
utilizing paper as an insulator should be avoided due to water absorption.
An even more robust cable for burning application is Diesel Locomotive
Cable (DLO). It has a 24 strand wire core versus the 30 strand wire core for
welding cable. In a permanent application such as aboard a DSV this can
work well between power source and safety switch. The reduced flexibility
might make it difficult to deploy and retrieve from the water.
4.4
26
Ground leads
It is essential that ground wires are constructed of the

same size and length as the lead wire to the torch.
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.
There should be no through-water grounding.
It is essential that the ground wire is attached to the

item being cut in an effort to keep stray current from
the diver and other equipment such as impressed
current protection systems.
A solid and well established ground produces a more reliable circuit.

The ground should have a brass or high copper alloy clamp arrangement
on the divers end to allow the ground to be securely attached to the work.
The ground lead attachment locations should be cleaned to bare metal.
The diver must avoid becoming part of the

electrical circuit.
It is essential that the position of the ground in
relation to the diver is such that at no time does the
diver or the divers equipment become positioned
between the ground and the electrode.
4.5

27
Wire (Cable) splices, connectors,

and terminations
Splices in the cutting leads should be kept to a minimum. A wire
continuity check can determine whether a spliced lead is fit for service.
Wire manufacturers might have guidance as to the maximum number of
splices a wire can have and still function within intended parameters.
When splices are needed:

Use wire splice kits designed for underwater
service.
Never use termination lugs that are bolted
together as a means of splicing this is not
their intended purpose.
Insulation provided by a waterproof moulded
casting, applied within manufacturers
instructions, as a splice cover is the
preferred means of restoring insulation over
a repair or splice.
Rubber, vinyl tape, and electrical sealant,
as an insulator is not recommended as the
sole means of insulation for long term use,
due to chaffing and possibility of arcing
through the chaffed area.
Underwater wire connectors may not be of
the twisted together type. A more positive
connection is recommended to reduce
resistance in the connector resulting in
amperage loss. Above-water connections
may be a lug and bolt type, or twist lock
connectors that can be disconnected.
These connections must be insulated.
All termination points should be cleaned
to bright copper prior to their use.
4.6
28
Continuity check
It is essential that burning leads are regularly

checked, including visual examination, functional test
of unit, including protective devices, plus continuity
and resistance testing of cables. Check and log
continuity using an appropriate insulation resistance
tester to determine if the leads are fit for service.
High resistance creates heat and can damage
equipment, including the power source and also
creates a large voltage loss between power source
and electrode.
Replace waterlogged and degraded leads.
Have these checked by an electrician where an
electrician is available.
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.
Oxygen pressure and flow requirements should be based on the
manufacturers recommendations for the material thickness to be cut.
4.8
Oxygen hose
Oxygen hoses should have a 0.375 inch (9.53 mm) inside diameter hose
minimum.
For depths greater than 200 ft, a in (12.7 mm) hose inside diameter
might be required.
29
Thermoplastic hose may not be used in oxygen

service for burning.
It is essential that the oxygen hose is non-collapsible.
Routinely maintain the hose for oxygen use. O2
clean is the verifiable absence of particulate, fibre,
oil, grease and other contaminants.
Restrictions through hose fittings should be minimized 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, it is essential that the

hose is cleaned prior to returning to oxygen service.
Air from HP (high pressure) cylinders is preferred to minimize or eliminate

the oil contamination that can occur with LP (low pressure) or HP air
produced by a compressor.
4.9
Oxygen regulators
It is essential that oxygen regulators used for burning

are high pressure/high flow regulators.
Regulators should be designed to work at maximum pressure and flow

against a backpressure. These regulators have larger ports within the
regulator body.
A flashback arrester and pressure relief valve should be incorporated into
the regulator on the downstream (low pressure) side.
30
4.10 Oxygen pressure

Oxygen pressure requirements should be verified by the diving supervisor
on the job site.
Using pressures greater than what is required

will increase the probability of an explosion
by introducing more oxygen than is needed or
producing a build-up behind the cut.
The high volume, high pressure, two-stage regulator should be capable

of delivering 70 CFM.
Oxygen pressure should be reduced to 40 bars or less at source
The pressure and volume of oxygen is critical to efficient cutting. To
calculate the required gauge pressure at any depth, always use the
manufacturers recommendations.
4.11 Torches or electrode holders

Torch heads require regular maintenance and should be marked with an
identification number.
Maintenance should be logged in the Equipment Maintenance System
(EMS) to track the life of a torch and burning umbilical.
A new torch should be inspected following the manufacturers
recommendation prior to use.
31
Inspect torches and after each burning operation.

Check all threaded pieces for contamination or
slag in the threads. Clean accordingly.
Check electrode collet for electrolysis erosion
or arc damage. Replace as required for tight
electrode fit.
Inspect all rubber washers and O-rings for
damage.
Inspect flash arrestor for serviceability.
The oxygen delivery system (field check) A
flash arrestor has to be installed in the torch.
Prior to use, inspect the torch, and assemble
it in accordance with the manufacturers
specification.
Follow the manufacturers specification for
pressure testing the torch and system.
Inspect the welding cable or torch lead
at the connection to the torch body.
Electrolysis will result in this connection
becoming loose over time. Re-tension it
according to manufacturers specification.
Warning: Electrolysis can produce hydrogen
as a by-product of the process. This hydrogen
can 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
might indicate the presence of broken
conductor strands inside the insulation.
Torch manufacturers should provide a schematic breakdown and

recommended maintenance program to the consumer.
32
5 Consumables
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 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.
For large burning projects, the electrodes should be qualified by testing to
establish the best fit for purpose.
Keep burning rods in a dry storage area. Do not

let them become exposed to extreme climatic
conditions or contaminates that can have a reaction
with oxygen.
Dispose of:
rusted rods
rods that have been in the water and returned
to the surface unused they are unfit for
service.
Never oil rods to reduce corrosion effects. Oil and
oxygen can produce an explosion.
A brief definition of each rod follows. Exact amperage requirements should

be established by testing. Examples given only suggest ranges for use.
5.1
Tubular steel
Tubular steel rods are composed of a hollow, solid steel tube that is
coated with a flux or waterproof coating. Some designs are covered with
a waterproof coating over the flux.
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.
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 20,000F, 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.
34
6 Pre-job considerations
Risk-assess all burning operations.
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.
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.
Paint or other petroleum-based coatings can

produce a flammable gas when not completely
burned. This can create an explosive environment if
mixed with oxygen.
Proper cleaning prior to cutting will reduce the amount of oxygen

