The practical visual inspection part of the AWS-CSWIP examination consists of the following categories:

AWS-CSWIP 3.1 Welding Inspector

Exam: Time allowed Practical butt welded pipe (specification supplied) 1 hour 45 minutes. *Practical assessment of 1 macro (code provided) 20 minutes. To successfully attempt the practical inspection elements of these examinations the inspector will require a number of important tools: 1 2 3 4 Good eyesight. Specialist gauges. Hand tools, ie magnifying glass, torch, mirror, graduated scale, etc. Pencil/pen, report forms, acceptance criteria and a watch.

Good eyesight To effectively carry out your scope of work as a CSWIP qualified Welding Inspector it is important that you have a current eyesight certificate for close vision and a colour blindness test is also required. This must be provided before your CSWIP Welding Inspection examination, as per the CSWIP-WI-6-92 document. All candidates for CSWIP examinations must be tested by a qualified optician. Holders of CSWIP Welding Inspection certificates should thus make every effort to have their vision professionally tested twice yearly. It is important to maintain this level of eyesight. Note: Your close vision ability may decay over time.

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Specialist gauges
A number of specialist gauges are available to measure the various elements that need to be measured in a welded fabrication including: Hilo gauges for measuring mismatch and root gap. Fillet weld profile gauges for measuring fillet weld face profile and sizes. Angle gauges for measuring weld preparation angles. Multi-functional weld gauges for measuring many different weld measurements.

Hi-lo gauge used to measure linear misalignment.

Hi-lo gauge can also be used to measure the root gap.

Rev 1 January 2010 Practical Visual Inspection Copyright TWI Ltd 2010

Adjustable fillet gauge Measures fillet welds from 3-25mm (-1 inch) with 0.8mm (1/32 inch) accuracy. It uses an offset arm, which slides at a 45 angle to make fillet weld length measurements. This gauge also measures weld throat thickness to 1.5mm (1/16 inch).

Fillet weld gauge Measures weld sizes from 3mm ( inch) up to 25mm (1 inch).

Multi-purpose welding gauge This rugged gauge, fabricated in stainless steel, will measure the important dimensions of weld preparations and of completed butt and fillet welds. It is intended for general fabrication work and rapidly measures angle of preparation, excess weld metal, fillet weld leg length and throat size, and misalignment in both metric and imperial.

Digital multi-purpose welding gauge This digital gauge will measure the important dimensions of weld preparations and completed butt and fillet welds. It is intended for general fabrication work and rapidly measures angle of preparation, excess weld metal, fillet weld leg length and throat size in both metric and imperial.

Rev 1 January 2010 Practical Visual Inspection Copyright TWI Ltd 2010

TWI Cambridge multi-purpose welding gauge

Angle of preparation This scale reads 0 to 60o in 5o steps. The angle is read against the chamfered edge of the plate or pipe.

Linear misalignment The gauge can be used to measure misalignment of members by placing the edge of the gauge on the lower member and rotating the segment until the pointed finger contacts the higher member.

Excess weld metal/root penetration The scale is used to measure excess weld metal height or root penetration bead height of single-sided butt welds, by placing the edge of the gauge on the plate and rotating the segment until the pointed finger contacts the excess weld metal or root bead at its highest point.

Pitting/mechanical damage, etc The gauge can be used to measure defects by placing the edge of the gauge on the plate and rotating the segment until the pointed finger contacts the lowest depth. The reading is taken on the scale to the left of the zero mark in mm or inches.

Rev 1 January 2010 Practical Visual Inspection Copyright TWI Ltd 2010

Fillet weld actual throat thickness The small sliding pointer reads up to 20mm ( inch). When measuring the throat it is supposed that the fillet weld has a nominal design throat thickness, as an effective design throat thickness cannot be measured in this manner.

Fillet weld leg length The gauge may be used to measure fillet weld leg lengths up to 25mm (1 inch), as shown on the left.

Excess weld metal can be easily calculated by measuring the leg length, and multiplying it by 0.7 This value is then subtracted from the measured throat thickness = excess weld metal. Example: For a measured leg length of 10mm and a throat thickness of 8mm 10 x 0.7 = 7 (throat thickness 8) - 7 = 1mm of excess weld metal.

Rev 1 January 2010 Practical Visual Inspection Copyright TWI Ltd 2010

FOR TRAINING PURPOSES ONLY Plate and Fillet Acceptance Standard TWI 1
Key: L = length. D = depth or height of defect. W = width of defect (Applicable to inclusions only)
No. 1 2 3 4 5 6 7 Defect name Cracks Porosity, gas pores elongated gas cavities (worm-holes) pipes Overlap Lack of sidewall fusion Lack of root fusion Lack of penetration Inclusions (slag/silica etc) Remarks Max dimension of any area or individual (as applicable) Accumulative total for both defects shall not exceed 20mm Accumulative total for both defects shall not exceed 20mm Accumulative total shall not exceed 15mm total L in weld length (root and face independent) Maximum allowed Not permitted 1mm 20mm in weld face length 20mm in weld root length Individual maximum L<12mm. W<3mm 10%t up to a maximum D 1mm Maximum D 1mm Not permitted Maximum D <10mm t 1.0mm >10mm t 1.5mm Not permitted Seek advice Accept 2mm D maximum 1.5mm D maximum

8 9 10 11 12 13 14 15 16

Undercut Root concavity Underfill/incompletely filled groove/lack of fill Linear misalignment Arc strikes/stray arc Mechanical damage Angular misalignment Excess weld metal* Excess penetration*

Dependent on depth and blend Smooth transition is required/All runs shall blend smoothly. No lack of interun fusion

*When linear misalignment is present the following shall be applied. Excess weld metal Maximum height to be measured from a direct line from the lowest plate, across weldment. Excess penetration Maximum height to be measured from lowest plate.

