Work Instruction for Welder

Pre-operation Check for safety

 We should vent the area, open, clean, tidy, safe, and suitable for the welding job. No
grease, oils, and other flammable and combustible goods. No other work to avoid
electrocution, fumes, noise, flying slags, and radiation in the room.
 Check the machine and cables for cracks and unwind the wires before working.
 Arrange personal protection equipment (PPE) for the operation.

Operational Check for safety

 The arc welder set with the proper current and voltage. The electrode holder and earthing
clamp tight. The loose clamp creates a short circuit. The accidental UV welding flash is
detrimental to eyes and skin. Erect a UV screen/ curtain at the welding bay.
 The workpiece free from any paint, rust, and oxide layer for better electrical contact.
 Check running welder and its accessories. Never left the welding machine unattended.
 Once welding interrupts or finished, secure the electrode holder, turn off the electric
supply.
 Avoid the area until the workpiece gets cool.

 Post- Operational Check for safety

 Make sure it switches your Welding Machine off. The fume extract if used again to stop.
 Hang the electrode holder and earthing clamp at a designated place.
 Contact point checking for any damage/corrosion.
 Clean the work area, welding bench, accessories, and make everything tidy for the next
use.

Personal Protection Equipment

1. Foot protection by safety shoes.

Potential Hazards

 Welding flashlight injuries to eyes and skin. The helmet, goggles, masks, and proper
instructions can reduce this risk.
 Eye injury by hot slags. The appropriate use of glasses and masks in removing the residue is
helpful.
 Skin burns are common. The protective clothing, mask, safety shoes help to cut the
damage.
 Explosion and fire is a possibility. Keeping the area clean may help to avoid it. 

Arc Welding Process

All the arc welding processes need a safe voltage. They need it for arc initiation and maintenance.
The melting of the base metal and electrode needs enough amperage. The arc welding process is
simple, reliable, and low cost for many years. There are many arc processes in welding and
fabrication industries.
Arc Welding Procedure

The welder put on safety shoes, welding suit, gloves, cap, mask, goggles, and helmet. Undertake
complete pre welding and welding safety instructions.

Striking An Arc: We bring the electrode in contact with a workpiece of metal. This contact
established with tapping action and withdrawal electrode a gap of 1.5 mm to 3.0 mm. This contact
generates an arc.

Maintain the Arc: The gap between arc and workpiece, which creates the arc needs to maintain.
The persistent, steady movement in one direction of the electrode continues. A constant current
passes through the electrode across the arc gap. The current generates heat to melt the electrode
and protective flux. The electrode melts over the workpiece under the protective slag from the
flux. Remove the residue on the cooling of metal with a chipping hammer or pointed tool.

Stop the Arc: Withdraw the electrode from the metal piece and break the circuit. The electric arc
melts the workpiece and electrode at the same time. We thus get a penetration when a molten
metal of electrode deposits over the hot metal workpiece. The fusion of electrode metal is
complete with the workpiece.

Selection of Electrode: The selection is a very tricky process as there are no fixed criteria for it. It
depends upon the welding and thickness of the workpiece. 

Warning & Advisory for Arc Welding Process

The user of the arc welding machine should follow the advice in the manual. To make the welding
process smooth and safe, we are sharing a few warnings and advisory.

Training of the Operator: The manual of the machine does not cover the process of welding. The
person needs the training to operate the welding machine. Qualified or experienced welder of
integrity is a choice.

Ventilate the Welding Area: Ventilate the welding area to avoid fumes from flux. The fumes and
gases are dangerous for health. An operator can move to on or off the main supply.

Handling the Workpiece: Hold the workpiece with gloves, pliers, and tongs only. It remains hot for
quite a long time. It takes time to cools for holding with bare hands.

Fire Risk: It generates fumes, sparks, molten metal droplets, slags, and projectile metals. They can
cause a severe fire in the workplace. Avoid any flammable material. Arrange fire extinguishers in
the welding area always.

