The number of workshops, manufacturing plants, garages, and industrial concerns utilising welding equipment every day is enormous. It is safe to say that the world as we know it would grind to a shuddering halt without it, and nothing could be more important than ensuring the safe, continued operation of welding equipment everywhere, no matter its use. As an industry leader in the subject, The Edge team is in a fantastic position to advise on any aspects of welding equipment and its maintenance requirements.
An Overview of Welding Equipment Maintenance and its Critical Importance
There are several critical reasons why all welding equipment needs a robust, appropriately spaced schedule of maintenance, including:
- Accident prevention—Welding equipment is no joke. It can be dangerous, especially when malfunctioning or in poor condition. Every welder and business that uses the equipment must ensure it is adequately maintained and poses no unnecessary risk to users.
- Preventing equipment failure—When equipment fails, lives are put at risk, schedules and supply chains break down, and costs are often incurred. Regular, thorough maintenance can avoid all this.
- Maintaining or increasing productivity—The best way to ensure the consistent function of any equipment or tool is to improve or maintain its maximum efficiency through careful maintenance. When standards fall, accidents happen, catastrophic failures become more likely, and work has to be redone, lowering output and profitability.
- Equipment longevity—Nothing will wear out expensive equipment faster than continuing to use it, even in sub-optimal condition, and regular maintenance ensures this is never the case.
Understanding Welding Equipment Maintenance
What do we mean when we talk about welding equipment maintenance? The following list includes some of the actions that should be performed during any competent maintenance inspection:
- Testing for performance issues
- Inspecting the electrics
- Assessing shielding gas cylinders
- Repairing or replacing hoses
- Examining all components and replacing worn or broken parts
The role of maintenance in preventing welding equipment failure
Equipment is more susceptible to damage if not regularly cleaned and maintained. Welding equipment is no exception, and maintenance must be regularly scheduled and performed if failures and dangers are to be mitigated.
Electrical Systems Maintenance
Inspecting electrical components for safety is a cornerstone of any decent maintenance and should include the following routine practices:
- Inspecting all cables and connections for damage
- Removing any accumulated oil and fuel from spillages
- Cleaning wire feeders and drive rolls
- Checking valves and regulators for leaks
Shielding Gas Cylinder Maintenance
It hardly needs to be mentioned that pressurised gas cylinders can be inherently dangerous. If those cylinders become damaged or compromised, the risks are magnified exponentially. Checking the gas cylinders regularly is a non-negotiable aspect of any welding equipment.
Best practices for storing cylinders
Some best practices for storing welding equipment gas cylinders include:
- Understanding the nature and properties of the gas in question—Not all are the same, and it is vital to know the distinctions. Whereas some are inert and unreactive, others are highly reactive and much more dangerous to handle.
- Storing canisters in well-ventilated areas—If leaks occur, having the gas vent away from the area is safer than allowing it to collect.
- Keeping upright and secured to an immovable structure—If unexpected events cause disruption and the danger of items moving around, securing them tightly is the best way to prevent this.
- Using only compatible equipment—As tempting as it might be to find a makeshift solution using non-compatible equipment when components break or wear out, it must be avoided at all costs.
- Wearing the correct protective gear for the gas used—The number of welding equipment users who fail to protect themselves during use is staggering, and a blasé attitude towards personal safety often leads to disaster.
- Inspecting and testing regulators, valves, and hoses
Routine Maintenance Schedule
Opinions vary and may change depending on the exact nature of the equipment; however, a safe maintenance schedule to adopt sees inspections at the following intervals (in hours)
- 8, 50, 100
- 200, 250
- 500, 1000
The Potential Consequences of Neglecting Welding Equipment Maintenance
The potential risks and hazards associated with poor welding equipment maintenance are significant and must be treated with respect. Although substantial, the impact of poor maintenance on equipment life and operational efficiency is nothing compared with the potential danger faced by users of sub-standard equipment.
Conclusion
To summarise, the critical nature of regular maintenance is hard to overstate and affects the following:
- The likelihood of accidents
- Potential equipment failure
- Reduced productivity
- Diminished equipment longevity
Adhering to a strict maintenance schedule might seem unnecessary to those comfortable using the equipment, but we hope this has proven otherwise. For optimal safety and performance, nothing comes close to regular maintenance.
Contact us
Please contact us at The Edge today if you have any questions or comments about what you have read or any other aspect of our products and the industries we supply. Our experienced, knowledgeable representatives will gladly give you all the information you require and any advice and guidance regarding our top-tier welding equipment.