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Poor maintenance and subsequent failure of welding equipment

During a recent mobilisation on a member’s vessel, sub-contractors were burning and welding sea fastenings on the main deck. Following a report that flames were coming from the contractors’ acetylene tank regulator situated inside the holding gas quad, a small fire was extinguished at the regulator, which was then cooled and removed for inspection (see Figure 1). On examination it was found that thread tape was being used in all the connections on the contractors’ equipment.

Figure 1 - Leaking regulator — Figure 1 – Leaking regulator

Figure 2 - Leaking regulator in-situ — Figure 2 – Leaking regulator in-situ

Further incidents with welding equipment on the same vessel were:

A ship welding cable was found to be smouldering at a connection point;
A midway cable connector was found arcing and smoking during deck welding operations;
A nozzle head was found detached from an oxy-acetylene torch.

Figure 3 - Welding cable found to be smouldering — Figure 3 – Welding cable found to be smouldering

Figure 4 - Midway cable connector found arcing and smoking — Figure 4 – Midway cable connector found arcing and smoking

Figure 5 - Detached nozzle head — Figure 5 – Detached nozzle head

The company would like to highlight the potential hazards of lack of control and maintenance of ship’s and sub-contractors’ welding equipment, as there have been a number of incidents involving welding equipment in a poor state of repair and being used whilst unfit for purpose onboard recently.

Members are also referred to the following incident report issued by the Marine Safety Forum regarding a further welding incident.

It highlights an incident involving a welder who was adjusting the pressure on an oxygen regulator. The welder had oil on his hand and there was an oxygen leak from the hose clamp. As a result the welder’s hand was badly burnt. Oxygen under pressure and hydrocarbons (oil and grease) can react violently, resulting in explosions, fire and injury to personnel and damage to property. Never allow oil or grease or any organic matter to come into contact with oxygen under pressure.

Figure 6 - Location of oxygen leak from hose clamp — Figure 6 – Location of oxygen leak from hose clamp

Figure 7 - Welder's burnt hand following oxygen/hydrocarbon fire at leaky hose clamp — Figure 7 – Welder’s burnt hand following oxygen/hydrocarbon fire at leaky hose clamp

Figure 8 - Welder's burnt hand following oxygen/hydrocarbon fire at leaky hose clamp — Figure 8 – Welder’s burnt hand following oxygen/hydrocarbon fire at leaky hose clamp

A member has provided the accompanying checklist for welding equipment which may be useful to members.

Safety Event

Published: 19 June 2009
Download: IMCA SF 09/09

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