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Shocking Truths About Welding

Glen Allan
Manager WTIA OzWeld
Technology Support Centres Network

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Copyright Oct 2012 WTIA

Welding Electrical Safety Update

Overview
Myth busting
Review of welding electrocutions over the

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Copyright Oct 2012 WTIA

past 16 years and key learning's


The ongoing need for awareness of welding
electrical safety
Developments in Standards
Developments in Equipment
Improvements in Industry Practice
Ongoing Issues

Myth Busting True or False


Electric shock is something welders should expect in

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Copyright Oct 2012 WTIA

a days work
Welders have to learn to get used to electric shock
Welders are capable of sustaining higher levels of
electric shock than other people
The electric shocks that welders get from welding
power sources are from a low voltage source & are
therefore harmless
All welding power sources have the same electrical
hazard MMAW, GTAW, GMAW, FCAW, SAW
A current of 1/10th of one amp (100 mA) for 1 second can
(and likely will) kill you (even if you are a welder)

Is The
Welding Circuit Hazardous?
22 fatalities in Australia
1958 to 1996
Cannington Mine 1997

Power
Source

ACME
Welding
Inc.

HRD

Electrode

Applied Voltage
Work

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Copyright Oct 2012 WTIA

Six fatalities in Australia


in the past 16 years

Overview of Welding
Electrocutions in Australia

SA
Qld
WA
NSW
NT
Qld

Shipyard
Cannington Mine
Shipyard
Kemblawarra
Darwin Harbour
Townsville

December 14
October 22
February 02
March 16

1996
1997
1999
2004
2006
2011

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Copyright Oct 2012 WTIA

The electrocutions in Australian industry over


the past sixteen years from contact with a
welding circuit include:

Learning's from Welding


Electrocutions in Australia
a.c. welding circuit
All electrocutions occurred using the manual
metal arc welding (MMAW) process
All environments should have been classified
and managed as Category C in accordance
with AS 1674.2 2007
As little as 5% w/w moisture renders clothing
and PPE sufficiently conductive for electric
shock and electrocution TestSafe & UoW

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Copyright Oct 2012 WTIA

All electrocutions were from contact with an

Voltages on Primary and Secondary


Circuits of Welding Power Sources
240 V a.c. or 415 V a.c.

Up to 80 V a.c. or 113 V d.c.


Extra-low voltage
Not exceeding
50 V a.c. or
120 V ripple-free d.c.

a.c. Power sources typically ~ 1.6 x ELV

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Copyright Oct 2012 WTIA

(Ref: AS/NZS 3000:2007)

Constant Current (CC) Power


Sources

Current Amps

14
0

13
0

12
0

Striking Voltage for GP electrodes

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Copyright Oct 2012 WTIA

Striking Voltage for LH electrodes

11
0

100
90
80
70
60
50
40
30
20
10
0
10
0

range
Voltage changes with arc length
only a minor change to amperage
Limited short-circuit current for
reduced stubbing and low spatter
Used for MMAW (stick), some wire
feeders (variable speed), air
carbon-arc gouging
May be d.c.+ve, d.c.-ve or a.c.
High no-load voltage necessary for
arc starting and re-ignition
especially for a.c. and low
hydrogen rods
High no-load voltages on these
power sources exceed ELV for
a.c. and d.c with ripple

Voltage

Drooping volt-amp curve


Constant current in the operating

Constant Voltage (CV) Power


Sources

Current Amps

14
0

13
0

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Copyright Oct 2012 WTIA

12
0

11
0

100
90
80
70
60
50
40
30
20
10
0

10
0

consistent voltage regardless of


the amperage output
Current increases rapidly with
decreased voltage
High short-circuit current helps to
maintain a consistent arc length
Used for wire feeder processes
with constant wire feed
Usually d.c. electrode +ve output
for GMAW and FCAW (ve for
some FCAW applications)
Much lower no-load voltage
combined with d.c. output
makes these power sources
inherently safer

Voltage

Relatively flat volt-amp curve


Maintains a relatively stable,

Risk vs Type of Current


Low Frequency a.c.

Highest risk

a.c. 50Hz causes fibrillation of the heart

High frequency (HF) a.c.

d.c. pulsed
Pulsed at 25 500 Hz

d.c. smoothed

Lowest risk

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Copyright Oct 2012 WTIA

d.c. with ripple (usually 50 Hz)

Effect of a.c. Frequency


Combined safety factor relative to 50Hz
5
4.5
3.5
3
2.5
2
1.5
1
0.5
0
1

10

100

Frequency (Hertz)

1000

10000
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Copyright Oct 2012 WTIA

Safety Factor

Amperage effects a.c.


