The Basics On Underwater Welding

Weld.com

1 Sept 202213:51

Summary

TLDRThis video features a commercial diver demonstrating underwater welding at the Ocean Corp in Houston, Texas. It explores the realities of the profession, debunking myths about high earnings and emphasizing the diverse tasks divers perform, such as construction and repairs, in addition to welding. The video discusses different techniques, equipment, and the learning curve between top-side and underwater welding. It also touches on diver career paths, including the progression from tender to diver and eventually saturation diver, with insights into pay scales, challenges, and life as a professional diver.

Takeaways

🌊 Underwater welding is part of commercial diving, where divers are trained to perform various tasks, not just welding.
🚨 A standby diver is always required during underwater operations for safety and assistance in case of emergencies.
🔧 Commercial divers engage in multiple tasks like construction, repair, and welding, often in difficult underwater conditions.
⚡ Only DC current is used for underwater stick welding, and welders need to adjust to the cooling effect of water, relying on feel more than visibility.
🛠️ The type and amount of welding work varies depending on location, with more repair work in inland diving versus offshore diving.
📜 Certifications for underwater welding focus on specific positions and tasks, like 2F and 4F for fillet welds, which are common in underwater work.
💸 The pay for underwater welders and commercial divers is not as high as some myths suggest, with starting salaries around $50,000, increasing with experience and specializations like saturation diving.
📈 Progression from a tender to a lead tender and eventually to a diver depends on personal work ethic and experience, typically taking 1 to 3 years.
🚀 Saturation diving involves deep-sea work at extreme depths, where divers live in pressurized chambers and work in shifts for extended periods.
🏆 The career span of a diver can be long if they stay healthy, with many divers continuing into their 40s and beyond, contrary to myths of short career lifespans.

Q & A

What is the role of the standby diver in underwater welding?
-The standby diver is responsible for assisting the primary diver if communication is lost or if the diver encounters any trouble. The standby diver gets dressed quickly and checks on the diver, then escorts them out of the water if necessary.
How do welding students perceive underwater welding, and what do they learn in reality?
-Many welding students come in thinking they'll only be doing underwater welding, but they quickly learn they are being trained as commercial divers. Underwater welding is just one aspect of the job, which also includes construction and repair work.
What type of welding is used underwater, and why is DC current preferred?
-Stick welding is used underwater, and only DC (Direct Current) is preferred. DC is used because it ensures the electrode tip heats up properly in water, which cools the weld quickly, and it prevents dangerous electrical risks associated with AC current.
What are the differences between Broco and Moo brand electrodes used in underwater welding?
-Broco electrodes are industry-standard and dipped in wax, which helps with starting the weld. Moo electrodes have a baked flux coating that makes them easier to start and stop, and they run hotter, which is beneficial underwater.
Are certifications needed for different welding positions underwater?
-Yes, certifications are needed for different welding positions. At the school, students can get certifications like 2F or 4F, which cover most of the types of welding required underwater, such as fillet welding for repairs.
What is Hyperbaric welding, and why is it less common in the Gulf of Mexico?
-Hyperbaric welding involves creating a dry environment using a habitat where water is blown out to perform welds. It’s less common in the Gulf of Mexico because it's expensive, requires more work, and divers need special training.
How much can an underwater welder expect to make early in their career?
-New underwater welders can expect to make around $50,000 per year. As they gain more experience, especially with certifications in mixed gas and saturation diving, their salary can increase to six figures, though $300,000 per year is unrealistic for most.
What is the career progression for commercial divers after graduating from school?
-Graduates start as a diver tender, assisting divers and managing their gear. With experience, they can become a lead tender, and eventually, after 1-3 years, they can become a full diver. Progression depends on the diver's work ethic and availability.
What is the lifespan of a commercial diver's career, and are there age limits?
-There’s no specific age limit for commercial divers. Many divers work into their 40s or 50s, and their career length depends on their health and desire. Some move into more stable roles after making money, while others remain active divers for decades.
What challenges do divers face when welding underwater compared to welding topside?
-Underwater welding is much harder due to poor visibility, faster cooling of the weld puddle, and the need to rely on feel rather than sight. These conditions make it very different from welding topside, requiring a shift in mindset and technique.

