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Underwater Welding Career Information

1. Прочитайте и переведите текст.

What is an Underwater Welder?

An underwater welder is someone who performs vital work related to various industrial applications, including building offshore oil platforms, repairing ships, and maintaining underwater pipelines. Underwater welders must have advanced skills in both diving and welding, including various specialized underwater welding techniques.

What Does an Underwater Welder Do?

Underwater welders are highly trained in both professional diving and welding in order to perform welding tasks in an underwater environment. They work with specialized welding equipment that is designed for safe use underwater without high risk of electric shock.

Although trained in various techniques, underwater welders perform tasks that can essentially be grouped into two classifications:

Wet welding:

Means that the welding process involves being directly exposed to wet or fully submerged conditions
Uses a special waterproof electrode that was invented in 1946
Requires the welding power supply to be connected to the welding equipment through cables and hoses
When performed at significant depths, requires a highly experienced underwater welder with specialized knowledge of ambient pressure and its effects on welds
Most commonly uses shielded metal arc welding (SMAW) techniques

Dry welding:

Takes place underwater but is performed in a dry environment, usually called a hyperbaric chamber (an enclosed container that is submerged under water)
Involves working within the hyperbaric chamber, which (similar to submarines) is pressurized to withstand underwater conditions
Is performed by sealing the hyperbaric chamber around the structure that requires welding work
Is usually restricted to maximum operational depths of 400 meters
Can theoretically involve most welding processes but most commonly uses gas tungsten arc welding (GTAW)

Some of the duties that underwater welders take on can include:

Repairing ships
Maintaining oil platforms
Inspecting, repairing, and maintaining underwater pipelines
Salvaging shipwrecked vessels
New construction projects, such as bridges
Building, repairing, and maintaining telecommunications equipment beneath the floor of the ocean

In addition, underwater welders are often responsible for taking on a variety of tasks prior to actually performing any welding.

Some of these duties can include:

Inspecting, photographing, and creating maps of the work environment
Researching and documenting all aspects of the prospective job
Testing equipment and explosive materials
Conducting experiments to ensure project viability and safety

Project length and working hours can vary greatly, depending on the scope of the project. Therefore, a job can range from just a few hours to days, months, or even years. However, it is important to note that, although the main purpose is the actual underwater welding task, the vast majority of time and effort is often spent on training, preparation, and safety precautions.

In addition, for safety reasons, underwater welders work with a team of trained professionals who remain on standby above the water and keep in constant contact in order to provide immediate assistance if, at any time, the welder ends up in danger.

What are the Pros and Cons of Becoming an Underwater Welder?

Many regulations exist to keep underwater welding as safe as possible, effectively controlling any chance of danger. Nevertheless, some risk will always be involved when you are diving and working with electric-powered equipment beneath the water. However, when it comes right down to it, the level of risk is relatively low the majority of the time. And, for most underwater welders, their love of the job far outweighs any risks.

That being said, it is important to understand the pros and cons of the job.

Pros

There's no denying that a little bit of risk comes with a whole lot of excitement and a powerful sense of adventure.
Working underwater, especially in offshore environments, is fascinating. The ocean always has been (and always will be) a constant source of undeniable mystery and awe.
The technologies and equipment related to underwater welding are constantly being updated, and continuous learning can create a strong feeling of satisfaction.
The continuous innovation in the field allows for more sophisticated and advanced engineering ideas to be brought to life. Witnessing this progress can be exhilarating.
The prospect of a six-figure salary can be extremely enticing.
You can have the opportunity to do extensive traveling—seeing new places, meeting new people, and gaining amazing experiences.

Cons

Even when following strict precautions, there is risk of electric shock.
Because of the need to work with a combination of hydrogen and oxygen, there is a risk of pockets of gas forming (due to the high-pressure depth) and causing an explosion.
There are dangers related to any type of diving. They include risk of drowning due to equipment failure, ear/nose/sinus/lung damage due to pressure, decompression sickness, and more.
The training to become an underwater welder can be intense and may require a significant amount of time and money to be invested.
You are apt to spend significantly more time and energy preparing for a project and ensuring safety precautions are met than actually performing underwater welding.
You may need to continuously travel in order to obtain steady work, which can be draining because it may mean not seeing family and friends very often.

2. Ответьте на вопросы.

1. Who can be a welder-diver?

2. What sorts of basic and supplementary skills must a welder-diver possess?

3. How can certified surface welders become welder-divers?

4. What is more important: receiving the welder-diver qualifications or

maintaining them?