consumed while making a cut.
If the areas of material require cutting are in places where effective
cleaning cannot be achieved, the selection of electrode/rod types should
be considered. Using an exothermic rod that does not require constant
electrical contact could be the preferred choice in this case.
An accurate assessment of the burning requirements is always required.
This should include inspection dives or ROV to trace out gas paths,
possible impact to adjacent structures or piping. The material to be cut
should also be known.
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.
Never cut materials such as aluminium,

magnesium, or zinc with the oxy-arc process.
These materials are very dangerous to the diver
doing the burning.
These metals will actually burn on their own in the
presence of high temperature and oxygen.
Cut these materials using alternative means.
36
8 Proper venting
It is essential that a suitable gas path for the elimination of
volatile gases from adjacent to and above the cut is achieved
prior to commencing the oxy-arc cutting operation.
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.
37
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:
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.
Verify venting to prove it is adequate. One recognized method is to introduce a
burst of air/inert gas into drilled hole at potential cut location and record the time
elapsed until it exits the vent window.
Monitor and verify venting when conditions, location, divers and supervisors are
changed.
38
9 Divers 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 divers 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.
Personal jewellery may not be worn during burning.

Gold is a highly conductive material and can
increase the chances of the diver becoming a part of
the electrical circuit.
39
10 Training and experience

requirements
10.1 Training course providers
The training provider should be an accredited commercial diver training
school, professional training establishment, or in-house training
conducted by a dive contractor.
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.
All training providers, regardless of affiliations or accreditations, should
conduct training and maintain the training facilities according to local
and/or national Health and Safety laws.
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.
10.2 Course contents, material and facility requirements

The course should be structured to establish Terminal Learning Objectives
and to establish a pass and fail criteria for the students performance.
Courses should be performed in a properly outfitted training facility that
is appropriate for the task. See Appendix B, IOGP oxy-arc cutting training
course assessment checklist.
Courses should be supported with training aids and learning material
which should include a lesson plan, course booklets, video and power
point presentations, diving equipment and cutting equipment that is
identified in this report.
Equipment set-up and dry burning instructions should be performed at a
properly outfitted hot-work location where safe and practical performance
of the task can be conducted.
Wet training may be performed in either a tank or open water location
that is appropriate for an entry level diver. It is essential that conditions
allow for safe and practical task performance and monitoring with closed
circuit video or other means, such as windows, that allows for close visual
witnessing of progress. More than one camera or window may be required
to obtain this level of inspection.
During wet training modules, there should be maximum of two divers in
the water for each diving supervisor/instructor at the dive site.
40
10.3 Classes sizes

There are several considerations for class size:
instructorstudent ratio
number of training aids available for students
time management for a 40 hour course of instruction
practical training module time available for each student
wet training time availability for each student diver. (Each diver will
require up to several hours in the water.)
It is envisioned that class size would be no larger than 15 divers.
Training module
Number of students
Number of
instructors
Class room lecture
15
Practical modules (Dry)
5 (2 diving at a time)
Wet training modules
Table 2: Suggested instructorstudent ratio per module of training
10.4 Specification for instructors

The instructor or instructing staff (more than one instructor) should
be qualified to plan and deliver the course within the scope of this
recommended practice. There is no limit to the number of instructors that
a provider may use.
The training course should have at least one instructor that is qualified
to plan and deliver the training course and to assess the trainees 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).
41
Level 1 and Refresher Training Instructor Qualifications

Instructors should have:
prior formal training in the theory and techniques of oxy-arc cutting.
Formal training may include accredited diver training courses or
military training that included oxy-arc cutting as part of the training
documented experience of oxy-arc cutting as an offshore or inland
diver, on at least 40 oxy-arc cutting dives
experience using exothermic and tubular steel rods. Experience for
use of both rod types may also be gained by practicing in the course
wet trainer
at least five years of experience as a diver and performed at least
250 dives
comprehensive knowledge and understanding of the topics and
information contained in this report and IOGP Report 411
the necessary qualification and/or skills to perform workplace
technical training and assessment according to the training providers
accreditation requirements. Where there is no accreditation
requirement for workplace training, the instructor should at least
attend a vocational education trainers course (Train the Trainer) or
Workplace Competence Assessor course
the ability to demonstrate in-water tasks.
An example of an accredited/qualified trainer is the Australian TAE40110
Certificate IV in Training & Assessment.
See IMCA C 007 Rev 1, Guidance on Assessor Training and IMCA C 016,
Guidance on Verifier Training for further information.
42
10.5 Specification for diver and supervisor training

10.5.1 Oxygen-arc cutting curriculum for Level 1 Beginner

and Refresher Training Courses
Training and assessment in the hazards and controls of conducting
oxy-arc cutting should contain the following topics and learning points.
The relevant parts of this report should be used as the basis for training
these points.
Risk assessment and MOC:
hazards
mitigation
controls.
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)
43
lift bag use while burning

lifting while burning
rigging techniques to aid burning.
Underwater cutting rods:
tubular steel electrodes
exothermic rods
general 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:
malfunction symptoms
probable causes
identification and problem solving.
Post-dive maintenance:
electrode storage
torch maintenance.
44
10.5.2 Level 1 Beginner Oxy-arc Burning Course

recommendations and suggested schedule
Level 1 is considered basic training and entry level. Students should be
given the opportunity to use exothermic and tubular steel.
The Level 1 Oxy-arc Burning Course should be set up to provide each
diver with a minimum of 40 hours of training and assessment.
Training module
Hours
Criteria
Classroom
Instruction
and Assessment
Lecture and instruction to the

suggested curriculum topics to be
completed over the course
Practical equipment
set-up
Equipment set-up may be performed

during the dry burning or wet training
phase
Dry burning
(Cutting in dry
conditions)
Dry burning may be substituted with

wet training where conditions applya
Wet training
modules
24
Diver should practice with each rod type

