WELDING SAFETY TIPS

WELDING SAFETY TIPS 

Installation

1.      Installation including power supply to welding equipment shall conform to the requirements laid down in the Indian Electricity Act, 2003.

2.      The frame or case of the welding machine shall be efficiently earthed in accordance with the Indian Electricity Rules, 1956.

3.      For individual welding machines, the rated current-carrying capacity of the supply conductors shall be not less than the maximum primary current of the welding machines.

4.      All the moving and rotating parts of the welding equipment shall be guarded.

5.      Incase of Engine-run welding machines, refueling shall not be done while the machine is running and spilling of oil shall be avoided.

Welding Service Cable and Connectors

1.      All welding cables shall be of completely insulated, flexible type, capable of handling the maximum current requirements of the work in progress.

2.      When it becomes necessary to connect or splice the cables, substantial insulated connectors of a capacity at least equivalent to that of the cable, shall be used. If connections are effected by means of cable lugs, then these lugs shall be securely fastened together by means of bolts to give good electrical contact. The exposed metal parts of the lugs shall be completely insulated.

3.      The work lead (welding lead) shall be attached firmly to the work.

4.      Work lead shall be as short as possible.

 Manual Electrode Holders

1.      Any current-carrying parts passing through the portion of the holder, which the welder grips in his hand shall be fully insulated against the maximum voltage encountered to ground. Insulation of all, metallic or current carrying parts, including the jaws, which grip the electrodes, is recommended wherever service conditions permit.

2.      The cable shall be free from repair or splices up to a minimum distance of 3.0 m from the electrode holder.

3.      Electrode holders shall be provided with discs or shields to protect the hands of the operator from the heat of the arcs.

 Earth Returns

1.      Welding current should preferably be returned to the welding machine by a single, cable from the work to the welding machine. Connection of a cable from the welding machine to a common conductor or structure on which the work rests, or to which the work is connected may be permitted.

2.           Pipelines containing gases or inflammable liquids or conduits carrying electrical conductors shall not be used for a ground return circuit. Chain or wire rope shall not be used to carry welding current

3.            When a building structure or pipeline is used as a ground return circuit, it shall be checked to ascertain whether proper electrical contact exists at all joints. Sparking or heating at any point shall cause the rejection of the structure or the pipeline as a ground circuit, particularly if inflammable vapours or gases are present.

4.            Where a structure or pipeline is continuously employed as a ground return circuit, all joints shall be bonded and appropriate periodic inspection shall be conducted to ascertain that no condition of electrolysis or fire hazard exists by virtue of such use.

5.            All earth connections shall be checked to determine that they are mechanically strong and electrically adequate for the required current.

Electric Shock

The following precautions shall be taken to prevent electric shock:

1.           Workmen/welders designated to operate arc-welding equipment shall have a thorough knowledge of requirements with regard to safety. They shall be instructed the method of avoiding electric shock.

2.            Voltages required for arc welding are low and normally would not cause injury or severe shock. Hence, parts having these voltages are liable to be handled carelessly. These voltages are, nevertheless, sufficiently high that under certain circumstances they may be dangerous to life. This danger is particularly marked in very hot weather, when the welder is sweaty or when he is wet.

3.            Welder shall develop the habit of always keeping his body insulated from both the work and the metal electrode and holder. He shall always wear shoes and gloves.

4.            Particularly, he shall never permit the metal part of air electrode, the electrode coverings, or any metal part of the electrode holder to touch either his bare skin or any wet coverings on his body. Consistent use of electrode holders with well-insulated jaws, well-insulated cables, dry protective coverings on the hands and body and insulations from ground would be helpful in avoiding contact.

5.            It shall never be assumed that because contact with the electrode at one time is not harmful, similar contacts at other times would also be harmless.

6.            Electrode shall be removed from holders when not in use to eliminate danger of electrical contact with persons or conducting objects. Electrode holders when not in use shall be so placed that possibilities of electrical contact between them and persons or conducting objects are eliminated.

7.           Engineer in-charge shall check welding machine regularly to ensure that electrical connections and insulation on the holders and cable are in good order.

8.            Anything that appears unsafe shall be promptly reported to Engineer in-charge and use of such welding equipment shall be discontinued until its safety has been assured. Only qualified personnel shall make repairs.

9.           Welding (secondary) terminals shall be so arranged that no current-carrying parts are exposed to accidental contact.

Operation and Maintenance

1.            Welding equipment shall be maintained in safe working order at all times. Periodic inspection shall be conducted.

2.            Printed rules and instructions covering operation and maintenance of welding equipment supplied by the manufacturers shall he strictly followed.

3.            When the welder has occasion to leave his work or stop work for any appreciable time, or when the machine is to be moved, the power supply switch in the equipment shall be open. The equipment shall be disconnected from the source of power when not in use.

4.            Welding equipment shall be maintained in good mechanical and electrical condition to avoid unnecessary hazards. Commutators shall be kept clean to prevent excessive flashing. Gasoline and other inflammable liquids shall not be used for cleaning Commutators. Fine sandpaper, such as No. 00 or commutator polish shall be used.

5.            Welding equipment used in the open shall be protected from inclement (rainy) weather conditions. Protective coverings shall not obstruct the ventilation necessary to prevent overheating of the machine. When not in use, the equipment shall be stored in a clean dry place. Machines, which have become wet, shall be thoroughly dried before being used.

6.            It is good practice to blow out the entire generator type-welding machine occasionally with clean, dry compressed air.

Cable

1.            When, in the course of work, a welding cable becomes worn, exposing bare conductors, the portion thus exposed shall be adequately insulated with heat resistance tape.

2.            Welding cables shall be kept dry where practicable, and free from grease and oil to prevent premature breakdown of the insulation.

3.            When it becomes necessary to carry cables some distance from machines, they shall be substantially supported overhead, if practicable. If this is not possible, and cables are laid on the floor or ground, they shall be protected in such a manner that they would not be damaged, entangled or interfere with safe movement of people. Special care shall be taken to see that welding supply cables are not in proximity to power supply cables or other high-tension wires.

4.         Also, laying of cables shall so as not to create tripping hazard in the work place.