5. Why do commercial divers pass an annual dive physical?

6. Do welder-divers have any future career opportunities?

7. Do you think surface welding equipment can be used underwater?
3. Перескажите текст своими словами на русском языке.

Unit 14
The workshop
1. Прочитайте диалоги по ролям, переведите их устно, выпишите выделенные слова, и выучите их.
1.

Paul: This is a workshop, isn't it?

Olga: I think it is.

Paul: And where is the workbench?

Olga: Well, it's in the middle of the room.

Paul: Where's the toolbox? Is it on the bench?

Olga: No, it isn't. It's under the bench.

Paul: And where are the nails? Are they on the bench or in

the box?

Olga: They are in the box.

Paul: I see. And where's the hammer?

Olga: It seems to me, it's on the shelf above the table.

Paul: Well, give me the hammer, please.

Olga: Here you are.

Paul: Thanks.
2.

Mike: Look here. What are these?

Andrew: These are screws.

Mike: And where are the nuts? Are they on the workbench?

Andrew: Yes, they are. Oh, no, I'm sorry. They are on the shelf under the bench.

Mike: Are they big or small?

Andrew: They are rather small.

Mike: How long are they?

Andrew: I think they are approximately 20 mm long.

Mike: How wide are they?

Andrew: I believe they are 4 mm wide.

Mike: O.K. Give me some, please.

Andrew: Here you are.

Mike: Thank you.

2. Прочитайте и переведите текст, ответьте на вопросы.

This is a workshop. Two students are here. They are Sveta and Oleg. They are electricians. A toolboard is in the middle of the workshop. Many tools are on the toolboard. They are chisels, screwdrivers, a pair of pliers, a set of spanners, etc.
A safety-notice is above the tool-board. A bench is on the left and a

shelf is on the right. There are many nails, nuts and screws on the shelf. They are large and small. A hammer is not on the shelf, it is on the bench. A switch is between the bench and the shelf. Sveta is to the right of the bench. Oleg is on the other side of the workshop just opposite the toolboard.
1. This is a workshop, isn't it?

What are the names of the students?
What are Oleg and Sveta?
Where is the toolboard?
Where are the tools?
What are they?
Is the bench on the right or on the left?
The hammer is not on the shelf, is it?
9.Where are the students?

3. Выпишите новые слова, отработайте их произношение5 и выучите.
rig какое-л. приспособление, устройство, механизм Syn: apparatus , device

hose шланг

spark искра

igniter воспламенитель

wrench гаечный ключ

outfit агрегат; оборудование, принадлежности, набор

(приборов, инструментов)

pressure gauge манометр

leak течь, протечка; утечка

orifice отверстие

single-stage (regulator) однокамерный

flashback обратный удар пламени (проникающий в шланг

сварочной горелки)

ductile гибкий, ковкий, поддающийся обработке

threaded с резьбой, нарезной

pin цапфа

shoulder буртик; поясок

debris осколки, обломки; обрезки; лом

shrinkage усадочная деформация

solute растворенное вещество, раствор
4.Составьте пять предложений, используя новую лексику.

Unit 15
Welding's Vital Part in Major American Historical Events
Part 1.

1. Прочитайте и переведите текст.
ASME, founded as the American Society of Mechanical Engineers, is a professional association that, in its own words, "promotes the art, science, and practice of multidisciplinary engineering and allied sciences around the globe" via "continuing education, training and professional development, codes and standards, research, conferences and publications, government relations, and other forms of outreach." ASME is thus an engineering society, a standards organization, a research and development organization, a lobbying organization, a provider of training and education, and a nonprofit organization. Founded as an engineering society focused on mechanical engineering in North America, ASME is today multidisciplinary and global.
ASME is one of the oldest standards-developing organizations in the world. It produces approximately 600 codes and standards, covering many technical areas, such as boiler components, elevators, measurement of fluid flow in closed conduits, cranes, hand tools, fasteners, and machine tools. Some ASME standards have been translated into other languages other than English, such Chinese, French, German, Japanese, Korean, Portuguese, Spanish and Swedish.

A Standard can be defined as a set of technical definitions and guidelines that function as instructions for designers, manufacturers, operators, or users of equipment.
A standard becomes a Code when it has been adopted by one or more governmental bodies and is enforceable by law, or when it has been incorporated into a business contract.

The ASME Code

In the late 1920s and early 1930s, the welding of pressure vessels came on the scene. Welding made possible a quantum jump in pressure attainable because the process eliminated the low structural efficiency of the riveted joint. Welding was widely utilized by industry as it strove to increase operating efficiencies by the use of higher pressures and temperatures, all of which meant thick-walled vessels. But

before this occurred, a code for fabrication was born from the aftermath of catastrophe.