Each student must burn at least 50 rods
of each type.
Each diver must complete the Level 1
Performance Proficiency Criteria. See
10.8 (Performance proficiency criteria)
The 100 rod minimum may be included
as part of the proficiency test
In some regions where laws governing air pollution are in effect, dry burning
can be substituted for more in water burning. Dry burning is a valuable method
for understanding the concept of oxy arc burning and should be incorporated in
the training where possible and should not be deleted unless required by outside
governance.
a
Table 3: Level 1 Beginner Oxy-arc Burning Course recommendations and

suggested schedule
45
10.5.3 Refresher Training Course (top-up)

recommendations and suggested schedule
Refresher training should consist of an 8 hours of review and practice.
Training module
Hours
Criteria
Classroom
Instruction and
Assessment
Refresh in oxy-arc cutting hazards

and mitigations and review of IOGP
Report471
Wet training
modules
Wet training and cutting practice to the

appropriate level of proficiency that the
student is requalifying for
Table 4: Refresher Training Course (top-up) recommendations and

suggested schedule
46
10.5.4 Specification for diving supervisor training

Dive Supervisors that do not have a diver burning qualification or have
not completed a Level 1 Oxy arc Burning course should follow this
recommended curriculum.
Training module
Classroom
Instruction and
Assessment
Hours
8
Criteria
Lecture and instruction in the
suggested curriculum topics listed in
10.5.1 (Oxygen-arc cutting curriculum
for Level 1 Beginner and Refresher
Training Courses)
(Maybe the same module as Diver Level
1 Oxy-arc Burning Course)
Practical equipment
set-up
Equipment set-up may be performed

during the dry-burning or wet training
phase.
Observation of wet
training modules
Student supervisors should have practical

training in the role and duties of the
oxy-arc burning supervisor. This training
should take place, under supervision of
the instructor and may take place during
a diver wet training module.
Table 5: Oxy-arc Burning Training for Dive Supervisors should consist of

16 hours of training in theory and practical assessment
47
10.6 Maintaining competency level and experience

Validity for each competency level should be maintained by performing
five hours of documented burning experience each year. Contractor or
client may recommend Refresher Training (Top-Up) if the diver has no
documented burning practice in the previous 12 months.
In addition to the normal dive profile information, divers and supervisors
should maintain the following information about each oxy-arc burning
dive in their personal logbooks and competency booklets.
Entries should be validated by the Contractor and Client Representative:
description of object(s) being burned
type of material and thickness
type of electrode and burning equipment being used
description of circumstances or environment where the cutting took place
common and uncommon hazards and mitigations relevant to the
burning task.
10.7 Grandfathering and Recognition of

Prior Experience (RPE)
Divers with prior training and experience in oxy-arc cutting may be
assessed and tested to qualify for a specific competency level.
An assessment of the candidates dive logs and experience should be
performed by the contractor and training provider. The assessment
should show evidence of experience equal to one of the diver competency
levels in Table 1 (Diver competency levels).
The candidate should then attend a Refresher Training Course and
complete the equivalent performance proficiency test criteria. See
Figure4 (Training and experience scheme flow chart).
48
10.8 Performance proficiency criteria

This performance proficiency recommendation has been incorporated to
provide additional criteria for the training and experience requirements in
this report.
The intent of this section is to allow for:
divers that have lapsed in competency level due to lack of recent
burning experience in previous 12 months
grandfathering and recognition of prior experience
client companies to establish a burning qualification for project
specific requirements.
The proficiency criteria levels in this section may supplement the diver
competency levels in Table 1 (Diver competency levels).
The recommended time criteria in Level 2 and Level 3 are suggestive
and are meant to place qualification criteria on the divers capability and
efficiency. The client operator may elect not to impose a minimum time
criteria. Training providers should endorse the students course completion
certificate with the electrode types and proficiency criteria achieved.
Level 1 Beginner Oxy-arc Burner

This is the starting level of proficiency. Candidates will be required
to satisfactorily demonstrate safe and successful burning technique
as follows.
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.
Tubular Steel Electrode
Burn inch thick clean steel for a distance of 18 inches using no
more than 4 rods. No Hangers.
49
Level 2 Intermediate Oxy-arc Burner

Candidates will be required to satisfactorily demonstrate safe and
successful burning technique as follows.
Level 2 allows a diver to qualify on either type of electrode. This is the only
level where a burner may qualify for either rod type, instead of both rod types.
Exothermic rod
Burn 6 inch dia. Schedule 80 pipe using no more than 3 rods. No
Hangers. 5 minute start to finish.
than 5 rods. No Hangers. 15 minute start to finish.
than 9 rods. No Hangers. 18 minutes start to finish.
Tubular steel electrode
more than 3 rods. No Hangers. 5 minutes start to finish.
Level 3 Advanced Oxy-arc Burner

This is the highest level of proficiency and candidates will be required to
satisfactorily demonstrate safe and successful burning technique
as follows:
Exothermic rod
Burn 6 inch dia. Schedule 80 pipe using no more than 3 rods. No
Hangers. 4 minute start to finish.
than 5 rods. No Hangers. 12 minute start to finish.
more than 3 rods. No Hangers. 4 minutes start to finish.
50
The timings are used when testing/training

candidates to evaluate performance they have no
bearing on operations.
Normal scheme
Refresher scheme
Grandfather and
RPE scheme
Complete the
Oxy-Arc Cutting
40 Hour Training
Course
To qualify for Refresher

training diver should
have completed prior
Oxy-Arc Cutting 40 Hour
Training Course
Contractor/Training prov.
perform diver experience
assessment compared to
Diver Competency Level
1, 2 or 3 (Sec 5.5)
Complete an Oxy-Arc
Cutting Refresher
Training Course
Complete an Oxy-Arc
Cutting Refresher
Training Course
Complete the
Performance Proficiency
Test equivalent to the
competency level
requalifying for (1,2 or 3)
after refresher training
Complete the
Performance Proficiency
Test to the equivalent level of
assessment (1,2 or 3) that
was conducted
Qualified Competency
Level 1 Diver Burner
Complete
Competency Level 2
Intermediate criteria
Complete
Competency Level 3
Advanced criteria
Maintain
5-hrs burning
practice in previous
12-months?
Yes
No
Figure 4: Training and experience scheme flow chart
51
11 Oxy-arc cutting risks and

mitigation (a commentary section)
The following commentary represents best industry practice and safety
warnings in regard to using the oxy-arc underwater cutting process.
Many of these comments are included in the reference documents and are
important enough to be mentioned here.
Underwater burning produces a combination

of pure oxygen and hydrogen gases as a by
product of electrolysis and heat generated over
2000F/1093C). When trapped in a confined or
unvented area, this gas mixture will produce a
serious explosion when ignited.
Holes in the outer insulation cover of a burning
lead can bleed a red copper oxide from the
electrolysis in the wire core if the lead has been
submerged in water.
Never burn where there is a pressure differential
from one side of the cut to the other. A differential
that causes either a pressure release or a
vacuum is an extreme danger to a diver.
The diver must ensure there are no
hydrocarbons present that can ignite during the
burning process.
Never burn into an area that is not vented.
In order to flush out any hydrogen gas pockets
in the equipment, oxygen must be flowed
through the torch and rod prior to energizing
the circuit.
Always follow manufacturers instructions
when using oxy-arc cutting equipment.
52
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-operation) Client Diving Representative oxy-arc cutting checklist will
provide a quick reference of compliance for project managers of both the client
organization and the contractors organization and is primarily to assist the IOGP
Diving Client Representative(s).
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
Client Diving Representative oxy-arc cutting checklist
No.
Criteria
Has a risk assessment been carried out to establish

whether alternative methods of cold cutting are more
appropriate?
Have site-specific procedures for oxy-arc cutting been

created for the task?
Yes/No
Comments
Including material composition, thickness, configuration,

surface condition, internal pressure, hydrocarbon
content, Identified cutting lines and venting positions,
measurement/proving of venting and PTW & isolations?
3
Are there sufficient competent divers and supervisors

trained to meet the requirements of this RP?
Has a site-specific risk assessment been carried out

on the work procedures with client personnel, diving
contractor personnel, including supervisors and divers?
Have all necessary isolations been identified and the

