Safety and Accident

Prevention:
Electrical Hazards

Presented by:
Mayo A. Malagkit
Sr. Mechanical Inspector
Khursaniyah United Safety Team
May 2006
 POWER SOURCE AND INSTALLATION
 Guidelines are given on the principal health and safety
considerations to ensure safe welding practices and prevent
accidents.

 The hazards associated with use of electrical equipment are

highlighted.
 THE ARC WELDING CIRCUIT
 MMA and TIG processes can be either alternating current (AC) or
direct current (DC) whilst MIG is usually only operated with DC.

 As arc processes need a large current (up to 500 A) but at a

relatively low arc voltage (10 to 40 V), the high voltage mains supply
(230 or 400 V) must be reduced.

 In its basic form, the power source for generating AC comprises a

transformer to reduce the mains voltage and increase the current for
welding.

 For generating the DC arc, a rectifier is placed on the secondary

side of the mains-fed transformer or alternatively, a motor or engine-
driven generator can be used.
 WELDING INSTALLATION
 Typical arc welding installations for both single and multi-welder
operations are described in HSE guideline No.118, Electrical Safety in
Arc Welding.
When welding circuit is connected, the following guidelines should be
adopted:
 The connection between the power source and the work piece 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 of the
welding return circuit unless part of the work piece itself
 The current return clamp should be as near to the welding arc as
possible
 WELDING INSTALLATION

NOTE:
 When attaching the welding current and current return cables, it is
essential that an efficient contact is achieved between the
connection device and the work piece 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.
 POWER SOURCE AND EARTHING
 The normal practice is to provide a separate earth connection to the
work piece, (circuit a) so that, in the unlikely event of an insulation
breakdown between primary and secondary circuits, the fuses will
blow.

 However, the separate earth connection increases the risk of stray

currents which may damage other equipment and conductors.

 As modern power sources have been designed to have a much

higher level of insulation (double or reinforced insulation), a
separate earth connection is not recommended (circuit b).
POWER SOURCE AND EARTHING
 POWER SOURCE AND EARTHING
 In very old designs, the welding circuit was sometimes connected
internally to the power source enclosure (circuit c).

 However, the danger is that even with the welding return lead
disconnected, and a separate connection, welding is possible with
current flowing through the earth.

 Because of the risk of damaging protective earth and the connectors,

this type of power source is considered to be obsolete and should not
be used.

 NOTE: There is a potential problem in that both designs can be found

in the same welding shop. The newer power source can be identified
by the power source’s Rating Plate, which indicates it has been
manufactured to recent standards e.g. EN60 974-1 or IEC 974-1.
 MANUFACTURER’S RATING PLATE
The following symbols are used on the manufacturer’s Rating Plate

to indicate the type of protection:

 ELECTRICAL 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 40, 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 Electro-technical Commission
shows that only voltages below 50V AC or 120V DC are likely to be
dangerous to healthy people in dry working environment.
 ELECTRICAL SHOCKS
 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

 NOTE: Appropriate protective clothing such as gloves, boots and

overalls will protect the welder from electric shock.
 STRAY WELDING CURRENTS
A different kind of electrical hazards 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 pipe work

 Bearings in motors

 Damage to PE conductor in particular could mean the equipment is no

longer being earthed.
 STRAY WELDING CURRENTS
 Stray currents may be substantial and comparable with the welding
current level, where there is poor or faulty insulation of the return lead
which may be short-circuited by other conductors.
 When welding on building structures and pipe work installations, the
return lead should be placed as close as possible to the point of welding.
 The exception is where the metallic grid, support structure or metallic ship
hull is used as part of the welding return circuit.
 There is an increased risk of stray currents when welding on structures
which have an inherent connection to earth such as ships or pipelines.
There could be an acceptable indirect current return path with damage
conductors, if the current return lead is detached and the circuit becomes
open. The recommendations for the electrical distribution systems and
earth connections in various situations are described in HS(G) 118.
SAFE PRACTICE & ACCIDENT AVOIDANCE
 Welding equipment should conform to the appropriate standards (as
listed at the end of the article); electrode holders that are insulated
overall are recommended so no bare metal can be inadvertently
touched.

 Welding leads and return leads should be insulated and thick

enough to carry the current safely; connectors should also be
insulated to avoid inadvertent access to live conductors and
adequate for the current being carried.

 The welding return lead should be connected as near as practicable

to the welding arc; metal rails, pipes and frames should be used as
part of the welding circuit unless they are part of the work piece
itself.
SAFE PRACTICE & ACCIDENT AVOIDANCE
 Check the work piece earthing requirements . When using a double or
reinforced insulation power source, stray currents can be avoided by not
earthing the work piece or the welding output circuit.

 The welding leads, connection devices and electrode holder or torch should
be checked at regular intervals for “fitness for use” ; repair or replace
damaged or worn components.

Publications and relevant standards

1. HS(G) 118 ‘Electrical Safety in Arc Welding’

2. BS EN 60974-1:1998, Arc welding Equipment. Power sources.