On April 27, 1865, the steamboat Sultana blew up while transporting 2200 passengers on the Mississippi River. The cause of the catastrophe was the sudden explosion of three of the steamboat's four boilers, and up to 1500 people were killed as a result. Most of the passengers were Union soldiers homeward bound after surviving Confederate prison camps. In another disaster on March 10, 1905, a fire tube boiler in a shoe factory in Brockton, Mass., exploded, killing 58, injuring 117 and causing damages valued at $250,000. These two incidents, and the many others between them, proved there was a need to bring safety to boiler operation. So, a voluntary code of construction went into effect in 1915 - the ASME Boiler Code.

As welding began to be used, a need for nondestructively examining those welds emerged. In the 1920s, inspectors tested welds by tapping them with hammers, then listening to the sound through stethoscopes. A dead sound indicated a defective weld. By 1931, the revised Boiler Code accepted welded vessels judged safe by radiographic testing. By this time, magnetic particle testing was used to detect surface cracks that had been missed by radiographic inspection. In his history of the ASME Code, A. M. Greene, Jr., referred to the late 1920s and early 1930s as "the great years." It was during this period that fusion welding received widespread acceptance. Nowadays, thousands of individuals who make their living in welding live and breathe the ASME Code every minute of the working day.

As far as welding interests are concerned, probably the most important part of the ASME Code is "Section IX - Welding and Brazing Qualifications." This section relates to the qualification of welders and welding operators, and the procedures they must follow to comply with the code. Under procedure qualifications, each process is listed, and the essential and nonessential variables of each are spelled out. Welding performance qualifications are also included.

In the early years of the ASME Code, fabricators were known to spend their own research dollars to develop a process so it could be used in Code construction work. Eventually, however, a code case would have to be submitted to the appropriate ASME Code committee, but first a procedure qualification had to be developed. The code authorities expected the quality of the weld metal and the heat-affected zone to be equal to that of the base metal.

In 1977, Leonard Zick, chairman of the main committee of the ASME Code, said, "It's more than a code; the related groups make up a safety system. Our main objective is to provide requirements for new construction of pressure-related items that, when followed, will provide safety to those who use them and those who might be affected by their use. "And, since the use of the code item might be for any type of process or for any discipline involving energy, the committee's activities do not play one against the other. We want all code items to be safe, period."

2. Перескажите текст своими словами на русском языке.

3. Задайте 5 вопросов к тексту.

Part 2.

4. Прочитайте и переведите текст.

LNG Tankers
A triumph of the code was the huge aluminum spheres built by General Dynamics in Charleston, S.C. They were built to criteria established by the U.S. Coast Guard and were based on Section VIII, Division 1, of the ASME Code.

At about 2 a.m. on October 2, 1976, the first welded aluminum sphere for a liquefied natural gas tanker was rolled out of a building in Charleston, then moved over to a special stand for final hydropneumatic testing. It soon passed the test with flying colors. The sphere itself weighed 850 tons and measured 120 ft (36 m) in diameter. Each sphere consisted of more than 100 precisely machined plates, "orange peel" in shape. The plates were gas metal arc welded together using 7036 lb (3166 kg) of filler metal. Total length of the welds on each sphere was 48.6 miles. Completed spheres were barged along the coast and delivered onto steel tankers under construction at General Dynamics' shipyard in Quincy, Mass. This type of LNG tanker was based on the Moss-Rosenberg design from Norway.

Meanwhile, Newport News Shipbuilding and Dry Dock Co. was building LNG tankers in Virginia. Based on the Technigaz design, the tankers featured a waffled membrane of stainless steel for containing the gas. Avondale Shipyards, Inc., New Orleans, La., was building still other LNG tankers based on the Conch design, which featured prismatic tanks of aluminum.

At General Dynamics' facility in Charleston, 80% of the metalworking manhours were spent welding. Much of the filler metal deposited in Charleston was 5183 aluminum. The vertical joints were welded using special equipment from Switzerland in which the operator rode in a custom-designed chair alongside the welding arc. At this distance, he was able to monitor the weld and observe the oscillation of the 1Z16-in. (1.5-mm) diameter filler metal. Actual welding was controlled remotely. About 30 weld passes were required for each joint.

The thicker 11Z2-in. (3.8-cm) joints were welded by Big MIG equipment, operating with a 1Z8-in. (3-mm) diameter wire at 500 A. The equipment was capable of completing the joint in four passes.