PTW issued
PTW Number added to this list
Have the cut areas been confirmed with the Procedures?

Have vent whole locations and cut lines been marked on
the material?
Is the burning equipment set-up, tested and

maintenance compliant with this RP?
Can the diver and supervisor confirm there are no areas

for gas entrapment in the cutting vicinity?
10
Confirm that the bell set up position and trunking have

been located to avoid any potential for bell atmosphere
contamination?
11
Has the material to be cut been cleaned of coatings and

marine growth?
12
Confirm that the diver is to cut vent holes on instruction

from the supervisor using the methods at the locations
stated in procedure.
13
Ensure that the supervisor and diver have confirmed all

vent paths are functioning and monitored.
14
Confirm that the diver is now ready to undertake oxy-arc

cutting operations safely.
PTW No.
54
Diving contractor oxy-arc checklist
Equipment
Oxygen
Cylinders
Marked according to IMCA

Oxygen warning signs in place
Oxygen purity certificate from the gas supplier.
Oxygen cylinders marked for Industrial Gas
Do not connect to BIBs lines
Do not connect to metabolic make up gas lines.
Cylinder Pressure test certificate in-date
Quad framework in good condition look for pits painted over
and/or filler.
Check under the frame for corrosion that could affect structural integrity.
Check Cylinders for corrosion on the base (contact area with quad frame).
Quad Lifting Pad Eyes pull test and MPI in-date
Quad Slings & Shackles fit for purpose & in-date load test certificates
Cylinder security
Cylinder paint and corrosion
Cylinder neck valves blanked and capped
Cylinder neck valves in good condition
Cylinders and neck valves grease-free
Dropped object protection in place
Burning oxygen segregated from DDC gas
Fire concern
Non-medical gasses connection to gas for
human consumption concern
Quads sea fastened securely
Fire detection in place
Fire suppression in place
Fire hose nearby
Burning Oxygen is not stored below deck
Quad Electrically grounded to hull of vessel.
Quantity Sufficient for the job
Quantity Burning gas is not included in Treatment mix or Metabolic
check/confirm on LSS gas board.
Quantity Quad can easily be changed out.
Yes
No
55
Equipment
Oxygen Manifold
(on the Quad)
Fit for purpose

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
Regulator
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.
Yes
No
56
Equipment
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
runs
Oxygen hose is fit for purpose and designated for oxygen transport
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.
Oxygen cleaned to an internationally recognized standard and certified by
a competent person.
Whip checks used where required.
Oxygen carrying hose/tube specifically related to thermal cutting operations
not bundled with life support gas, electrical, communications or other
services critical to the diver, bell or DDCs life support functions
Oxygen carrying hose/tube does 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.)
Oxygen carrying hose/tube does 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.)
Designated SWL must be marked on the frame
Umbilical winch
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.
Yes
No
57
Equipment
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
Valves oxygen clean
Electrical connections must be designed for the application intended and
fit for purpose.
Umbilical winch Lifting Pad Eyes in pull test and MPI date
Umbilical winch Slings & Shackles fit for purpose and in date.
Must be electrically grounded to the vessel with heavy duty cable.
AC welding current output machines are unacceptable.
Only Direct Current (DC) output machines used
Welding
Machine
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 is 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 and MPI in-date
Welding machine Slings & Shackles fit for purpose & in-date load test
certificates.
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
Yes
No
58
Equipment
Cutting
Umbilical
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)
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)
The ground clamp should be in good condition.
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
Yes
No
59
Equipment
Cables
Supported
Protected from dropped objects
Ground (positive) does not be through the vessel hull
Cables do not pass through areas that contain flammable substances.
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
connectors
Stab (Lenco style) connections should not go sub surface unless

specifically designed to do be immersed in salt water.
Joints should be waterproofed using approved materials and process.
Direct Current (DC) rated.
Twin Pole solenoid operated.
Cutting &
welding switch
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, etc.)
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 mounted on an
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.
Yes
No
60
Equipment
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?
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 on site?
Are variations managed by the contractor
MOC process?
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 and Others have read the Dive Plan
Tool Box Talk Includes divers and others
Knife switch Open
Sufficient oxygen
Regulator set
Oxygen hose pre-charged pressure noted.
Yes
No
61
Equipment
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
Yes
No
62
Equipment
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 and marked out
Clean to a bright surface offers the best cutting quality and speed
Clean the back side of the cut if possible
Vent hole location(s) verified prior to cutting
Vent holes are cut and 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 150 mm
horizontal flow
Do not place hands in front of the rod to test oxygen pressure
Do not energize 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 75 mm
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 and burning equipment should be increased
Yes
No
Appendix B - Training course assessment checklist
63
Appendix B
IOGP oxy-arc cutting training course
assessment checklist
1 Purpose
64
2 Instructions, Qualifications and Experience
64
3 Teaching Facilities
65
4 Administration
69
5 Fire Prevention
70
6 First-Aid
70
7 Training Plans
71
The primary instructor should have at least 5 years of commercial diving

experience, have received formal training in oxy-arc cutting at an accredited diver
training school or industry recognized training establishment and have evidence
of completing 40 oxy-arc cutting dives. Should be able to demonstrate the cutting
process in the training tank or have an assistant instructor qualified to level 2 or 3
that can perform this task.
Primary Instructor (10.4 Specification for instructors)
There should be sufficient number of instructors that can properly provide

lecturing, practical assessment and safety oversight suitable to the class size. For
the diving portion of the course, risk assessment shall determine the minimum
number of diving supervisors and dive team size.
The instructor staff should have:

a primary instructor
a Diving Supervisor
assistant instructors when required
Instruction Staff (10.3 Class sizes)
Instructors should have a thorough knowledge and practical experience in the

subjects they are to teach. Training providers should have a method for ensuring
instructors are proficient performing and instructing the relevant course tasks.
Instructors should have formal training in vocational instruction techniques.
INSTRUCTIONS, QUALIFICATIONS AND EXPERIENCE
This checklist has been developed to assist the assessment team in interpreting
the recommended practice as it relates to its guidance on training.
Diver/Supervisor certificate
Logbook entries
Training records
Contractor/Training Establishment
competence assessment
e) Experience in teaching subject
a)
b)
c)
d)
a) Minimum/maximum class size

b) Support equipment to be operated
c) Single or multiple simultaneous training
modules
d) Class room and dive tank organizational
set-up
CHECKS/PROMPTS
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
2.2
2.1
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.
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