Short exposure @ 50 Hz
Heart cramps increasing risk of
ventricular fibrillation 50 mA
Threshold of ventricular
fibrillation 30 mA
Intense pain, severe cramps,
loss of voluntary muscle
control, involuntary
movements 10-30 mA

Threshold of let-go 10 mA

Body
Current

mA

Ventricular fibrillation 70 mA
Probability of death
very high > 70 mA

Threshold of reaction 0.5 mA

Refer AS/NZS 60479.1 2010 Effects of current on human


beings and livestock Part 1: General Aspects Section 5

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Copyright Oct 2012 WTIA

Pain, cramps, muscle control


increasingly difficult tending
towards immobilisation 0.5-10 mA

Loss of consciousness 60 mA

Amperage effects d.c.


Short exposure ripple free
For longitudinal rising current
(feet positive), duration shorter
than 0.2 sec threshold of
ventricular fibrillation
30 mA (as for a.c.)
Sensation only at making and
breaking of the current with
the possibility of involuntary
movements and cramp like
sensation, no loss of
voluntary muscle control
10-30 mA

Loss of consciousness > 300 mA

mA
Sensation of warmth
in the extremities and painful
sensations on the skin 100 mA

Transverse currents cause reversible cardiac


dysrhythmias, current marks, burns, dizziness
and sometimes unconsciousness up to 300
mA

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Copyright Oct 2012 WTIA

Threshold of reaction 2 mA

Body
Current

For longitudinal downward


current (feet negative),
duration shorter than
0.2 sec threshold of
ventricular fibrillation
60 mA (2 x a.c.)

Refer AS 60479.1 2010

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Copyright Oct 2012 WTIA

Effects of current on human beings and livestock Part 1: General aspects

Refer AS 60479.1 2010

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Copyright Oct 2012 WTIA

Effects of current on human beings and livestock Part 1: General aspects

a.c. vs d.c.
An a.c. (or d.c. with ripple) welding current is
considered to be 2 to 4 times more hazardous
than ripple free d.c.
With a.c. there is a higher risk of heart fibrillation
Difficulty letting go at 10 mA or greater
Good impedance match at 50Hz

Welders have died from d.c. welding current


fibrillation if they coincide with the vulnerable period of
the heartbeat approx. 1/5 of the cycle
Timing is all important Russian Roulette
No welding electrocutions on d.c. in Australia, so far

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Copyright Oct 2012 WTIA

Very short duration d.c. shocks are likely to cause

Welding Environments
Australian Standard 1674.2 2007 classifies
welding environments into three categories
Category A

Category C

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Copyright Oct 2012 WTIA

Category B

AS 1674.2 2007
Welding Environments
Definition
1.3.6.1
1.3.6.2
1.3.6.3

Category A environment
Category B environment
Category C environment

2.2 (a)
2.2 (b)
2.2 (c)

Category A environment
Category B environment
Category C environment

Control measures
2.3.1
2.3.2
2.3.3

Category A environment
Category B environment
Category C environment

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Classification

Allowable Voltages Welding


AS 1674.2 2007, WTIA TN 7 2004, WTIA TN 22 2003
Working environment categories
Category A

environment (AS 1674.2 Clauses 1.3.6.1,


2.2 (a) and 2.3.1) is where the risk of electric shock or
electrocution is low due to controls to prevent the possibility
of the welder being in contact with the workpiece in the event
of being in contact with a live part of the welding circuit.

Category B

Category C

environment (AS 1674.2 Clauses 1.3.6.3,


2.2 (c) and 2.3.3) is where there is a high probability of the
welder being in contact with the workpiece and the risk of an
electric shock or electrocution is greatly increased due to the
presence of moisture, e.g. from high humidity, high ambient
temperature, perspiration or water.

d.c. 113 V peak, or


a.c. 113 V Peak, 80 V r.m.s.
without an observer
d.c. up to 113 V
peak,
with an observer

d.c. 35 V peak,
without an observer

a.c. up to 68 V
peak, 48 V r.m.s.,
with an observer

a.c. 35 V peak,
25 V r.m.s.,
without an observer

d.c. 35 V peak,
always with an observer, or
a.c. 35 V peak and 25 V r.m.s., always
with an observer

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Copyright Oct 2012 WTIA

environment (AS 1674.2 Clauses 1.3.6.2,


2.2 (b) and 2.3.2) is where there is a high probability of the
welder being in contact with the workpiece. Freedom of
movement may be restricted.

Maximum permitted open circuit


voltage (OCV)

Allowable Voltages Welding


AS 1674.2 2007, WTIA TN 7 2004, WTIA TN 22 2003
Environment

Maximum OCV d.c.