Outlines

00:00

🤿 Introduction to Underwater Welding at Ocean Corp

The video begins with the host introducing the underwater welding task at the Ocean Corp facility in Houston, Texas. She explains the importance of having a standby diver for safety, who is responsible for assisting in case of emergencies. The standby diver in this scenario is also the camera operator. The host discusses how many welders come to the course expecting to weld underwater, only to learn that commercial divers do various tasks, not just welding, as diving serves as transportation to work sites for underwater construction.

05:00

🔧 Stick Welding and Techniques for Underwater Welding

The second part dives into the specifics of underwater welding. Only DC current is used, and divers use stick welding techniques. The challenges of underwater welding include difficulty seeing due to bubbles and the cooling effect of water on the welding tip. The host explains the feel-based welding approach necessary underwater. She introduces two types of electrodes, Broco and Moo, and discusses their differences in wax coating and ease of use. Welding certification procedures are also covered, with details on the specific positions welders can practice for, like 2F and 4F.

10:03

💦 Wet Welding, Hyperbaric Welding, and the Cost Factor

This paragraph covers the distinction between wet welding, where the diver is fully submerged while welding, and Hyperbaric Welding, where the water is displaced from a habitat, creating a dry environment for welding. Hyperbaric Welding is rare and expensive, especially in regions like the Gulf of Mexico. Most underwater welding is wet welding, where divers use exothermic rods to cut through materials such as barnacles and metals. The paragraph also details the difficulties of night diving, as visibility becomes a significant challenge.

💰 The Financial Realities of Underwater Welding

This segment debunks the myths about how much money underwater welders make, addressing misconceptions that welders earn $300,000 a year. Starting salaries for divers depend on whether they work inland or offshore. Inland divers handle projects like bridges, dams, and sewage treatment plants, while offshore divers work on oil and gas platforms. Graduates usually start as a 'tender,' assisting more experienced divers. With experience, divers progress to higher-paying positions, but new divers aren’t immediately assigned to deep or complex dives.

🏗 Career Progression and Diver Roles

This paragraph explores the career progression of a commercial diver. After school, divers start as tenders, working their way up to lead tenders and then divers. The time it takes to become a full diver varies based on individual effort and willingness to take on extended jobs. It usually takes one to three years to make diver status. The deeper and more complex the dive, the higher the pay, especially for mixed-gas divers who work in depths of up to 300 feet. Career advancement depends heavily on persistence and work ethic.

🔋 Saturation Diving: Life at Depth

This part introduces saturation diving, a specialized form of deep-sea diving. Saturation divers work at depths of 300 to 1,000 feet and live in pressurized chambers for extended periods, typically around 30 days. These chambers are designed to simulate the pressure at the work depth, allowing divers to live at that pressure. The divers are lowered in a bell, where they work in shifts. Although the working conditions are extreme, the pay for saturation diving is higher, with potential for six-figure salaries after gaining experience.

⏳ The Demands and Rewards of Saturation Diving

Saturation divers live in confined chambers for days, working in pairs in shifts that last about 3 hours per dive. The host explains how the chamber is pressurized to match the depth and that the divers are picked up and lowered into the water in a bell. While these dives can be challenging, the work is rewarding for those willing to make sacrifices. The financial benefits increase significantly with experience, especially for divers who choose to continue in this line of work over several years.

📅 Career Longevity and Personal Sacrifices

The final paragraph discusses the longevity and lifestyle of commercial divers. Although there are myths about short career spans and health risks, many divers continue working for decades, building financial stability through their careers. However, the job demands long periods away from home, causing divers to miss important family events. Divers often use their earnings to secure a stable life outside of work, sometimes retiring early after a successful career. The host, a third-generation diver, dispels misconceptions about career limits, emphasizing the importance of staying healthy to sustain long-term diving careers.

Mindmap

Keywords

💡Underwater Welding

Underwater welding involves performing welding tasks underwater, typically in marine environments. In the video, this is the main focus, as the instructor explains the specifics of the process, including the use of DC current, the challenges of visibility, and the need for welders to adjust their techniques for underwater conditions. It's highlighted as a key skill within commercial diving, often paired with other construction tasks.