64
Facilities for practical cutting, equipment set-up and dive tanks should meet all
applicable local building and operating codes regarding structural, electrical,
compressed oxygen handling and water and industrial waste. Facilities should also
be supported by the organizations safety management system.
The environmental conditions and ergonomic arrangements of the lecture rooms

can affect the individuals ability to absorb information during the lectures. The
following section details the standard of educational arrangements which should
be provided to ensure suitable learning facilities are provided within the classroom
environment.
TEACHING FACILITIES
Instructor staff should be familiar with industry references to oxy-arc cutting in

diving, such as those listed the references of Report 471. Additionally instructors
should be familiar with equipment manufacturers, IMCA and ADCI technical and
safety alerts.
Diving Safety and Oxy-Arc Practices and Procedures
Instructors should have undergone training that teaches classroom

communication, leadership and instruction techniques. Additionally the
instructor should have been trained on competence assessment techniques
such as the IMCA C 007 Guidance on Assessor Training. The instructor should
meet the minimum requirements defined in the training providers accreditation
requirements, where applicable.
Instructor Training and Competence Assessment

(10.4 Specification for instructors)
Note: The primary instructor may be the diving supervisor if qualified.
a) Building operating permits

b) EHS policies and procedures
a) IMCA safety flashes regarding oxy-arc cutting

b) Oxy-arc equipment manufacture technical
notes
c) IMCA D 003, IMCA D 031 and IMCA D 045
d) US Navy Underwater Cutting and Welding
Manual
a) Formal training in leadership and

communication skills
b) Experience in teaching
c) Trained in-house
d) Gained expertise by experience only
a) Supervisor certificate
b) Supervisor logbook
c) Experience in teaching subject
CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
2.5
2.4
Diving Supervisor (10.1 Training course providers)
2.3
The Diving Supervisor will be responsible for the diving portion of the training
course. The Diving Supervisor should be certified and competent. The supervisor
should be supported with a letter of appointment from the training establishment
and/or dive contractor that is supplying the supervisor.
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

65
The dive tank should be of suitable design and construction to allow for safe and
practical oxy-arc training. A dive tank can be substituted for a sheltered open water
location such as harbour, bay, etc. It should be large enough and deep enough to
accommodate a diver and stand-by diver, and have sufficient room to allow for
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.
Dive Tank or Sheltered Water Location

(10.2 Course contents, material and facility requirements)
Proper fire prevention equipment should be immediately available at the cutting location.
The area used to set-up and operate the oxy-arc cutting equipment should be
sufficiently constructed, located and equipped to allow for the electrical equipment
and compressed oxygen handling.
The area used for dry cutting should be properly located to allow for such activity. It
should be outside in open air or inside a shop type facility that is built and equipped
to accommodate the heat and by-products of the oxy-arc cutting process. Either
location should be constructed of materials such as steel, concrete, or gravel that
will not promote fire/combustion.
Sufficient size
Sufficient ventilation and illumination
Safe operating and viewing areas
Proper material stands and tables
a)
b)
c)
d)
e)
Tank engineered and built for purpose

Tank has cathodic protection
Lifting appliances are fit for purpose
Proper ingress/egress equipment
Visibility and conditions to allow instructor
view
a) Proper electrical supply and wiring

b) Suitable ventilation
c) Proper compressed oxygen storage and
handling equipment.
a)
b)
c)
d)
a) Lecture rooms cleaned regularly.

b) Organized with good housekeeping
Rooms should be clean and tidy and be maintained in a state of good repair
Dry Cutting and Equipment Area

a) External noises noted during lectures

b) Room temperature suitably controlled
c) Proper overhead lighting
Rooms should be illuminated and climate controlled/ventilated properly. Outside

noise should not interfere with the training environment.
c) Room is large enough for personnel and

equipment
d) Ergonomically appropriate furnishings
CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
3.3
3.2
Lecture/Class Rooms
3.1
Rooms should be sized appropriately for the class, and be furnished with chairs
and tables suitable for all anticipated training functions.
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

66
a) DC output only
b) Installed correctly according to code
c) Correct amperage and duty cycle
a) Has sufficient pole disconnects
b) Electrical rating higher than source,
marked on the gear
c) Location and wiring configuration
Welding power source meets 4.1.
Safety switch is of sufficient type and meets 4.2.
Equipment selected for use during the training course should meet section 4 of
IOGP 471.
a) Equipment manager is competent
a) Training facilities visible from all parts of

the lecture room
b) Sufficient number of practical training aids
Training aids should be easily visible from all parts of the lecture room and where
practical equipment is used there should be a sufficient number of training aids
which should be easily accessible to all students
Oxy-Arc Cutting Equipment
a) Sufficient spares available for the

equipment being used
PowerPoint Presentations
Technique video Presentations
Cutting equipment
Diver cutting PPE
Cut coupons
Electrode samples
There should be a number of spare units or components readily available to

minimize interruptions should an equipment failure occur.
There should be a suitable and sufficient supply of teaching aids provided which
should be well maintained and relevant to the lecture being given.
a)
b)
c)
d)
e)
f)
a) Injured diver removal from the tank

b) Ample room for personnel to move and work
c) Hand railing, ladders, fall prevention, slip
prevention
d) Sufficient illumination
e) Electrical Ground Fault Interrupters (GFI)
f) Cable trays
Working deck/area around the tank or open water location is suitably constructed
and is fit for diving and oxy-arc training tasks. It is organized and laid-out in a fashion
that promotes a safe working and observation area for personnel and equipment.
Teaching Aids (10.2 Course contents, material and facility requirements)
CHECKS/PROMPTS
DESCRIPTION
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
3.5
3.4
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

