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Discover the Detailed Occupational Safety Guide for Operating Electric Welding Machines. This document provides important regulations and necessary safety measures when working with electric welding machines, helping to protect the health and safety of employees in an industrial work environment.

Table of Contents

PART I: CURRENT STATE OF SAFETY PRACTICES FOR WORK INVOLVING ELECTRIC WELDING MACHINES

I. General Situation

The Ministry of Labour, Invalids and Social Affairs informs sectors and localities of the occupational accident situation in the first 6 months of 2024 and outlines key solutions to proactively prevent incidents and accidents in the last 6 months of 2024. According to reports from 61 out of 63 centrally governed provinces and cities, in the first 6 months of 2024, there were a total of 3,201 occupational accidents nationwide (a decrease of 227 cases, equivalent to 7.09% compared to the same period in 2023), resulting in 3,065 victims (a decrease of 197 people, equivalent to 6.04% compared to the first 6 months of 2023), including both employees under labor contracts and those working without labor contracts. Specifically:

Number of fatal occupational accidents: 320 cases, a decrease of 25 cases (7.25%) compared to the first 6 months of 2023 (including 245 cases in areas with labor relations, a decrease of 28 cases or 10.3%; and 75 cases in areas without labor contracts, an increase of 3 cases or 4.2% compared to the first 6 months of 2023);
Number of deaths due to occupational accidents: 346 people, a decrease of 7 people or 1.98% compared to the same period in 2023 (including 268 in areas with labor relations, a decrease of 13 people or 4.63%; and 78 in areas without labor contracts, an increase of 6 people or 8.33%).
Number of people seriously injured: 810 people, an increase of 26 people or 3.32% compared to the first 6 months of 2023 (including 710 in areas with labor relations, a decrease of 5 people or 0.7%; and 100 in areas without labor contracts, an increase of 31 people or 44.92%).

Download the PDF file Occupational Accident Report – First 6 Months of 2024 issued by the Ministry of Labour, Invalids and Social Affairs.

The occupational accident situation in the first 6 months of 2024 in both sectors with and without labor relations saw a decrease in the number of deaths and fatal accidents compared to the same period in 2023.

II. Some occupational accidents while operating electric welding machines

When performing tasks related to electric welding, the risk of occupational accidents is always present due to the hazardous nature of this process. Below are some common accidents that occur when operating electric welding machines:

Fire and explosion due to improper storage of chemicals: Some chemicals such as welding gases, solvents, or oils used in the welding process can cause fires and explosions if not stored correctly. If the welding machine is used near these materials without careful attention, the risk of fire and explosion will increase significantly.
Risk of electric shock: Electric welding machines operate with a large power source, so the risk of electric shock is always present, especially when cables are damaged or insulation is not guaranteed. Workers can be in danger if they do not follow safety measures such as wearing insulated gloves or regularly checking the condition of the cables.
Forgetting materials or tools: Forgetting materials or tools such as welding rods, safety glasses, or gas cylinders can lead to accidents. If the welding machine is activated while these materials are still in the workspace, it can cause explosions or injuries to surrounding workers.
Incidents due to equipment failure: Electric welding machines can also fail due to technical breakdowns, such as water getting inside the machine, or broken or cracked cables. When an incident occurs during operation, the risk of an accident increases significantly if not repaired in time.
Non-compliance with safety procedures: A major cause of accidents is worker negligence, including failure to follow established safety procedures or not using proper protective equipment. This can lead to serious accidents, especially in high-risk work environments like using electric welding machines.

To minimize the risk of accidents when operating electric welding machines, adhering to safety procedures and ensuring protective equipment is very important. Necessary training and risk awareness must also be promoted to protect worker safety.

PART II: OCCUPATIONAL SAFETY AND HEALTH WHEN OPERATING ELECTRIC WELDING MACHINES

I. Introduction

A. Overview of the importance of occupational safety when operating electric welding machines

Occupational safety when operating electric welding machines plays a crucial role not only in protecting the health and lives of workers but also in affecting work efficiency and the stability of the production process. When performing electric welding, the risk of accidents is always present, from fires and explosions to electric shocks and equipment failures. To minimize this risk, adhering to safety procedures is a necessary step. Adequate training and risk awareness also play a vital role in ensuring the safety of everyone involved in this work process.

