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Holcim Philippines, Inc. 2012
Welding Machine Inspection
Safety Inspection of Welding Machines used in Holcim
Plants
Mabini Team
Freddie Hillier
Rudy Emanel
T & E
October 4th, 2012
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Why Are We Having This Presentation
Failure to maintain the equipment is a major cause
of accidents involving electrical equipment.
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Starting The Inspection
Disconnect and isolate the power supply
(if connected) to the welding machine prior toperforming 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 haveinsulation in place.
Ensure the welding machine has at least an IP23
rating.
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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 anycuts, 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 Cable And Earth
Ensure that the earth cable is incorporated in the
supply cable and that it is connected to the earthterminal 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 weldingmachine 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 currentcarrying 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; contactsurfaces 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
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Welding (Work) Extension Cables
Carry out same condition tests as for work cables
Check that both the male and female connectionsare fully insulated with clean contact surfaces andall fittings are tightened properly with no conductorsexposed
Check the welding hand piece is the correct type, ingood condition and fully insulated
The hand piece must be rated for the maximumcurrent rating and duty cycle of the welding activity
Check the work return (ground) clampis the correcttype, in good condition
Cracked or damaged hand pieces shall be takenout of service immediately
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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
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Questions
?Any Questions
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The End
Thank you!
Ensure that you plant remains a safe plant!