💡Commercial Diver

A commercial diver is a professional who performs underwater tasks such as construction, welding, inspection, and repair. In the video, the emphasis is placed on students learning to be commercial divers, not just underwater welders. They are trained to perform various tasks underwater, and welding is just one of many skills they may use in their profession.

💡Standby Diver

A standby diver is a safety role in underwater operations, responsible for being ready to assist the primary diver in case of emergencies. In the video, the standby diver also acts as a camera operator and assistant, highlighting the collaborative and safety-conscious nature of diving operations.

💡DC Current

Direct Current (DC) is the electrical current used in underwater welding because it allows for a stable and consistent flow of electricity, which is crucial for welding in water. The video explains that DC current helps control the welding process underwater, as it ensures the electrode heats up quickly, compensating for the cooling effect of the water.

💡Electrode

An electrode is a metal rod used in welding to conduct electricity and create an arc that melts and fuses materials together. The video discusses different types of electrodes, such as Broco and Moo brands, and their coatings that make them suitable for underwater welding. The instructor explains how the water cools the electrode quickly, making technique and speed crucial.

💡Hyperbaric Welding

Hyperbaric welding occurs in a dry, pressurized environment created underwater, usually within a habitat that removes the water from the work area. This method is expensive and complex, as mentioned in the video, and is mainly used for critical repairs in deeper waters or specialized jobs, unlike more common wet welding.

💡Tender

A tender is an entry-level position in commercial diving where an individual assists divers by managing their equipment, hoses, and communications. The video explains that after graduating from diving school, students start as tenders before gaining experience and advancing to lead tender or diver positions. It's a crucial step in gaining the necessary skills and respect in the industry.

💡Saturation Diving

Saturation diving is a technique used for deep-sea dives where divers live in a pressurized environment, allowing them to work at depths between 300 and 1,000 feet. The video explains that saturation divers stay at depth for extended periods, working in shifts to maximize their time underwater. It’s considered one of the more advanced and high-paying forms of commercial diving.

💡Exothermic Rod

An exothermic rod is a tool used in underwater cutting, producing extreme heat through a chemical reaction to cut through materials like metal. The video details how these rods, connected to a welding machine, are used in underwater burning tasks, with temperatures reaching up to 10,000 degrees to cut through materials like barnacles and iron.

💡Mixed Gas Diving

Mixed gas diving uses a blend of gases, typically helium and oxygen, to allow divers to work at greater depths safely. The video mentions this method as an advanced form of diving used between 165 and 300 feet. The deeper divers go, the less time they have to work, making mixed gas diving essential for managing time and safety at significant depths.

Highlights

The standby diver is essential for safety, always present during underwater operations to assist if any issues arise.

Underwater welders are trained primarily as commercial divers, not just specialized welders.

The main task for underwater welders is not welding alone but includes a range of construction-related tasks.

Underwater welding primarily uses stick welding with DC current for optimal performance in water.

The welding rods are coated in wax or baked flux to ensure ease of use and prevent malfunction underwater.

Hyperbaric welding, a dry welding technique, is rarely used due to high costs and complexity.

Wet welding is more common and involves divers welding directly in water, managing environmental factors like cooling and visibility.

Divers must adjust their approach and rely on tactile feedback when welding underwater, as visibility can be very limited.

The process for cutting underwater uses exothermic rods that can heat up to 10,000 degrees, allowing cutting through various materials.

Night diving adds an additional challenge as visibility drops significantly, making underwater tasks even harder.

The myth that underwater welders can earn $300,000 annually is debunked; most start at around $50,000 with potential growth depending on experience.

There are two main career paths for underwater welders: inland diving (rivers, dams) and offshore diving (oil platforms, gas pipelines).

New divers usually start as tenders, supporting experienced divers with equipment, and gradually work their way up to become lead divers.

Divers can advance from surface-applied air diving to mixed-gas diving, and eventually to saturation diving, which allows working at depths of 1,000 feet.

Saturation divers work for around 30 days at a time, living in a pressurized chamber and performing deep-sea tasks in highly challenging conditions.