Protective measures such as wearing full protective gear, periodically checking the condition of the welding machine, and maintaining a clean work environment must also be strictly implemented. Strong management and the commitment of all parties are essential to ensure that the work environment involving electric welding machines is safe and efficient.

B. Important safety protocols and regulations when operating electric welding machines

Adhering to safety protocols and regulations is extremely important when operating an electric welding machine. First, workers must be trained on how to use the welding machine safely and effectively. This includes understanding potential hazards such as fire, explosion, electric shock, and equipment failure. In addition, ensure that personal protective equipment such as welding helmets, insulated gloves, and protective clothing are fully and correctly equipped.

The process of regular inspection and maintenance is also a key factor in ensuring safety when operating an electric welding machine. The components of the welding machine need to be checked regularly to ensure they are functioning correctly and safely. Cables and electrical connections also need to be checked to ensure there is no damage that could cause a risk of electric shock.

Furthermore, maintaining a clean and safe working environment is an indispensable part of safety regulations. Flammable materials such as cloth, paper, or chemicals should be removed from the work area to minimize the risk of fire and explosion. In addition, using a spacious and well-ventilated workspace helps reduce the risk of explosion and enhances worker safety.

II. Components and Functions of Electric Welding Machines

A. The different components of electric welding machines

An electric welding machine consists of many different components, each playing a crucial role in the welding process. One of the main components is the power source, which supplies the necessary energy to create the appropriate current intensity and temperature for welding. Besides that, the welding electrode, also known as the welding rod, is the component that comes into direct contact with the material being welded and is used to transmit the electric current to create the weld joint.

The welding machine also includes a control unit, which helps to adjust parameters such as current intensity and welding time to ensure accurate and stable welding results. In addition, the cooling system helps to cool the welding machine and prevent overheating, keeping the machine operating stably and efficiently.

Protective parts are also an indispensable part of the welding machine to ensure user safety. This includes a welding helmet to protect the eyes and face from the effects of sparks and UV radiation, as well as insulated gloves to protect hands from the risk of electric shock and burns.

B. Structure and operating principle of electric welding machines

An electric welding machine often has a simple structure but is a complex system in operation. The basic structure of an electric welding machine includes a power source, a welding electrode, a control unit, and protective parts.

The power source provides the necessary energy to create the appropriate current intensity and temperature for welding. Common types of power sources include alternating current (AC) or direct current (DC), depending on the specific requirements of the welding process.

The welding electrode, commonly called a welding rod, is the part that directly contacts the material being welded and is used to transmit the electric current to create the weld joint. Different types of welding rods are used depending on the type of material and specific welding requirements.

The control unit helps adjust parameters such as current intensity and welding time to ensure accurate and stable welding results. These changes are usually made through adjustments on the welding machine’s control panel.

C. Applications in the metal welding and cutting industry of electric welding machines

Electric welding machines are widely used in the metal welding and cutting industry due to their flexibility and efficiency. During the welding process, the electric welding machine creates an electrical circuit through the welding electrode, generating high temperatures sufficient to melt the work material and create a strong weld joint. This allows users to create high-quality welded structures in various applications.

Electric welding machines are also used in the metal cutting process. During cutting, the electric welding machine creates a high current through a thin cutting wire, called a plasma cutting wire, creating a hot plasma stream to cut through the metal. This process can be adjusted to cut different metal materials, from carbon steel to stainless steel and aluminum.

In addition, electric welding machines can also be used to weld non-metallic materials such as plastics and ceramics. This welding process is often used in the production of electronic products, automobiles, and other household products.