@ < 10% ripple (ripple free)
Working
Without an
Observer

Working With
an Observer

AS 1674.2
Category A

113 V

Non electrically
Hazardous

Electrically
Hazardous (dry)

AS 1674.2
Category C
Electrically
Hazardous (wet)

Working With
an Observer

Working
Without an
Observer

113 V peak or 80 V r.m.s.

113 V

35 V

68 V peak or
48 V r.m.s.

35 V peak or
25 V r.m.s.

35 V

Not Permitted

35 V peak or
25 V r.m.s.

Not Permitted
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Copyright Oct 2012 WTIA

AS 1674.2
Category B

Maximum OCV a.c. or d.c.


@ > 10% ripple

MMAW in a
Category C Environment
Requirements for use of a MMAW welding
power source in a Cat. C environment:
A hazard reducing device (HRD), i.e. a switch or
voltage reducing device (VRD), and
An observer providing constant surveillance of the
welder (person welding)

Maintains visual contact with the welder


Has the capacity to immediately isolate the output
circuit of the welding power source in the event of
an incident

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Copyright Oct 2012 WTIA

The observer:

Personal Protective Equipment


(PPE)
PPE is the least effective control but is
essential for cutting and welding
All PPE should be:

against electrical, heat and radiation hazards


Maintained in good condition and replaced as
necessary
Supplied / purchased in accordance with relevant
Standards

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Copyright Oct 2012 WTIA

Kept dry changed if necessary


Used correctly often PPE is the only protection

Welding Circuit Connections


Welding circuits carry large currents and rely
on very good connections to carry that
current

Work return clamps must make a good


connection on clean metal and should be
placed as close as practicable to the welding
point

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Copyright Oct 2012 WTIA

Connections to the power source


Line connectors
Connection to work

Welding Circuit Connections


the return clamp and the arc must be low
resistance and ideally contain no joints
Any unavoidable joints in the work piece must
be either sound welds or clean tightly bolted
connections with clean metal to metal contact
The use of dual return clamps (equipotential
bond) connected to a common return cable to
ensure good connection to both parts being
joined is recommended

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Copyright Oct 2012 WTIA

The current path in the work piece between

Preventing Electrical Shock

VRDs do not provide


protection in all situations!
power on, the welder is relying on the VRD
and the insulation of their gloves to prevent
electrical shock
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Copyright Oct 2012 WTIA

When changing an electrode (stick) with the

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VRDs Do Not Provide Protection


In All Situations!
welding circuit while holding a work piece in
place and are quite common
An equipotential bond (current carrying cable)
attached to the piece being held and
connected to the return circuit or main job
provides a low resistance path
Alternatives such as using clamps or
insulated tools to secure the unattached
piece should be considered

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Electric shocks to people in contact with the

26

Power Off for Electrode Changes


It is a requirement of a number of
organisations that power to the electrode
holder is isolated when performing an
electrode change either by:

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Copyright Oct 2012 WTIA

Using an output circuit safety switch, or


Turning off power to the welding power source

27

Industry Changes 1996 to Present


Improved awareness of the hazards inherent

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Copyright Oct 2012 WTIA

in electric arc welding


Widespread elimination of a.c. power sources
for MMAW, unfortunately not yet universal
Many organisations now permit only d.c.
output welding power sources for MMAW
Greater awareness of conditions that
constitute a Category C environment, and
Implementation of requirements of AS 1674.2
for management of Category C environments

Industry Changes 1996 to Present


hazard reduction by way of switches and/or
voltage reduction devices (VRDs)
Equipment manufactured with integral VRDs
providing superior performance to retro-fitted
VRDs
Widespread use of HRDs in Australian
industry, by way of:
A switch, or
A VRD, and
In some cases, both a VRD and a switch

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Copyright Oct 2012 WTIA

Most suppliers of welding equipment offering

Industry Changes 1996 to Present


hazard management processes implemented
Better understanding of conditions that
exacerbate electrical hazards and the
tendency to deterioration of conditions during
a days work, i.e. Cat. B deteriorating to Cat. C
Better understanding and implementation of
simple precautions such as use of insulation
mats, using correctly selected and maintained
PPE, and minimising moisture

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Hazard identification, risk assessment and

Ongoing Issues
Inspection and Testing

between AS 3760 and AS 1674.2


Poor understanding and implementation of
requirements of AS 1674.2 2007 for
periodic inspection and testing of output
circuits of welding power sources
Poor understanding and implementation of
requirements of AS 1674.2 2007 for
periodic inspection and testing of accessories

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Copyright Oct 2012 WTIA

Inadequate understanding of welding circuits


Tag and test personnel unaware of the link

Ongoing Issues
Equipment Use
start safety checks and simple maintenance
Inadequate maintenance of welding
equipment particularly electrode holders,
electrode and return cables and work clamps
Incorrect placement of return clamps and
poor preparation of surfaces for high currents
Lack of appreciation of the very low moisture
levels required to change an environment
from Category B to Category C classification

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Copyright Oct 2012 WTIA

Lack of diligence in implementation of pre-

Copyright Oct 2012 WTIA

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