Welding equipment inspection checklist

Before you use it

• OSHA 29 CFR 1910.254(d) covers the operation and maintenance of arc welding equipment. Before starting operations, all connections to the machine are checked to make certain they are properly made, the work lead is firmly attached to the work, magnetic work clamps are freed of adherent spatter on their contact surfaces, and coiled welding cable is spread out before use to avoid serious overheating and damage to the insulation (1910.254(d)(2)). Grounding of the machine frame is checked, with special attention to the safety ground connections of portable machines ((d)(3)); there must be no leaks of cooling water, shielding gas or engine fuel ((d)(4)); and proper switching equipment for shutting down the machine must be provided ((d)(5)).
• Cables with splices within 10 feet (3 m) of the holder may not be used ((d)(8)). Cables with damaged insulation or exposed bare conductors are replaced, and lengths of work and electrode cable are joined only with connecting means specifically intended for the purpose, insulated for the service conditions ((d)(9)(iii)). Electrode holders not in use are placed so they cannot make electrical contact with persons, conducting objects, fuel or compressed gas tanks ((d)(7)). A machine that has become wet is thoroughly dried and tested before it is used ((d)(9)(ii)).
• Under (d)(9)(i), the operator should report any equipment defect or safety hazard to the supervisor, and use of the equipment is discontinued until its safety has been assured; repairs are made only by qualified personnel. Workers assigned to operate or maintain arc welding equipment must be acquainted with 1910.254 and with 1910.252(a), (b) and (c) ((d)(1)), and the manufacturer’s printed rules and instructions are strictly followed ((d)(6)).
• Installation items that the walk-up can see: a disconnecting switch or controller at or near each machine that has none mounted as an integral part ((c)(3)(i)); the frame or case grounded, except on engine-driven machines ((c)(2)(i)); chains, wire ropes, cranes, hoists and elevators never used to carry welding current ((c)(2)(iii)); conduits not used to complete a work-lead circuit, and pipelines not used as a permanent part of one ((c)(2)(ii)); control apparatus enclosed except for operating wheels, levers or handles, and input power terminals and live parts completely enclosed and accessible only by means of tools ((b)(4)(ii)–(iii)).
• OSHA sets no interval for this check beyond “before starting operations”, so run it per machine before each job or shift. The fire precautions for the welding itself, such as the 35-foot clearance, the fire watch and the permit, are in 1910.252(a) and in our hot work permit template.