This is not really what you're looking for Al, but some info to consider...
Here's what Z49.1 : 2012 has to say about weld cable insulation repair:
11.5.4 Welding Cable. Welding cable shall be
inspected for wear or damage. Cables with damaged
insulation or connectors shall be replaced or repaired to
achieve the mechanical strength, insulating quality,
electrical conductivity, and water tightness of the original
cable. Joining lengths of cables shall be done by methods
specifically intended for the purpose. The connection
methods shall have insulation adequate for service.
Which is contrary to what OSHA says:
https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=INTERPRETATIONS&p_id=25149I think their view is largely based on “weld lead” that is typically strung out in 50’ – 500’ lengths all over construction jobs like buildings and ships. These are known to be hazardous because the welding machine is typically grounded to the structure being built, which creates a giant circuit in that a bare spot in a lead will arc out on almost anything conductive. This causes fires and situations like this –
http://www.public-health.uiowa.edu/face/Reports/REPORT-017.htmlIn these cases, OSHA 1910.254(d)(9)(iii) is pointing out that damaged leads can’t be “repaired” (which is most typically done through poor application of electrical tape), but they can be cut and spliced through appropriate means, such as-
http://www.northerntool.com/images/product/2000x2000/164/1640820_2000x2000.jpgSo, what we wind up with is a blanket restriction in which any type of “welding cable” that is insulated, has to be replaced, or spliced, if the insulation becomes damaged.
This has little to do with electrical safety. For example:
• Welding ground clamps are not insulated.
• The weldments we weld on are not insulated.
Even though they conduct the same electrical current as the insulated weld lead, during welding operations.
High volume manufacturing operations are so different from those that this OSHA requirement is based on that we suffer, rather than receive a personnel safety benefit, from the restriction. Our expensive, insulated GMAW weld guns cannot be spliced in the case of insulation damage, which means we have to replace in the case of even a small nick in the insulation, regardless of the fact there is no real safety concern in this unique situation.
In the case of our work circuits, or weld ground connections, we use a combination of insulated weld lead and bare copper flat bar, connected to bare steel fixtures and weldments. The example situation below is an unsafe condition because of a tripping hazard. However, it is OSHA compliant as there is no tape or insulation damage. It would not be unsafe if there was a nick in the rubber insulation, though according to OSHA, the weld lead would have to be replaced.
In the bottom picture, because the connecting point between the stripped insulation and the connector lug has been reinforced with tape, it could be defined as an illegal repair by OSHA-
I've worked on oil rigs and in shipyards where hundreds of feet of weld lead are strung out, with bare spots in the insulation arcing out on things they shouldn't, and energizing water puddles. I understand that wrapping a little bit of electrical tape around an insulation tear is not and should not be an approved repair.
However, I think this is a case where over restrictive OSHA blanket requirements have been put in place by clueless people...
Tim