67
a) Rods are produced by an approved

manufacturer
b) Working condition of the rods
c) Storage and handling of the rods
d) Meets manufacturers requirements
e) Identifiable for maintenance tracking
f) Condition and evidence of maintenance
a)
b)
c)
d)
e)
f)
a) Contractor Oxy-Arc Checklist in Appendix A
b) Manufactures instructions
a)
b)
c)
d)
Cutting rods of both types, exothermic and tubular steel should meet section 5.
Torches and electrode holders meets 4.11
Compressed oxygen equipment meets 4.7, 4.8 and 4.9. Care of maintenance and
handling meets oxygen cleaning practice, such as IMCA D031 Cleaning for Oxygen
Service or an equivalent practice.
There should be equipment set-up, testing and operation procedures in the vicinity
of the operation area and made available to the instruction staff and students.
There should be PPE that is suitable for the Dry and Wet Cutting portions of the
training.
A proper two person/two compartment decompression chamber is available within

two-hours if diving shallower than 10 metres. A decompression chamber should be
onsite if training dives are deeper than 10 metres.
Diving equipment should be inspected and be compliant with the relevant sections
of the IMCA D023 or IMCA D 040 design standard.
Dive Equipment
a) Correct diameter and length

b) Proper connections and insulation
c) Condition and storage
Electrical cables, torch lead, ground lead, and splicing hardware meets 4.3, 4.4 and 4.5.
a) Chamber is verified available during training

b) Transportation to chamber is established
a) Latest IMCA DESIGN audit

b) Maintenance, testing register
c) Competent maintenance person
Protective over clothing

Shields, lenses, eye protection, etc.
Welding and nonconductive gloves
Foot protection
Hoses are manufacture approved for oxygen

Oxygen compatible fitting
Oxygen compatible regulators
Oxygen cleanliness
Maintenance practice and storage
HP cylinder handling
CHECKS/PROMPTS
DESCRIPTION
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
3.6
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

68
a) Lecture times
b) Enabling objectives
c) Examples and application of the topics
a) Covers the theoretical sections
b) Questions are representative of material
covered
There should be written or computer based tests that cover the theoretical
portions of the training course. These should be satisfied before practical
assessment begins.
a) IOGP Report 471

b) IMCA guidance notes
c) US Navy Underwater Cutting and
Welding Manual
d) Manufacturers product manuals
a) Passport validation
b) Logbook validation
c) Diving certificate validation
a) Course syllabus
b) Course manual
There should be a written Training/Lesson Plan that lays out the steps and flow
of the course. It should be broken down into timed modules based on subject,
objective and application.
There should be written learning material, such as training manuals and

equipment information sheets that provides study aids to the student.
Learning and Testing Documentation

The source and authenticity of student application forms should be randomly

checked for validity, i.e. reviews of log books, photographic evidence.
Confirmation should be sought to ensure that the school has taken all
reasonable measures to ensure that no fraudulent means have been employed
to obtain a certificate of training, e.g. the use of a substitute to undertake the
training and examination.
Student Identification
The training establishment should set the attendance and pass/fail criteria for
the training course. The attendance criteria in section 10 should be observed.
Retest criteria should also be identified. This should written into a course
procedure or syllabus.
Course Policies, Procedures and Controls

CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
4.3
4.2
4.1
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.
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

69
At the dive tank there should be a medical kit that meets the DMAC 15 standard,
AED and a personnel litter suitable for transporting injured personnel. Staff should
be trained in the use of AED.
There should be adequate first aid supplies readily available which should be
checked and replenished regularly.
a) Last inspection
First aid kit available

Eye wash stations
Burn treatment first aid
Defibrillation unit
Medical oxygen
a) Sufficient number of in date fire extinguishers

b) Fire Extinguishers suitable for electrical fires
Fire extinguishers should be installed in all work areas/lecture halls/dive tank.

a)
a)
b)
c)
d)
a) Emergency exits available from all parts of

the building
b) Fire doors and emergency exits free from
obstructions
c) Clearly marked
There should be suitable emergency exits from all areas which should be clear of
obstructions, clearly sign posted and can be opened from the inside.
FIRST AID
a) Emergency evacuation arrangements in place
a) Certificate of completion
b) Logbook entries
There should be suitable emergency arrangements in place for the evacuation of

students from the building or work area in the event of a fire.
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.
FIRE PREVENTION
There should be a method of documenting successful completion of the course.

This should have the completion date, hours of instruction, level of proficiency and
electrode types.
a) Attendance rosters
b) Exam and quiz register
c) Practical assessment of task check lists
CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
Student Tracking
4.4
Training establishment should monitor and track the students attendance,

progress and accomplishments.
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

70
This should be relevant to oxy-arc cutting
The following elements should be covered in the lesson plan:

Hazards
Mitigations
Controls
Management of change
Lesson/Topic: Risk Assessment
The Lesson Plan should be laid out to clearly identify each lesson topic and the
associated elements that make up each topic.
These objectives give the instructor the ability to measure the success of the
student in each lesson. Students should not pass the course unless all terminal
objectives are satisfied.
The (TLO) should identify what task the student should be able to demonstrate
correctly to the instructor. The (EO) are the smaller tasks or steps that are
performed in order to accomplish the (TLO).
Each Lesson should be supported with the Terminal Learning Objectives (TLO) and
Enabling Objectives (EO).
The Lesson Plan should be made up of individual lessons that are consistent with
the course topics identified in bulleted sections of 10.5.
Lesson Plans, Terminal and Enabling 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.
Enabling Objective Examples:

a) Identify common hazards associated with
the scenario
b) Select proper mitigations for the identified
hazards
Terminal Objective Examples:

a) Perform a risk assessment for underwater
oxy-arc burning
a) Lesson plan
b) Terminal Learning Objectives are identified
c) Enabling Objectives are used to support
the TLO
d) TLO are measurable and can be
demonstrated to the instructor
CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
7.2
7.1
TRAINING PLANS
Compliance with Objectives.
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

71
Lesson/Topic: Principles of Operation
7.3
Terminal objectives that are a measure of

theoretical knowledge may be demonstrated
with written or computer based examinations
or interview type discussion

a) Describe what chemical and physical
reactions happen during the oxy-arc process
b) Describe what explosive gasses are
produced how gas accumulation can form
c) Describe what hazards exist when cutting
into a tubular object
d) Explain why venting should be performed
with a cold cut technique

a) Explain the process of oxy-arc cutting
b) Identify alternative cutting methods
c) Identify different items suitable to cut
d) Identify potential and kinetic forces related
to cutting materials
e) Explain cutting in different environments
f) Explain the proper use of additional tools
used in conjunction with cutting
CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent

