Welding and cutting processes involve high-voltage electricity that exceeds safe limits, making safety precautions essential. In China, the no-load voltage of welding machines typically ranges from 50 to 90 volts, while plasma cutting systems operate at 300 to 450 volts. Hydrogen arc welding uses about 300 volts, and electron beam welding can reach as high as 80 to 150 kilovolts. The input voltage for domestic motors is usually between 220 and 380 volts, with power frequency AC at 50 Hz, which is significantly above the safe voltage level. There are two main types of electric shock accidents during welding: direct and indirect shocks. Direct shocks occur when a person comes into contact with live parts of the welding equipment or near high-voltage electrical systems. Indirect shocks happen when a normally non-conductive object becomes charged due to insulation failure or equipment malfunction. Direct electric shocks often occur in situations where a part of the body, such as a hand or foot, touches a live component without proper insulation. This is especially common in wet or humid environments, where sweat increases the risk of electric shock. During wiring or adjusting welding equipment, touching live terminals or components can also lead to electric shocks. Additionally, climbing or working near high-voltage power lines can result in dangerous contact. Indirect electric shocks may be caused by faulty welding equipment that leaks electricity. Common causes include moisture damage, prolonged overload, or short-circuit heating that damages insulation. Improper installation of welding devices can also contribute to this risk. If the insulation between the primary and secondary windings of a welding transformer is damaged, or if the wiring is incorrect, it can create a dangerous situation. Touching cables with damaged insulation, broken switches, or faulty bakelite locks can also lead to electric shocks. Another cause of electric shock is using metal structures like factory frames, pipes, rails, or crane hooks as part of the welding circuit. These conductive materials can unintentionally carry current, increasing the risk of electrocution. Proper grounding, regular maintenance, and adherence to safety protocols are crucial to preventing these incidents and ensuring the safety of workers involved in welding and cutting operations.
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