Metal Surfaces for Welding: The surfaces need free from paint, varnish, and coatings. They may
emit dangerous fumes. Never weld on pipes and containers filled with flammable gases and liquids.

Extension Cables: Better to avoid the extension leads. In necessity, it should be of suitable rating
and have an earth connection. The welding cables should be away from the weld area and hot
articles.

Electric Shock Protection: Use a 30 ma residual current device (RCD).

Electrical Insulation: The insulation secure at electrode and accessories. Never touch the welding
circuit.

Working Environment: The welding work area should be illuminated and do not weld in rainy or
humid places.
Proper Dress: Use a suitable dress and avoid UV light radiates from an arc of the machine. The
suite includes a jacket, trousers, gloves, masks, goggles, helmet. A welder is safe from metal
projectiles, sparks, and slag.

Isolate Damaged Part: Locate the damaged part. It can affect the functioning and results of
welding. Replace or repair immediately.

Switching Off the Welder: After your work, switch off the welder and disconnect the power
supply. Keep the torch, electrode holder, and earthing clamp in place. Take care of the hot
workpiece before leaving the machine.

Welding Machine Ventilates: Make sure the ventilation of the welder is on by enough air passage
with a fan. It will switch once heated beyond a limit.

Surface Holding Welding Machine: The horizontal surface is ideal for the device. Never put your
device on an incline, uneven surfaces, or strap on your back while welding.

Not Working Situation: Change of the Teflon, wire guide and electrode wire roll is not advisable.
Never lift the machine when connected to the main supply.

Significant Hazards of Arc Welding Machine

1. Electric Shock
2. Fumes
3. Radiations
4. Fire & Explosion
5. Burns

1. Electric Shock

The welder may experience convulsions, muscle spasms, and, in rare cases, paralysis or even death.
Safety measures eliminate the possibility of electric shock. The welder needs dry gloves, dry safety
shoes in good condition, and quality.

Keep the equipment insulated and serviced. Switch off the machine when changing the leads. A
rubber mat or wooden is better to avoid electric shock. The sweat of welder is an excellent
conductor to electricity. Keep the temperature and ventilation reasonable to prevent perspiration.

2. Fumes

Welder exposes to fumes in arc welding. The fumes are from atmospheric gases, shielding gases,
metal vapors, flux gases. The metals like beryllium, cadmium, zinc, lead, and aluminum are
dangerous. They are harmful to the liver, kidneys, lungs, blood, and central nervous system. The
concentration of the fumes kept in safe limits. The operators can work for a limited period to avoid
overexposure.

Clean the welding workpiece from any contaminants. The ventilation is the mainstay to level the
fumes at a permissible level. The ventilation is a significant effort for the fumes. The natural
ventilation, ceiling exhaust fan, local ventilation requires for it.

3. Radiations

It exposes welder to visible radiation, UV light radiation, infra-red radiation. The visible radiation
of high intensity causes a dazzling state. Infrared radiation causes burns and discomfort, and
Ultraviolet radiation is exceptionally intense to cause corneal and skin injuries.
The UV light causes inflammation of the cornea called welding flashlight keratitis. Keratitis resolves
by itself. It has detrimental effects on the cornea. Personal protection is the answer to the
radiation. The welder can use goggles, helmet, gloves, masks, and welding suit to ward off the
radiation’s effect.

4. Fire & Explosion

Paper, synthetic materials, oils, paints, wood products, and oils ignite. The spatters, projectile
metals, and slag can cause the ignition of the material. Liquid fuel tanks are potential hazards for
the explosion in the welder’s vicinity.

Clean and remove any flammable and combustible material from the welding zone. The welder uses
proper clothes and arranges fire extinguisher, a handy thing always.

5. Burns

Welding can cause superficial, intermediate, and severe burns depending upon its severity. UV
light, infra-red radiation, sparks, slag, heated workpiece, and projectile metals cause injuries.

Use protective articles of clothing, safety shoes, masks, and other protective equipment. Use a
tong to hold the hot workpiece and dispose of the hot metal piece to prevent burns.