D. Risks associated with operating electric welding machines

Operating an electric welding machine carries many potential risks that workers need to be aware of and face. One of the biggest risks is fire and explosion due to the combination of heat from the welding process and the presence of flammable materials such as grease or solvents in the work environment. Without careful management, the risk of fire and explosion can harm the health of workers and cause property damage.

The risk of electric shock is also a significant issue when operating an electric welding machine. A large power source and high current can cause electric shock if safety measures such as wearing insulated gloves or regularly checking the condition of the cables are not followed. This risk is particularly dangerous when working in a humid environment or when water seeps into the welding machine.

Equipment failure is also a potential risk. An electric welding machine can fail due to technical breakdowns, such as water getting inside the machine, or broken or cracked cables. If not repaired in a timely manner, this failure can lead to serious danger for workers and property.

III. Safety Inspection and Maintenance Before Operating Electric Welding Machines

A. Safety inspection before operating electric welding machines

Before starting to operate an electric welding machine, performing a safety inspection is a crucial step to help ensure the safety of the worker and the surrounding environment. First, thoroughly inspect the welding machine to ensure that all parts are functioning correctly. Check the condition of the cables, welding electrode, and other accessories to ensure there is no damage.

Next, ensure that the work environment is sufficiently ventilated and there are no flammable materials near the welding machine. Remove all flammable materials such as paper, cloth, or grease from the work area to minimize the risk of fire and explosion.

Check personal protective equipment such as welding helmets, insulated gloves, and protective clothing to ensure they are working effectively and are used correctly. It is especially important to ensure the welding helmet is used to protect the eyes and face from the effects of sparks and UV radiation.

B. Guide to periodic maintenance of electric welding machines

Periodic maintenance is an important part of maintaining the performance and safety of an electric welding machine. First, check the cables and electrical connections to ensure they are not damaged or affected by insulation issues. This is especially important to prevent the risk of electric shock and to ensure the current is transmitted safely.

Next, inspect and clean the cooling unit of the welding machine to ensure that it is operating efficiently. Regular maintenance of the cooling unit helps prevent overheating and ensures that the welding machine operates stably and effectively.

Periodically inspecting and replacing the welding electrode is also an important part of welding machine maintenance. The welding electrode often wears down after a period of use and needs to be replaced to ensure quality and stable welding results.

Finally, inspect and maintain the control unit of the welding machine to ensure that all welding parameters are adjusted correctly and the machine operates accurately. Ensuring that all parts and components of the welding machine are regularly inspected and maintained will help ensure the safety and performance of the machine throughout its use.

IV. Safe Operating Procedure for Electric Welding Machines

A. Step-by-step guide on the safe operating procedure for electric welding machines

The first step in the operating procedure for an electric welding machine is to thoroughly inspect the machine and the work environment to ensure safety. Check the condition of the welding machine, cables, welding electrode, and other parts to ensure they are working correctly and have no issues. At the same time, ensure there are no flammable materials or substances near the welding machine.

Next, ensure that you are fully equipped with personal protective equipment such as a welding helmet, insulated gloves, and protective clothing. A welding helmet is a crucial element to protect the eyes and face from the effects of sparks and UV radiation.

Then, set the appropriate welding parameters on the control panel of the welding machine, including current intensity and welding time. Ensure that you have been fully trained on how to use the welding machine and know how to respond to emergency situations.

When you start welding, work carefully and with focus. Make sure you maintain your concentration and focus on your work to avoid unwanted accidents.

B. Emergency handling measures and incident response mechanisms when operating electric welding machines

In the event of an incident while operating an electric welding machine, having emergency handling measures and response mechanisms is very important to ensure the safety of workers and the work environment.

One of the most important measures is to turn off the power immediately upon detecting any incident related to the welding machine. This can prevent the risk of electric shock and the risk of fire and explosion from continuing to supply power to the machine when there is a problem.

If there is a risk of fire or explosion, workers must know how to use firefighting equipment such as fire extinguishers or isolation sprayers to extinguish the flames. At the same time, it is necessary to immediately notify safety personnel or managers for prompt support and response.

