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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 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. 4
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 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
it’s 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
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 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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 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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 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 10
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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 11
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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 13
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 Questions

?
Any Questions

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 The End

Thank you!

Ensure that you plant remains a safe plant!

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