Theory of burning
Oxygen system
Grounding
Electrical risks underwater and topside
Circuit breaker types
Safe materials and their correct application
Surface cleaning
Venting techniques
Gas migration
Divers body position relative to the cut
Visibility limitation
Slag
Types of material, ferrous and non-ferrous
Configuration (tubular, wire, structural)
Residual energy release when cutting
Differential pressure caused by cutting
Water depth effects on oxy-arc cutting
Crane and Lift bag use when cutting
Hydrocarbon hazards when cutting
Bell position during cutting operations
Confined space burning
Dredging and below mud lines
Contaminated water
Tides, currents, splash zone
Alternative cutting methods
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

72

Oxygen delivery pressure
Oxygen purity
Oxygen safety
Burning oxygen
Lesson/Topic: Oxygen Requirements

a) Identify the recommended oxygen pressure
for an exothermic cutting rod
b) Discuss what PPE should be used when
handling oxygen
c) Identify the oxygen suppliers contents
data sheet

a) Identify hazards in oxygen handling
b) Identify suitable oxygen hoses
c) Identify acceptable oxygen regulators

a) Describe the manufactures recommended
amperage of a tubular steel electrode
b) Explain why exothermic rods utilize
magnesium in the rod construction

a) Identify the different types of cutting rods
b) Explain the different characteristics and
method of using each rod type
c) Explain which rod is preferable in different
applications
CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
7.5
Lesson/Topic: Underwater Cutting Rods
7.4

Tubular steel electrodes
Exothermic rods
Cutting rod amperage requirements
Tubular steel electrode amperage
Exothermic rod amperage
Rod condition (rust, damage, etc.)
Other rod options
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

73
Lesson/Topic: Cutting Techniques

Exothermic rod
Other rod options
Lesson/Topic: Trouble Shooting

Symptoms
Probable causes
Identification and problem solving
7.6
7.7

a) Describe the purpose of the different
components in the torch head
b) Identify what damage or corrosion
impedes a rods performance
c) Identify how leads and fittings should be
properly insulated

a) Identify common causes of a rods failure
to ignite
b) Identify common causes of electrical
shock to the divers hands
c) Explain the common causes for oxygen
leaks around the torch head

a) Discuss the process of starting and ending
a cut with a tubular steel rod
b) Explain the proper position of a divers hands
and head while burning a tubular object

a) In the class room, use a disconnected
torch and cutting rod to simulate how to
initiate, drag and end a cut on an object.
b) Explain the difference between pushing
and dragging the electrode
CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

74
Lesson/Topic: Post Dive Maintenance

Inspection
Cleaning
Repair
Replace
Testing
Lesson: Practical Equipment Set-up
7.8
7.9

a) Connect the torch and ground leads to the
welding power source
b) Connect the oxygen regulator to the
oxygen source and torch oxygen hose
c) Ensure the welding power source is
correctly connected to the electrical supply
and grounding

a) Personnel should be able to demonstrate
how to set-up and test the torch to a point
that ensures proper polarity is established.
b) Personnel should be able to safely connect
and test the oxygen system to the torch

a) Demonstrate how to use a resistance
measuring device to measure continuity in
a cable lead
b) Using the manufactures technical manual,
disassemble and reassemble a torch head

a) Demonstrate how to ensure the torch is
operating properly
b) Describe what steps are taken to repair
the insulation on a ground lead
CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
Equipment should include:

Oxygen equipment
Torch leads
Ground leads
Cut material (the work)
PPE
Consumables
A JSA should be performed at the beginning of the lesson covering relevant areas.
The time taken for this lesson should be a 3 5 hours. Personnel should practically
set-up and test all the equipment identified in section 5.
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

75
Lesson: Practice Burning in Dry Conditions (10.5.2 Level 1 Beginner Oxy-arc

Burning Course recommendations and suggested schedule)
7.10

a) Should demonstrate how to locate and
remove a coupon hanger
b) Should demonstrate proper placement of
hands and head while burning
c) Should demonstrate proper
communication and terminology during
the cutting process.

a) Should be able to complete a cut 24 long
on flat plate material
b) Should be able to cut a section off a
coupon of 6 pipe
CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
Topside monitoring and operation of welding, oxygen and umbilical equipment
Instructors should closely observe the student for proper:

body positioning
holding of the torch
Initiating the cut
drag or push rate
ending the cut
Hanger inspection
Hanger removal
Communication between diver and supervisor
Supervisors operation of the circuit breaker
A JSA and Hot Work permit should be issued for this lesson. Additional personnel
may need to be present for the role of Fire Watch.
This exercise should employ roll play between the diver and supervisor so that
proper communication and terminology is practiced before entering the water.
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
closely resembling the set up for in-water as possible.
This module may be substituted for in-water training when circumstances dont allow
for dry training.
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

76
Lesson: Wet Tank/Location Practical Training
7.11
a) Review JSA and Permit to Work

b) Monitoring the diving
c) Review the dive record sheets

a) Should practice burning on varied wall
thickness material
b) Should practice burning on pipe coated
with FBE or mastic
c) Should practice burning on different
objects such as sheet pile, anchor chain
links and tubular.

a) Should be able to complete a 24" vertical
and horizontal cut on flat plate material.
b) Should be able to cut and remove a coupon
from a 6" pipe.
c) Should use 25 of each type rod on flat plate
and tubular material.
CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
During the wet tank practical training module the diving supervisor ensures and
observes that proper diving procedures, checks and operations are conducted
during the cutting training.
Pre-dive checks
Pre-dive briefing
Top-side crew using proper PPE
Diver proper wearing of apparatus and cutting PPE
Proper umbilical tending
Proper monitoring divers gas manifold
Tracking dive profile and time
Dive record sheets
Post dive checks
Post dive briefing
Instructors should be monitoring for the same items in the wet exercise as the dry
exercise.
A task procedure/burning plan should be developed for each diver.

Students should use 50 exothermic rods and 50 tubular steel rods
Instructors should closely observe the students techniques through the use
of diver worn camera and either tank observation windows or tank mounted
camera equipment.
Injured diver recovery and emergency planning shall be performed before diving.
A JSA and Hot Work permit is performed before diving and cutting operations begin.
The time taken for this lesson should be a minimum of 24 hours. Personnel should
practice the burning techniques of each rod type in an underwater environment.
A tank or open water location is acceptable, so long as it meets the requirements
of Items 3.6 and 3.7 of this checklist.
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

77
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent

Burn 1/2 inch clean steel for a distance
of 18 inches using no more than 4 rods.
No Hangers.
Burn 1 inch clean steel for a distance
No Hangers.
No Hangers.
Exothermic rod
Burn 6 inch Schedule 80 pipe using no
more than 4 rods. No Hangers.
No Hangers.
No Hangers.
Students should perform safe and effective cutting technique on a variety of

materials in times evolutions.
Students should utilize and be tested on both exothermic and tubular steel
cutting rods.
Terminal Objective:
Lesson: Level 1 Burner Performance Proficiency Testing
7.12
CHECKS/PROMPTS
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

78
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
In accordance with Table 1, students should have provided evidence of Level 1

qualification to the training establishment in order to qualify to test for Level 2.