In the event of an incident involving a worker, rescue and first aid measures must be carried out immediately. Ensure that all employees have been trained on how to respond to emergency situations and have a ready plan to handle these situations quickly and effectively.

V. Risk Assessment and Hazard Management When Operating Electric Welding Machines

A. Identifying potential risks and hazards in operating electric welding machines

During the operation of an electric welding machine, identifying and understanding potential risks and hazards is important to ensure the safety of workers and the work environment. One of the biggest risks is fire and explosion due to the combination of heat from the welding process and the presence of flammable materials such as grease or solvents in the work environment. Failure to manage this carefully can lead to the risk of fire and explosion, causing harm to health and property.

The risk of electric shock is also a potential hazard when operating an electric welding machine. With a large and high-intensity current, failure to comply with safety measures such as wearing insulated gloves or periodically checking the condition of the cables can cause a risk of electric shock, especially in a humid environment or when water seeps into the welding machine.

In addition, equipment failure is also a potential hazard. An electric welding machine can fail due to technical breakdowns such as water getting inside the machine, or broken or cracked cables. Proposing regular inspection and maintenance will help minimize this risk and ensure safety during the work process.

B. Effective hazard prevention strategies when operating electric welding machines

1. Regular inspection and maintenance of electric welding machines for safe operation

Performing regular inspection and maintenance of an electric welding machine is important to ensure safety during operation. First, it is necessary to check the general condition of the welding machine, including inspecting the cables, welding electrode, and other parts to ensure they are not damaged or broken. This helps prevent unwanted incidents during operation.

Next, it is necessary to inspect and clean the cooling unit of the welding machine to ensure that it is operating efficiently. Regular maintenance of the cooling unit helps prevent overheating and ensures that the welding machine operates stably and safely.

Periodically inspecting and replacing the welding electrode is also an important part of maintenance. The welding electrode often wears down after a period of use and needs to be replaced to ensure quality and stable welding results.

2. Comply with occupational safety regulations for the safe operation of electric welding machines

To ensure the safe operation of an electric welding machine, complying with occupational safety regulations is very important. First, workers must be fully trained on the risks and preventive measures during the operation of the welding machine. This includes using personal protective equipment such as a welding helmet, insulated gloves, and protective clothing.

In addition, performing a safety check before operation is an important part of complying with safety regulations. Before starting work, workers need to thoroughly inspect the welding machine and the work environment to ensure there is no risk of fire, explosion, or electric shock.

Furthermore, implementing preventive measures such as regular inspection and maintenance is also an important part of complying with safety regulations. Regular maintenance helps ensure that the welding machine operates stably and does not cause unwanted incidents.

3. Identify and mark safe zones when operating electric welding machines

Identifying and marking safe zones during the operation of an electric welding machine is an important part of ensuring the safety of workers and the work environment. First, it is necessary to determine the location and size of the work area required to perform the welding work safely and effectively.

Then, it is necessary to clearly mark the safe zones around the welding machine, including a safe distance from the heat source and flammable materials. Marking safe zones helps prevent the risk of fire and explosion and protects workers from potential dangers.

In addition, it is necessary to ensure that the safe zones are protected and not encroached upon by other workers or work materials. This may include using barriers or guards to prevent unsafe access to the work areas.

4. Use personal protective equipment when operating electric welding machines

During the operation of an electric welding machine, the use of personal protective equipment is extremely important to ensure worker safety. One of the most important pieces of personal protective equipment is the welding helmet, used to protect the eyes and face from the effects of sparks and UV radiation from the welding process.

Insulated gloves are another indispensable part of personal protective equipment when operating an electric welding machine. They help protect the hands from the risk of electric shock and the thermal effects of the welding process. Protective clothing is also very important to protect the body from any impact from sparks or molten materials.

In addition, safety shoes should also be used to protect the feet from the risks of falling heavy materials or from work tools. Ensure that all personal protective equipment is used correctly and is regularly inspected to ensure its effectiveness and safety when working around an electric welding machine.

