Welding Safety Checklist

This checklist is designed to ensure safe welding operations. Complete it before starting any welding work. Mark each item as 'Yes' if compliant, 'No' if not, and 'N/A' if not applicable. Note any corrective actions needed.

I. Pre-Operation Checks

• 1.1. Equipment Installation: All equipment is installed by a qualified electrician in conformance with Subpart S of this part [1].
• 1.2. Disconnect Switch: A safety-type disconnecting switch or circuit breaker is conveniently located at or near the machine [1].
• 1.3. Thermal Protection: Ignitron tubes are equipped with a thermal protection switch [1].
• 1.4. Personnel Training: Workmen are properly instructed and competent to operate the equipment [1].
• 1.5. Machine Shut-off: Proper switching equipment for shutting down the machines is provided [2].
• 1.6. Manufacturer Instructions: Printed rules and instructions covering operation of equipment supplied by the manufacturers are strictly followed [2].
• 1.7. Equipment Condition: Inspect the equipment daily to ascertain that it is in good condition [3].

II. Personal Protective Equipment (PPE)

• 2.1. Head Protection: Head protection meeting the requirements of ANSI Z89.2-1971 is provided and used where there is exposure to possible high voltage electrical contact [4].
• 2.2. Eye Protection: Eye protection meeting the requirements of OAR 437-002-0134(8)(b) is provided and used where foreign objects may enter the eyes [4].
• 2.3. Hexavalent Chromium Exposure: Employees are protected from exposure to hexavalent chromium during stainless steel welding process [5].

III. General Safety Measures

• 3.1. Shields: The hazard of flying sparks is eliminated by installing a shield guard of safety glass or suitable fire-resistant plastic at the point of operation [6].
• 3.2. Additional Shields: Additional shields or curtains are installed as necessary to protect passing persons from flying sparks [6].
• 3.3. Foot Switch Guards: All foot switches are guarded to prevent accidental operation of the machine [6].
• 3.4. Electrode Holders: Electrode holders when not in use are so placed that they cannot make electrical contact with persons, conducting objects, fuel, or compressed gas tanks [2].
• 3.5. Cables: Cables with splices within 10 feet (3 m) of the holder are not used [2].
• 3.6. Grounding: Where technically practical, the secondary of all welding transformers used in multispot, projection, and seam welding machines is grounded [6].
• 3.7. Ventilation: Flash welding machines are equipped with a hood to control flying flash [7].
• 3.8. Fire Safety: Fire-resistant curtains or suitable shields are set up around the machine to protect operators of nearby equipment [7].

IV. Portable Welding Machines

• 4.1. Counterbalance: All portable welding guns have suitable counterbalanced devices for supporting the guns, including cables, unless the design makes it impractical [6].
• 4.2. Safety Chains: All portable welding guns, transformers, and related equipment suspended from overhead structures are equipped with safety chains or cables [6].
• 4.3. Switch Guards: All initiating switches on the portable welding gun are equipped with suitable guards capable of preventing accidental initiation [7].
• 4.4. Grounding: The secondary and case of all portable welding transformers are grounded [7].

V. Maintenance and Reporting

• 5.1. Periodic Inspection: Periodic inspection is made by qualified maintenance personnel, and a certification record is maintained [7].
• 5.2. Defect Reporting: The operator is instructed to report any equipment defects to his supervisor [7].
• 5.3. Wet Machines: Machines which have become wet are thoroughly dried and tested before being used [2].
• 5.4. Damaged Cables: Cables with damaged insulation or exposed bare conductors are replaced [2].

VI. Resistance Welding

• 6.1. Low Voltage: All external weld initiating control circuits operate on low voltage, not over 120 volts, for the safety of the operators [1].
• 6.2. Capacitor Welding: Stored energy or capacitor discharge type of resistance welding equipment and control panels involving high voltage are suitably insulated and protected by complete enclosures [1].
• 6.3. Interlocks: All doors and access panels of all resistance welding machines and control panels are kept locked and interlocked to prevent access by unauthorized persons [1].
• 6.4. Guarding: All press welding machine operations, where there is a possibility of the operator's fingers being under the point of operation, are effectively guarded [1].

VII. Emergency Stop Buttons and Safety Pins

• 7.1. Stop Buttons: Two or more safety emergency stop buttons are provided on all special multispot welding machines, including 2-post and 4-post weld presses [6].
• 7.2. Safety Pins: On large machines, four safety pins with plugs and receptacles (one in each corner) are provided so that when safety pins are removed and inserted in the ram or platen, the press becomes inoperative [6].

VIII. Post Welding

• 8.1. Cool Down: Allow equipment to cool down before storage.
• 8.2. Housekeeping: Ensure the work area is clean and free of flammable materials.

Notes/Corrective Actions: [Space for notes on corrective actions needed]

Inspector: [Inspector Name]

Date: [Date]

Supervisor Signature: [Signature]