Welding Machine Inspection

Safety Inspection of Welding Machines used in Holcim Plants

Mabini Team
Freddie Hillier

Rudy Emanel T&E October 4th, 2012

Holcim Philippines, Inc. 2012

Why Are We Having This Presentation

Failure to maintain the equipment is a major cause of accidents involving electrical equipment.

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Heavy Duty Portable Electrical Equipment

Dangerous Situation
The likelihood of accidents occurring and their severity will vary; depending on the type of electrical equipment, the way in which they are used, the protective devices installed, and the environment.

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Starting The Inspection Disconnect and isolate the power supply (if connected) to the welding machine prior to performing inspection Inspect the welding machine for obvious damage to the cabinet, power switches, indicator lights, covers, or controls.
Heavy rusted areas or large dents may indicate an improperly maintained welding unit that requires close inspection before use. Ensure any unused or exposed terminals have insulation in place.

Ensure the welding machine has at least an IP23 rating.

Holcim Philippines, Inc. 2011

Heavy Duty Portable Electrical Equipment

Power Supply Cable And Plug

Check for any damage to the terminal box, plug or cable. Special attention should be given to any cuts, burns, abrasions, and fraying or other damage to the cable insulation, which could expose live wires. There are to be no joints in the cable.

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Power Supply Connections

Open welding machine supply terminal box cover and plug back cover Inspect connections and ensure that the correct type and size of crimp lugs are used and correctly crimped, on all conductors connected to studs Conductor strands are to be firmly twisted before terminating in terminal block or receptacle

There must be no bear exposed conductor between its insulation and the crimp lug or terminal
Cables shall be properly secured so that the conductor terminations are not be placed under strain (gland or clamp)
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Power Supply Cable And Earth Ensure that the earth cable is incorporated in the supply cable and that it is connected to the earth terminal on the machine and the plug

Ensure the cable outer sheath is securely anchored onto the welding machine and the plug
Holcim Philippines, Inc. 2011

Heavy Duty Portable Electrical Equipment

Conductor Terminations Ensure that that all terminations are correctly connected and secured in the plug and welding machine power supply terminal block

Cutting or adding of some conductor strands to fit into lug/terminal is prohibited

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Heavy Duty Portable Electrical Equipment

Welding (Work) Cables

Electrode and return cables should be of similar length (with no joints) and of the same current carrying capacity (size), rated for the maximum current rating and duty cycle of the welding activity Observe electrode holder and ground clamp for loose cable connections, faulty jaws or bad insulation Building steelwork shall not be used as a work return path

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Holcim Philippines, Inc. 2011
Heavy Duty Portable Electrical Equipment

Welding (Work) Cable Connection To Machine

Ensure that welding (work) cable connections to the welding machine are in good condition; contact surfaces are clean and are properly tightened. If terminal posts are used ensure only brass washers and the correct insulated type brass nut is used. Twisting of conductors around studs is prohibited

Connections shall be insulated or covered with suitable cover

Holcim Philippines, Inc. 2011

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Welding (Work) Extension Cables

Carry out same condition tests as for work cables Check that both the male and female connections are fully insulated with clean contact surfaces and all fittings are tightened properly with no conductors exposed Check the welding hand piece is the correct type, in good condition and fully insulated

The hand piece must be rated for the maximum current rating and duty cycle of the welding activity
Check the work return (ground) clamp is the correct type, in good condition Cracked or damaged hand pieces shall be taken out of service immediately
Holcim Philippines, Inc. 2011

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Note
If you are unsure of the safety of any part of the equipment - DO NOT ALLOW TO BE USED

Isolate the equipment (if connected) and notify the electrical department or responsible contactor immediately, in order that remedial action can be taken

If, for some reason, equipment has to be dismantled to verify safety, this action is only to be performed by a technically qualified and competent Electrician If all OK, fit correct colour inspection tag and record findings in register
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Example Of Inspection Checklist

Each plant to create their own checklist, then send a copy to T&E for evaluation
Holcim Philippines, Inc. 2011

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Questions

?
Any Questions
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Holcim Philippines, Inc. 2011
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The End

Thank you!

Ensure that you plant remains a safe plant!

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Holcim Philippines, Inc. 2011
Heavy Duty Portable Electrical Equipment