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Page 1 of 3

EXAMPLE PLATE REPORT

Signature: Welding process: MMA/SMAW Length & thickness of plate: 300mm x 10 mm

Name: [Block capitals] STUART DENT Code/Specification used: TWI 09-09-02 Welding position: Flat /PA

S DENT

Test piece ident: Joint type: Single V Butt Date 8 Nov 2001

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MEASURE

001

A WELD FACE

Lack of sidewall fusion 87 22

Gas pore 1.5 230 236

Undercut smooth 1.5 max 30

FROM THIS

51 8 Slag inclusion

153

40 Underfill 241

Arc Strike

DATUM EDGE

Excess weld metal height : 4mm. Weld width: 12-14mm Toe blend: Poor Linear misalignment: 2mm Spatter along weld length

Page 2 of 3

EXAMPLE PLATE REPORT

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MEASURE
A

WELD ROOT

Root concavity 2 deep Cluster porosity <1.0mm 113 10 10 23

Lack of root fusion 247 20

FROM THIS 128 Lack of penetration 50 DATUM EDGE Penetration height: 4mm max Penetration width: 3 6mm Toe blend: smooth Linear misalignment: 2mm

Page 3 of 3 SENTENCE SHEET for PIPE/PLATE INSPECTION REPORT PRINT FULL NAME S.DENT SPECIMEN NUMBER 001 Face imperfections
Imperfection types Imperfections reported Maximum value or total length 1

Code or specification reference Maximum Code allowed by code section or 2 Table No.3

Sentence Accept or reject 4

Excess weld metal (height) Toe blend/inter-run blend Incomplete filling Slag inclusions Undercut Surface porosity Cracks Lack of fusion Arc strikes Mechanical damage Misalignment

4mm Poor/uneven 40mm 8mm 1.5mm deep None None 87mm 3 Grinding mark 2mm

2mm Smooth None 15mm 10%t Max 1mm 20mm None Seek advice 1.5mm

15 15 10 7 8 4 13 11

Reject Reject Reject Accept Reject Accept Accept Reject Reject? Refer? Reject

ROOT IMPERFECTIONS
Misalignment Penetration (height) Lack of root penetration Lack of root fusion Root concavity Root undercut Cracks Porosity Burn through

2mm 4mm 50mm 20mm 10mm L 2mm None None Cluster <1mm None

1.5mm 1.5mm 20mm 20mm 10%t max 1mm Max 1mm N/A

11 16 6 5 8 2 NA

Reject Reject Reject Reject Reject Accept Accept Accept Accept

This pipe/plate* has been examined to the requirements of [code/specification] TWI 1 and is accepted/rejected* accordingly. [*Delete whichever is not applicable]
Signature.

S DENT

Date.00/00/0000.

Comments:

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Training Sample Only

MACRO INSTRUCTION/REPORT SHEET [I.D: AM1030] CHECK PHOTOGRAPH I.D MATCHES THIS REPORT I.D All defects to be reported [and sized if required] Then sentenced to ISO 5817 Level B [Stringent] Note: Photograph is at X10 Magnification Chapter 1 Material: Low carbon steel Chapter 2 Welding process: [MMA/SMAW]

# 1 2 3 4 5 6 7 8 9 10 11 12

Defect

Size

Accept/Reject

Excess weld metal Excess penetration

Comments Signature: Print full name: Date:

Rev 1 January 2010 Practical Visual Inspection Copyright TWI Ltd 2010

Example/Work Instruction For Macro

Check photograph ident matches form supplied. All line drawing and writing must be in ink. All measurements in mm/ Photograph @ X10 magnification Record actual sizes, therefore divide by 10.
1

Record defects as you see them These macros have been mastered from the photographs interpretation Difficulties have been recorded.
# 1 2 3 4 5 6 7 8 9 10 11 12 Defect Laminations/inclusions Lack of sidewall fusion + slag Slag inclusion Lack of side wall fusion / incomplete filled groove Size 10mmarea 4mm 3mm ---------Accept/reject Accept* Reject Reject Reject

Excess weld metal Excess penetration

2X 4mm None DATE: */*/**

Reject Accept

COMMENTS: * Material defect. Acceptance dependent on application. - seek advice

Signature: e.xame Print full name: Examinee

Rev 1 January 2010 Practical Visual Inspection Copyright TWI Ltd 2010

Training Samples
Macro Examination: Acceptance Standard
(Ref. TWI-N/WIS-ME-sentence-2002-rev 0)
# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Imperfection designation Cracks Porosity/gas pores/ elongated gas cavities [worm-holes] Lack of fusion Incompletely filled groove Undercut Arc strikes/stray flash Excess weld metal * Solid inclusions (slag, silica, etc) Copper inclusions Overlap Lack of penetration Root concavity/shrinkage groove Excessive penetration * Laps, laminations Mechanical damage Angular misalignment Linear misalignment Remarks Maximum dimension of any individual Sidewall, inter-run, root Smooth transition is required Smooth transition is required and all runs shall blend smoothly Any inclusion except copper Depends on application; make your own judgement High/low Chapter 4 Maximum allowance Not permitted 1.5mm Not permitted Not permitted 1mm max. depth Not permitted 1mm + (0.1 x weld width); max. 4mm 1.5mm. Not permitted Not permitted Not permitted 1mm max. depth 1mm + (0.3 x bead width); max. 3.5mm Not permitted Accept 10% t up to max. 2mm

* When linear misalignment is present, measure from the lower plate as shown
Excess weld metal

Excess penetration

Rev 1 January 2010 Practical Visual Inspection Copyright TWI Ltd 2010