5. Emergency procedure and response in case of an incident when operating electric welding machines

In the event of an incident while operating an electric welding machine, an emergency procedure and a quick response are very important to ensure the safety of workers and the work environment. First, the worker must immediately stop using the welding machine and turn off the power source to prevent potential risks such as electric shock or fire and explosion.

Then, the worker must immediately report the incident to the safety officer or manager so they can provide prompt support and response. If necessary, a call should be made to emergency or fire services to ensure the situation is handled safely and effectively.

If there is a risk of fire or explosion, the worker must use firefighting equipment such as fire extinguishers or isolation sprayers to extinguish the flames. At the same time, it is necessary to move away from the danger zone and ensure the safety of oneself and those around.

6. Participate in occupational safety courses when operating electric welding machines

Occupational safety and health training is not only a legal requirement but also a commitment to the safety and health of workers. It helps employees recognize and deal with risks and hazardous situations, thereby reducing accidents, injuries, or fatalities in daily work.

The risk of accidents is always present and can happen at any time in the work environment due to the possibility of human error and the unpredictability of all situations. This emphasizes the need for occupational safety training and constant vigilance.

When participating in occupational safety training at Nam Viet Safety Center, workers will be thoroughly trained from theory to real-life risk scenarios. Accordingly, there will be measures to identify and prevent occupational accident risks that may occur during work. After the training course, trainees will take occupational safety tests to obtain an occupational safety certificate. From there, workers will grasp safety knowledge as well as have a valid certification for their work.

VI. Factors Affecting Occupational Safety When Operating Electric Welding Machines

A. How do weather conditions affect the operation of electric welding machines?

Weather conditions can significantly affect the operation of an electric welding machine. In a hot work environment, the welding machine may operate at a higher temperature than normal, posing a risk of overheating and reducing the machine’s work efficiency. In addition, in a cold work environment, grease and other lubricants can solidify, damaging or reducing the functionality of parts within the welding machine.

Humid weather can also create a high-humidity environment, posing a risk of electric shock when working with an electric welding machine. This increases the risk for workers and requires caution and the use of appropriate personal protective equipment.

In addition, strong winds or rain can also increase the risk of accidents during the operation of the welding machine. Strong winds can cause sparks from the welding process to fly uncontrollably, while rain can wet the work environment, increasing the risk of electric shock.

B. How does the work environment affect the operation of electric welding machines?

The work environment plays a crucial role in the operation of an electric welding machine. In a confined work environment, the ventilation of gases and fumes from the welding process can be restricted, leading to an increased risk of poisoning or harm to the health of workers. This makes providing an effective ventilation system extremely important to ensure a safe and healthy work environment.

In addition, a dusty or liquid-filled work environment can reduce the efficiency of the electric welding machine. Dust and liquids can clog parts of the welding machine or reduce the contact between the electrode and the material, leading to uneven or poor-quality welding results.

The work environment can affect the mood and concentration of workers. For example, a noisy or excessively hot work environment can reduce concentration and increase the risk of accidents.

C. How does the technical condition of electric welding machines affect their operation?

The technical condition of an electric welding machine plays a crucial role in ensuring the safety and efficiency of its operation. The electric welding machine must be regularly maintained and inspected to ensure that all parts are functioning correctly and do not cause unwanted incidents.

If the electric welding machine is not properly maintained, technical problems such as breakdowns or performance degradation of important parts can occur. This can lead to a reduction in the machine’s operational capability or cause unwanted incidents such as the risk of fire, explosion, or electric shock.

In addition, the electric welding machine needs to be checked regularly to ensure that safety and protective devices such as overheating sensors or circuit breakers are working correctly. If these devices do not work properly, it can increase the risk of accidents or harm to workers.

In summary, the technical condition of an electric welding machine directly affects its operation and the safety of the work process. Performing regular maintenance and technical checks is important to ensure that the electric welding machine operates stably and safely throughout its use.