No Hangers. 5 minutes start to finish.
Exothermic rod
more than 3 rods. No Hangers. 5 minutes
start to finish.

Students may utilize either exothermic or tubular steel cutting rods.
Terminal Objective:
Lesson: Level 2 Burner Performance Proficiency Testing
7.13
CHECKS/PROMPTS
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

79
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
In accordance with Table 1, students should have provided evidence of Level 2

qualification to the training establishment in order to qualify to test for Level 3.

No Hangers. 10 minutes start to finish
Exothermic rod
more than 3 rods. No Hangers. 4 minutes
start to finish.

Students should utilize and be tested on both exothermic and tubular steel cutting
rods.
Terminal Objective:
Lesson: Level 3 Performance Proficiency Testing
7.14
CHECKS/PROMPTS
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

80
Lesson: Diving Supervisor Training
7.15

a) Identify the useful industry references to
oxy-arc cutting.
b) Locate and use manufacture
recommended practices for oxy-arc
equipment
c) Identify suitable methods of cold cutting
vents in material to be cut with oxy-arc
technique
d) Describe techniques used to ensure
venting flow paths are established

a) Conduct a risk assessment and perform a
JSA for an oxy-arc cutting task on a diving
project
b) Explain the oxy-arc cutting process
c) Identify and discuss the purpose of all oxyarc cutting equipment
d) Identify all of the common hazards and
mitigations associated with oxy-arc cutting
in the different scenarios.
e) Perform trouble shooting analysis
regarding a cutting torch not working
correctly
CHECKS/PROMPTS
Explanatory Notes:
(1) Poor
(2) Fair
(3) Good
(4) Excellent
Lesson Plan should cover the following topics and be relevant to the supervisor
during an oxy-arc cutting operation:
Risk Assessment and MOC
Principles of operation
Cutting rods
Supervisor candidates should perform 5 hours of diver burning monitoring during

wet training.
The Supervisor course should be performed over a minimum of 16 hours of training.
Diving Supervisors that require training that are not participating in the diver
Level1 course should be trained to the same topics and objectives identified in
sections 7.2 7.9 of the Diver Level 1 course.
DESCRIPTION
ITEM
Yes/
No
COMMENTS
(1), (2), (3), (4)

81
82
Bibliography
Additional information can be obtained from these documents.
DEPARTMENT OF ENERGY (DoE) [UK]. Safe Underwater Oxy-Arc Cutting.
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 C 007. Rev 1,
Guidance on Assessor Training. London, April 2013.
INTERNATIONAL MARINE CONTRACTORS ASSOCIATION. IMCA C 016, Guidance on
Verifier Training. London, December 2013.
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 411. Diving Recommended Practice. London, June 2008.
IOGP. Report 431. Diving worksite representative roles, responsibilities and training.
London, November 2009.
UNITED STATES. U.S. Navy Underwater Cutting and Welding Manual. S0300BB-MAN-010. Washington DC, April 1989. Change B revised June 2002.
83
Registered Office
Level 5
209215 Blackfriars Rd
London SE1 8NL
United Kingdom
Brussels Office
Bd du Souverain,165
4th Floor
B-1160 Brussels
Belgium
T +44 (0)20 3763 9700

F +44 (0)20 3763 9701
reception@iogp.org
T +32 (0)2 566 9150

F +32 (0)2 566 9159
The frequency of diver fatalities,

injuries, incidents, and asset damage
occurring during underwater oxyarc cutting or burning processes
continues to be unacceptably high
within the global diving industry.
Divers engaged in burning need to be
competent in the task.
This recommended practice has been
developed to assist with managing
this activity through training,
knowledge and experience and to
provide control measures, guidance
and processes to ensure the safe
execution of this technique.
www.iogp.org

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REPORT

Oxy-arc underwater cutting

Oxy-arc underwater cutting

Mitigate risk by using alternative cutting methods

Arc water gouging

Thermal cutting techniques that use no oxygen

Plasma arc cutting

Water jet cutting

Chain feed cutters

Orbital pipe cutters

2.10 Casing cutters

Roles, responsibilities and

The diving contractor

Client on-site representatives

Dive support crew

Welding power source

Safety switch or circuit breaker

Burning leads or burning umbilical

Wire (Cable) splices, connectors, and terminations

4.10 Oxygen pressure

4.11 Torches or electrode holders

On-site considerations and the burning operation

10 Training and experience requirements

10.1 Training course providers

10.2 Course contents, material and facility requirements

10.3 Classes sizes

10.4 Specification for instructors

Level 1 and Refresher Training Instructor Qualifications

10.5 Specification for diver and supervisor training

10.5.3 Refresher Training Course (top-up) recommendations and suggested schedule

10.5.4 Specification for diving supervisor training

10.6 Maintaining competency level and experience

10.7 Grandfathering and Recognition of Prior Experience (RPE)

10.8 Performance proficiency criteria

Level 1 Beginner Oxy-arc Burner

Level 2 Intermediate Oxy-arc Burner

Level 3 Advanced Oxy-arc Burner

11 Oxy-arc cutting risks and mitigation (a commentary section)

Appendix A: Checklists for oxy-arc operations

Client Diving Representative oxy-arc cutting checklist

Diving contractor oxy-arc checklist

Appendix B: Training course assessment checklist

Oxy-arc underwater cutting recommended practice

Oxy-arc underwater cutting recommended practice

2 Mitigate risk by using

HSE (OTH 349) Evaluation, Selection, and Development

Oxy-arc underwater cutting recommended practice

Arc water gouging

Thermal cutting techniques that use no oxygen

Oxy-arc underwater cutting recommended practice

Plasma arc cutting

Water jet cutting

Chain feed cutters

Orbital pipe cutters

2.10 Casing cutters

Oxy-arc underwater cutting recommended practice

2.11 Hydraulic hand tools

Oxy-arc underwater cutting recommended practice

3 Roles, responsibilities and

All personnel on a project have the right, authority,

Oxy-arc underwater cutting recommended practice

The diving contractor

HAZID Hazard Identification

Job Safety Analysis (JSA)