Health, safety and accident prevention: electrical hazards - power source

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

Health, safety and accident prevention

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.

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 40V), the high voltage mains
supply (230 or 400V) 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 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.

Power source and earthing

The normal practice in the UK has been to provide a separate earth connection to the
workpiece, ( 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).
There is a potential problem in that both designs can often 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. EN
60 974-1 or IEC 974-1.
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 earth connection, welding is
possible with current flowing through the earth. Because of the risk of damaging
protective earth and other connectors, this type of power source is considered to be
obsolete and should not be used.
Manufacturer's rating plate
The following symbols are used on the manufacturer's Rating Plate to indicate the
type of protection:

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

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

being earthed.
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 pipework
installations, the welding 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
unacceptable indirect current return path with damage to conductors if, for example,
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 and 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 not be used as part of the welding circuit
unless they are a part of the workpiece itself.
Check the workpiece earthing requirements. When using a double or reinforced
insulation power source, stray currents can be avoided by not earthing the workpiece
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', HSE Books, 1994
2. 'The Arc Welder at Work', Welding Manufacturer's Association
3. BS EN 60974-1: 2005, Arc Welding Equipment. Power Sources.
4. BS EN 470-1: 1995, 'Protective Clothing for Use in Welding and Allied
Processes'
5. BS EN 60974-7: 2005, Arc Welding Equipment. Torches.
6. CLC/TS 62081:2000 'Arc Welding Equipment - Installation and Use'
(IEC62081:1999)
7. BSEN 60974-6:2003 'Arc Welding Equipment - Limited duty manual metal arc
power sources'.
8. BS 638-4:1996 'Arc welding power sources, equipment and accessories.
Specification for welding cables.'
9. BS 638-5:1988 'Arc welding power sources, equipment and accessories.
Specification for accessories.'
10. BS EN 60974-11:2004 'Arc welding equipment. Electrode holders.'
11. BS EN 60974-12:2005 'Arc welding equipment. Coupling devices for welding
cables.'
12. BS EN 60974-8:2004 'Arc welding equipment. Gas consoles for welding and
plasma cutting systems.'