Tool Box Talk - Welding on Equipment

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Too many organizations weld of machinery causing electrical and mechanical failures. This Tool Box Talks explains the "how to" in a way anyway can understand and make it happen. All I ask is your feedback to this document. I have many other Tool Boxes, download them at www.maintenancephoenix.com.

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  • Hello Chris, thank you for your comment! let me know how I can help further
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  • Can't tell you how many hydraulic failures I've seen due to mig splatter in hydraulic tanks, and that spatter has been super heated and cooled at ambient, these hard little balls have a habit of reaching all parts of a hydraulic circuit, from destroying pumps and motors, to scoring cylinders and pistons, and shuttle valves and pistons in hammers. THEY ARE INDISCRIMINATE
    Manufacturing processes must change!!!

    Hi guys, im Chris Baker, condition monitoring industry
    Just had to get that of my chest
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Tool Box Talk - Welding on Equipment

  1. 1. WELDING ON EQUIPMENT “TOOL BOX TRAINING”Maintenance Supervisors should use this tool to train their maintenance techs, welders andcontractors - 10-20 minutes – Post them in the Maintenance Shop after useElectric Arc caused by welding on equipment is one of the Failure Modes for Rolling Element and NonRolling Bearings. Electric Arcing can also cause electrical component failure in MCCs and ElectricMotors and Drives.So why do we accept this failure mode when it can be eliminated?General Rules which must be followed by maintenance personnel and contractors:(Caution: follow these recommendations only if you want to stop self induced failures caused by welding)1. Ground leads and welding leads must be the same length on all welding machines by maintenance and contractors. (correct immediately)2. Grounding of welded surface must be within 6” of welded surface or a Reliability Engineer must approve the variation to the process. (Post this notice on welding machines)3. All contractors must follow this policy. (insure policy is followed by all)Failure Modes experienced from Maintenance Welding - Electric Arcing caused by Welding on equipment - Flaking caused by Electric Arcing (secondary failure mode)WARNING: Ensure your contractors follow the same process to eliminate electric arcing.Warning: failure to accomplish this one task properly will cause bearing failure by “electric arcing”which is a failure mode of bearings. In addition it will cause failure of many different electricalcomponents. Remember: Electric current from welding will always follow the path of least Resistance.Remember Welders are not reliability experts but professionals who know how to weld to construct and repairusing all types of welding processes. I was a certified welder for many early years and later became a reliabilityspecialist and conducted Root Cause Analysis on many failures around the world and have seen this problem inalmost every plant and site I have visited. Stop this on your site now.If you have questions or comments please send them to me at rsmith@gpallied.com Page 1 of 1 GPAllied 4360 Corporate Road “When commissioning any new existing pump use Vibration Analysis to Suite 110 ensure there are no identifiable defect on the pump or motor” Charleston, SC 29405 www.gpallied.com Office (843) 414-5760 Fax (843) 414-5779 Copyright 2010

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