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and installation
Article gives the principal health and safety considerations to ensure safe welding
practices and prevent accidents, particularly on power source installation and
electrical hazards
Electricalhazards-Power
sources and installation
Guidelines are given on the principal health and safety considerations to ensure safe
welding practices and prevent accidents. The hazards associated with the use of
electrical equipment are highlighted.
Welding installations
Typical arc welding installations for both single
and multi-welder operations are described in HSE
guideline No 118, Electrical Safety in Arc Welding.
When the welding circuit is connected, the
following guidelines should be adopted:
the connection between the power source
and the workpiece should be as direct as
practicable
use insulated cables and connection
devices of adequate current-carrying
capacity
extraneous conductive parts should not be
used as part of the welding return circuit
unless part of the workpiece itself
the current return clamp should be as near to the welding arc as possible
When attaching the welding current and current return cables, it is essential that an
efficient contact is achieved between the connection device and the workpiece to
prevent overheating and arcing. For example, current and return clamps must be
securely attached to 'bright' metal i.e. any rust or primer coatings should be locally
removed.
Electrical hazards
Electric shock
In all manual arc welding operations, the principal risk is from electric shock, most
likely from contact with bare live parts of the welding circuit. The arc voltage is
within the range 10 to 40V, but, as the voltage required to strike the arc may be
substantially higher, power sources have an open circuit voltage (OCV), typically up
to 80V. Although these voltages appear low compared with the 230V domestic mains
supply, work by the International Electrotechnical Commission shows that only
voltages below 50V AC or 120V DC are unlikely to be dangerous to healthy people in
a dry working environment. In other conditions such as restricted conducting
locations or wet surroundings, potentials of 80V AC have been the cause of fatal
electric shocks. Devices are available which reduce the open circuit voltage when
welding is not being carried out. These voltage reduction devices (VRD) should meet
the requirement of BSEN 60974-1.
Appropriate protective clothing such as gloves, boots and overalls will protect the
welder from electric shock.
Stray welding currents
A different kind of electrical hazard can arise from stray welding currents which
return to the welding transformer by paths other than the welding return lead. For
example, although the return is disconnected, welding is possible when the return
current flows through:
protective earth (PE) conductors of other electrical equipment, or the power
source itself
wire ropes, slings and chains
metal fittings and pipework
bearings in motors