The massive equatorial ring was welded outdoors. In this setup, nine heavily machined, curved aluminum extrusions had to be welded together. To do it, 88 GMA weld passes were made from the outside and 60 more from the inside.

One engineer on site at the time had just transferred from one of the company's aerospace divisions, a division known for extremely high weld quality on sensitive material. "As far as quality is concerned," he noted, "there's really not that much difference (between Charleston and the aerospace division). I do think that the weld quality achievement here in Charleston is as high, if not higher, than it is in aerospace, but then 5083-0 is a very forgiving aluminum alloy."

Выделите главную мысль в каждом обзаце.

Part 3.

7.Прочитайте текст. Выпишите главные мысли из текста и письменно переведите их.

High-Rise Construction

About 30 years ago, steel construction went into orbit. The 100-story John Hancock Center in Chicago and the 110-story twin towers of New York's World Trade Center were under construction. Above ground, the World Trade Center required some 176,000 tons of fabricated structural steel. The Sears Tower came later. Bethlehem Steel Corp. had received orders for 200,000 tons of rolled steel products for the South Mall complex in Albany, N.Y. Allied Structural Steel Co. was reported to have used multiple-electrode gas metal arc welding in the fabrication of the First National Bank of Chicago Building.

In a progress report on the erection of the critical corner pieces for the first 22 floors of the 1107-ft (332-m) high John Hancock Center, an Allied Structural Steel spokesman said various welding processes were being used in that portion of the high-rise building. More than 12,000 tons of structural steel were used in that section. Webs and flanges for each interior H column were made up of A36 steel plate with thicknesses up to 61Z2 in. (16.5 cm). The long fillet welds at the web-to-flange contact faces were made using the submerged arc process, while the box sections were being welded by CO2-shielded E70T-1 flux cored electrodes. On the box sections, welding operators were averaging deposition rates of 90 lb (40.5 kg) per day. A total of 310,000 lb (139,500 kg) of weld metal was consumed in shop fabrication for this building, while 165,000 lb (74,250 kg) of weld metal was consumed during field erection.

Weld metal consumption in shop fabrication for the U.S. Steel Building in Pittsburgh, Pa., reached 609,000 lb (274,050 kg).

During this same period, Kaiser Steel Corp. had used the consumable guide version of electroslag welding to deposit 24,000 welds in the Bank of America world headquarters building in San Francisco. At the time, this building was regarded as the tallest earthquake-proof structure ever erected on the West Coast.

In terms of welding, one of the most intensive structures built during this period was NASA's Vertical Assembly Building on Merritt Island, Fla. Shop-welded sections for this giant structure consumed 830,000 lb (373,500 kg) of weld metal.

For the World Trade Center, Leslie E. Robertson, a partner in charge of the New York office of Skilling, Helle, Christiansen, Robertson, said a computer was used to produce the drawing lists, beam schedules, column details and all schedules for exterior wall panels. Millions of IBM cards were then sent to every fabricator. These cards gave fabricators the width, length, thickness and grade of steel of every plate and section in all of the columns and panels. "In addition," he said, "the fabricators are given all of the requirements of every weld needed to make up the columns and panels. Many of these cards are used as equatable to the production of drawings. They are sent directly from the designer to the fabricators. Draftsmen never become involved."

Elsewhere in New York City, Leo Plofker, a partner in one of the city's leading design engineering firms, extensively used welding in design. Among Plofker's achievements are the Pan-Am Building and the all-welded, 52-story office building known as 140 Broadway.

"Our decision to make extensive use of welding is strictly based on economics," he said. "Welded design results in savings in steel. Field welding can cause some problems, but they are not too serious as long as you maintain control over the welders and you insist that qualified personnel be employed to perform nondestructive testing of the welds."

Unit 16
Health, Safety and Accident prevention.
1.Запишите новые слова, выучите их.
Irritation раздражение

respiratory tract дыхательные пути

susceptibility чувствительность; восприимчивость

fever жар, лихорадка; какое-л. заболевание, основным

симптомом которого является очень высокая

температура

tickling першение (в горле)

chest tightness стесненное дыхание

flu грипп

coughing кашель

limb конечность (человека или животного)

siderosis сидероз

pneumonia воспаление легких, пневмония

pulmonary oedema отек легких

asphyxiation удушье

exposure подвергание какому-л. воздействию; выставление,

оставление на солнце, под дождем и т. п.

cancer рак

2. Прочитайте и переведите текст.