Exploring a Risky yet Rewarding Career
Underwater welding is a challenging profession that requires welders to be proficient in both welding techniques and diving skills. The deep sea welder faces numerous dangers, from deadly sea creatures to the risk of decompression sickness. In this article, we delve into the world of deep sea welding, examining different welding methods, safety precautions, and the earning potential of this exciting career.
Dry Welding: An Alternative Technique
Dry welding emerges as an alternative to traditional underwater welding techniques. This method necessitates a specially designed chamber that matches the water pressure at the working depth. By displacing the surrounding water, the chamber keeps the welder and the welding wires separate. Dry welding is most effective when working with stainless steel and aluminum.
Divers engaged in extensive deep sea welds typically work in pairs. A diving operator lowers the chambers to the weld site, while the welder-diver ventures into the habitat. Working up to six to eight hours a day, these divers must ensure that their electrodes are properly positioned and the base metal is clean. They also need to clear the area of any obstructions before triggering the electric arc.
Pressure Welding: Overcoming Challenges Underwater
Pressure welding underwater presents its own set of challenges. The conductive nature of water increases the risk of electrical shock, making it crucial to use insulated equipment with controlled voltage. Regular monitoring for equipment defects is essential to ensure safe working conditions. Deep sea welders must also consider the threat of decompression sickness when submerged.
Hyperbaric chambers facilitate pressure welding. After sealing off the area to be welded, the water in the chamber is pumped out through hoses. Oxygen and helium are then introduced, pressurizing the chamber to prevent decompression sickness. The size of the chamber determines the viable welding methods. For deep sea welders, the saturating chamber operates at 18-19 times the atmospheric pressure and accommodates a crew of six men for approximately 28 days, working at depths over 500 feet.
Dive teams play a crucial role in preparing the welding environment, ensuring clean electrodes and debris-free base metals. Safety hazards are meticulously examined to prevent any interference with the weld process. Once the electrodes are cleaned and ready, the diver signals the team to initiate the electric arc, which typically ranges from 300 to 400 amperes.
Shielded Metal Arc Welding: Techniques and Considerations
Shielded Metal Arc welding, commonly used in underwater welding, requires a powerful power supply to meet the welding electrode’s demands. Underwater, the current needed is usually 30% higher than in topside welding, with water absorbing heat rapidly. Additionally, electrode positioning plays a crucial role, with a 45-degree angle to the plate’s end surfaces and a lead angle of fifteen degrees, varying according to electrode size and diver technique.
Before diving, welders undergo a thorough physical examination to ensure they are fit for the physically demanding job. With the extreme demands involved, underwater welders rarely reach retirement age.
Two primary techniques for shielded metal arc wet welding exist: the self-consuming technique and the manipulative technique. The former utilizes a diving mask to shield the welder from harsh light, while the latter demands more skill to control the electrode’s position and speed.
Gaseous Bubbles for Weld Shielding
Gaseous bubbles play a crucial role in shielding the weld from spatter and reflow during the welding process. Formation of these bubbles involves a complex process known as Flux-Cored Arc Welding (FCAW), where droplets transfer from a wire to an arc, exhibiting multiple bubble behaviors.
When dealing with gasses in welding, precise electrode positioning becomes paramount, as even slight deviations can lead to gas explosions. Care must be taken to position the electrode at an optimal distance from the work surface, avoiding the expulsion of gas bubbles from the weld.
Shielding gases, such as argon or oxygen, are used depending on the joining material. Welding thin steel sections, for instance, requires a lower CO2 ratio compared to thicker sections. A gas blend of 80% CO2 and 95% argon is an alternative, delivering a smoother bead and deeper penetration.
Shielding gas rates are adjusted based on the material and the welder’s experience. It is crucial to choose the appropriate gas to ensure the highest weld quality. Additionally, employing the proper electrode and windscreen is vital for achieving optimal weld quality.
The Perils of Underwater Welding
Embracing a career as an underwater welder demands specialized training. Not only must welders possess exceptional welding skills, but also swimming and diving proficiency. They need to lay quality welds on various metals while submerged in deep waters.
The risk of drowning during underwater welding cannot be ignored. Suction forces at depths of three meters and differential pressure pose significant hazards. Strict adherence to lockout procedures and double isolation procedures is crucial to maintain safety. Underwater welding isn’t limited to oceans alone; it can be performed in lakes, rivers, dams, and various underwater environments.
Despite the risks, underwater welding offers an enticing and rewarding career. The potential for lucrative earnings and the opportunity for travel and adventure make it an attractive choice for those who enjoy working outside traditional office settings. However, it is essential to understand and mitigate the potential hazards associated with the profession.
Earning Potential: The Rewards of Deep Sea Welding
Becoming a deep sea welder can lead to significant financial rewards. This field requires exceptional physical strength and endurance, as welders need to withstand constant water pressure and handle heavy equipment. While the pay is substantial, it’s important to have realistic expectations.
On average, a deep sea welder can earn up to 280,000 USD per year, but salaries can vary depending on the project. Building diverse experience is key to earning more in this field. With the right skills and experience, it is not uncommon for welders to earn more than half their yearly salary in just a few months.
Two primary paths exist for becoming a deep sea welder. One option is to complete a training program, which can take months or even years. Many training programs offer tuition assistance, especially for veterans or post-9/11 students. These programs equip aspiring welders with the necessary skills to excel in this demanding profession.
Deep sea welders should be prepared for the unique challenges of the job, including the possibility of encountering sharks. While the risks are undeniable, the rewards are worth considering.
In Conclusion
Deep sea welding is a remarkable profession that combines welding expertise with diving skills. Though it poses numerous hazards, from underwater creatures to decompression sickness, it offers an exciting and financially rewarding career path. With proper training, experience, and dedication, a deep sea welder can enjoy a fulfilling journey of adventure and success.
If you have any questions or would like to explore this field further, feel free to reach out to us at Tools Working.