Precautions and Safe Practices for Welding



Do not touch live electrical parts.

Live electrical parts can include the power supply, the power and work cables, the torch and the work itself (if the work is not connected to earth ground.)

Electric shock can be avoided. Follow the recommended practices listed below. Faulty installation, improper grounding, and incorrect operation and maintenance of electrical equipment are always sources of danger.

Connect electrical equipment and work piece correctly. Prevent electrical shock.
Connect power supply and control cabinet chassis to approved earth ground.
Connect work piece to “work” output connection of power supply.
Connect work piece (as illustrated below) OR power supply work terminal (but not both) to approved earth ground. “Double-grounding” can cause welding/cutting current to occur in conductors intended only for safety grounding and can result in destruction of the safety ground.

NOTE: The work lead is NOT a ground lead; the work lead is to be used only to complete the welding circuit.

Make good electrical connections of the work lead to the power supply work terminal and to the work piece. A missing or poorly-connected work lead can cause a fatal shock. Make sure the work lead is always in good condition.

Use the correct cable size. Sustained overloading will cause cable failure and result in possible electrical shock or fire hazard. Work cable should be the same rating as the torch cable.

Make sure all electrical connections are tight, clean, and dry. Poor electrical connections can heat up, and even melt. They can also cause bad welds and produce dangerous arcs and sparks. Do not try to make an electrical connection through paint. Do not allow water, grease, or dirt to accumulate on plugs, sockets, or electrical units.

Insulate yourself from work piece and ground. Moisture and water can conduct electricity. To prevent shock, it is advisable to keep work areas, equipment, and clothing dry at all times. Fix water leaks immediately. Keep hoses from touching hot metal. Do not exceed recommended water pressures. Make sure that you are well insulated. Wear dry insulated gloves, rubber-soled shoes, or stand on a dry board or platform.

Use only the proper equipment if welding must be done in electrically-hazardous conditions. Such conditions include damp or warm locations, wet clothing, metal structures such as floors or scaffolds, cramped positions or wherever there is a high risk of contact with work piece or ground. In any of these situations use:

 DC MIG welding
DC manual (stick electrode) welding
AC welder with reduced open-circuit voltage control

Keep cables and connectors in good condition. Improper or worn electrical connections can increase the chance of an electrical shock. Do not use worn, damaged or bare cables.

Avoid open-circuit voltage. Open circuit voltage of welding, cutting and gouging power supplies can cause electric shock. When several welders are working with arcs of different polarities, or when using multiple alternating current machines, the open-circuit voltages can be additive, the added voltages increase the severity of the shock hazard.

Remove metal jewelry. It is recommended that rings, watches, necklaces, and other metallic items be removed before welding or cutting. Accidental contact of jewelry with welding power can cause metal to become hot or even melt. It can also increase the possibility of a fatal shock.

Follow recognized safety standards. Follow the recommendations in American National Standard Z49.1, “Safety in Welding and Cutting,” available from the American Welding Society, P. 0. Box 351040, Miami, FL 33135, and also the National Electrical Code, NFPA No. 70, which is available from the National Fire Protection Association, Battery march Park, Quincy, MA 02269.



Comments