D. How do the safety knowledge and skills of workers affect the operation of electric welding machines?

The safety knowledge and skills of workers play a crucial role in ensuring the safety and efficiency of the electric welding machine operation process. Workers must have a clear understanding of the risks and preventive measures during the operation of the welding machine, including how to properly use personal protective equipment such as welding helmets, insulated gloves, and protective clothing.

Besides that, the skill of performing welding operations safely and accurately is also an important factor. Knowing how to set up and adjust the parameters of the welding machine, periodically inspect and maintain the machine, as well as recognize and handle emergency situations are important skills that workers must have.

In addition, participating in occupational safety training and coaching courses also helps to enhance the knowledge and skills of workers in operating electric welding machines. Through this, they can apply this knowledge and these skills to their practical work, helping to enhance safety and efficiency in the process of working with electric welding machines.

VII. Occupational Safety Training on Skills for Safe Operation of Electric Welding Machines

A. Why do electric welding machine operators need to be trained in occupational safety?

Occupational safety training is important for electric welding machine operators because it helps them understand and recognize the risks and hazards that can occur during their work. Through training, they have the opportunity to learn about the use of personal protective equipment, accident prevention measures, and emergency response procedures in case of an incident.

Training also helps operators understand how to operate and maintain the electric welding machine safely and effectively. They are instructed on how to check and adjust the machine’s parameters, ensuring that the machine operates correctly and does not pose a risk to themselves and surrounding workers.

In addition, occupational safety training also helps raise awareness of the importance of occupational safety in the work environment. Operators will have a better understanding of safety regulations and procedures, and will also have a higher sense of their role and responsibility in protecting their own safety and that of their colleagues.

B. Where to get occupational safety training for operating electric welding machines?

An Toan Nam Viet is a reputable and high-quality occupational safety training center in Vietnam today. With occupational safety training sessions held continuously at production workshops, factories, or construction sites across the country (63 provinces in Vietnam).

To ensure effective training, An Toan Nam Viet prepares carefully and meticulously down to the smallest detail. From preparing tools, equipment, teaching aids to curriculum, materials, sound, and lighting.

The occupational safety training instructors at An Toan Nam Viet are experts with many years of experience in the field. They even have research projects identifying hazards in all industries and how to prevent them.

The instructors’ lectures are drawn from practical experience and are conveyed in a lively and easy-to-visualize manner to the workers. These factors help workers feel comfortable during the learning process and absorb the teaching knowledge well. Of course, the knowledge conveyed always adheres to Decree 44/2016/ND-CP. From there, they will grasp many measures to prevent hazards and how to protect themselves. At the same time, they can also apply it most appropriately in their actual work.

VIII. The Significance of Occupational Safety in Operating Electric Welding Machines

A. The importance of maintaining occupational safety in operating electric welding machines

Maintaining occupational safety in the operation of an electric welding machine is not only a legal obligation but also a crucial factor in ensuring the health and lives of workers. An electric welding machine is a particularly high-risk piece of equipment, therefore, adhering to safety rules and measures is extremely important.

Maintaining occupational safety not only helps to minimize the risk of accidents and injuries but also creates a positive and safe working environment. When workers feel safe and protected, they will increase their work efficiency and create job satisfaction.

In addition, maintaining occupational safety also helps to avoid risks of property and production losses. Occupational accidents can cause severe damage to both workers and the business, including the loss of time, money, and reputation.

B. Important safety measures to know before operating electric welding machines

Before operating an electric welding machine, workers need to master several safety measures to ensure the safety and efficiency of the work process. First, ensuring a clean and well-ventilated work environment is very important to reduce the risk of poisoning and explosion.

In addition, the proper use of personal protective equipment such as welding helmets, safety glasses, insulated gloves, and protective clothing is necessary to protect the health of workers from the negative effects of sparks, welding fumes, and thermal impact.

Regular inspection and maintenance of the welding machine is also an important safety measure. Ensure that the welding machine is working correctly and that there are no defects that increase the risk of incidents and accidents. Complete an occupational safety training course to be issued an occupational safety card by the training center to properly complete your work profile.