Welding and gas cutting happen on almost every construction site, plant and workshop in India, and they are behind many fires, burns and electric shocks. A damaged cable, a missing earth clamp, a leaking hose or a spark landing on stored material can turn a routine job into a serious incident. Many of these hazards are visible before the work starts. A short pre-use check of the machine, the gas set and the work area, backed by a hot work permit, prevents them. This checklist covers it, and shows how supervisors track every welding set in HVI.
Welding Machine Pre-Use Safety Checklist for Indian Sites
Cables and connections, earthing, electrode holders, gas cylinders and flashback arrestors, ventilation, fire safety, PPE and hot work permits.
Arc Welding Machine Checks
Check these with the machine switched off before every job. Do not use a set with any defect.
Machine and supply
- Casing and covers in place
- Supply cable and plug undamaged
- Switch and controls work properly
Welding cables
- No cuts, burns or bare copper
- Joints made with proper connectors
- Cables kept clear of traffic and water
Earthing and return
- Machine body earthed
- Return clamp fixed close to the work
- Clean, tight connection
Electrode holder
- Insulation intact, no cracks
- Jaws grip the electrode firmly
- Cable joint secure and covered
Gas Cutting Set Checks
Oxygen and fuel gas sets carry their own fire and explosion risks. Check every part before lighting the torch.
| Item | What to check | Do not use if |
|---|---|---|
| Cylinders | Upright, chained and valves in good order | Damaged, leaking or unsecured |
| Regulators | Gauges readable, fittings tight | Broken gauge or leaking connection |
| Hoses | Correct colours, clamps, no cracks | Cracked, burnt or taped repairs |
| Flashback arrestors | Fitted on both gas lines | Missing or damaged |
| Torch | Valves, nozzle and connections | Leaking valves or damaged nozzle |
Never use oil or grease on oxygen fittings, as they can ignite. Keep cylinders upright and secured, test for leaks with soapy water, never with a flame, and close the cylinder valves when work stops.
Take Unsafe Welding Sets Out of Use Straight Away
HVI gives welders and supervisors this checklist on their phones, records defects with photos and marks any failed set as out of use until it is repaired.
Ventilation and Personal Protection
Welding fumes, UV light and hot metal harm welders and the people around them.
- Weld in open or well-ventilated areas
- Use fume extraction in enclosed spaces
- Follow confined space rules where they apply
- Screen the area to protect others from arc flash
- Welding helmet with the correct filter shade
- Flame-resistant clothing and leather gloves
- Safety shoes and apron
- Respiratory protection where fumes are heavy
Fire Safety Before, During and After Work
Some welding fires start after the welder has left, from sparks smouldering in hidden places.
Before
Clear or cover combustibles and get the permit.
During
Keep an extinguisher and fire watcher close.
After
Watch the area for smouldering after work ends.
Close out
Switch off, close valves and sign off the permit.
Welding Equipment Register in HVI
A sample view of welding and cutting sets across a site, showing each set's latest check.
| Equipment | Location | Last pre-use check | Defect | Status |
|---|---|---|---|---|
| WS-04 arc welder | Fabrication yard | Today, 8:10 am | None | In use |
| GC-02 cutting set | Steel store | Today, 8:25 am | Hose clamp loose | Fix before use |
| WS-07 arc welder | Basement level 2 | Today, 8:40 am | Bare cable near holder | Out of use |
Welding Safety FAQs
What should be checked on a welding machine before use?
The machine casing and supply cable, welding cables and joints, machine earthing, the return clamp and the electrode holder, along with the work area, fire extinguisher and the welder's PPE.
Why are flashback arrestors needed on gas cutting sets?
They stop a flame travelling back through the hose into the regulator or cylinder, which could cause a fire or explosion. They should be fitted on both the oxygen and fuel gas lines.
What is a hot work permit?
It is a written approval for welding, cutting or other spark-producing work, confirming that the area has been made safe, fire protection is in place and a fire watcher is assigned before work starts.
How long should a fire watch continue after welding?
Keep watching the area for a period after work ends, as set by your site rules, because sparks can smoulder before flaring up. Teams that record permits in HVI can log when the watch ended.
Can welding equipment checks be done on a phone?
Yes. Each set gets its own record, and welders log their pre-use check and any defects with photos. Book a demo to see welding checklists in HVI.
Safer Hot Work on Every Site
Check every welding and cutting set before use, run hot work permits and keep an equipment register in HVI. Fewer fires, fewer shocks and safer welders.
