23-WIS5 Visual Inspection 2006-1

CSWIP 3.
1 Welding Inspection
Practical
TWI Training & Examination

Services
Course Reference WIS 5
Course notes section reference 23
World Centre for Materials Joining Technology Copyright © 2006, TWI Ltd
Weld Examination
Page 1 of 3 PLATE REPORT - EXAMPLE
Name: [Block capitals] xxxxxxxxxxxxSignature: ssssssss Test
: piece Identity: 001
Code/Specification used:
TWI 09-09-03 Welding Process: MMA/SMAW Joint Type: Single-V butt
Welding Position: Flat /PA Length &Thickness of Plate:

300mm x 10 mm Date 02/04/2005
PLATE
MEASURE
WELD FACE mechanical 236

damage
A B C
lack of sidewall fusion undercut
gas pore
FROM
(+ incomplete fill) 1.5 max

1.5 Ø
87 246
22 230
30
THIS
51 8 153 40
D A T U M - E D G E OF
arc strike
slag
centreline 261
inclusion
crack
Excess weld metal: 4 max
Weld appearance / toe blend: poor
Linear misalignment: 2 max
Angular distortion: present
Spatter: over full length of weld
Oxide scale: on both plates
Weld Examination
ACCEPTANCE STANDARD
Plate Inspection: Acceptance Standard
Ref. TWI-N/WIS-PI-sentence
Rev 2
# IMPERFECTION REMARKS LIMITS FOR

DESIGNATION IMPERFECTION
(see Key below)
1 Cracks all types of cracks not permitted
2 Porosity/Gas pores/elongated cluster: max. dimension of area L = 13mm max.
Gas cavities [wormholes]/pipes single pore: max. dimension L = 1mm max.
3 Lack of sidewall fusion sum of total length in weld face L = 15mm max.
4 Overlap sum of total length in weld face L = 30mm max.
5 Incompletely filled groove not permitted
6 Undercut (face & root) smooth transition is required D = 1mm max.
7 Arc strikes/stray flash not permitted
8 Excess weld metal * smooth transition is required and all runs D = 3mm max.
shall blend smoothly
9 Inclusions (slag and silica) sum of total length for weld face (or root) L = 50mm max.
10 Lack of root fusion sum of total length in weld root L = 30mm max.
11 Lack of root penetration sum of total length in weld root L = 15mm max.
12 Root concavity/shrinkage groove D = 2mm max.
13 Excessive penetration * D = 2mm max.
14 Mechanical damage dependent on extent & severity seek advice
(make your own
judgement)
15 Linear Misalignment high/low D = 10% t max.
* when linear misalignment is present, excess weld metal and excessive penetration
should be
measured from the lower plate (as shown below)
excess weld
metal height
excess penetration bead height
Weld Examination
SENTENCING (Accept/Reject)
WELD INSPECTION REPORT/SENTENCING SHEET
PRINT FULL NAME

SPECIMEN NUMBER Example Only PLATE
THICKNESS = 11mm
EXTERNAL DEFECTS Defects Noted Code or Specification Reference

Defect Type Pipe/Plate Accumulative Maximum Section/ Accept/Reject
Section Total Allowance Table No.
1 2 3 4 5
Excess Weld Metal (Height) A-C 3 max 3 8 accept
Excess Weld Metal (Appearance) A-C smooth smooth 8 accept
Incomplete filling A-C 35 none 5 reject
Inadequate Weld Width A -C none - - accept
Slag Inclusions A-C none - - accept
Undercut A-C 1.5 max. 1 6 reject
Surface Porosity A-B cluster 8 13 2 accept
isolated 2 dia. 1 reject
Cracks/Crack-like Defects B-C none - - accept
Lack of Fusion B-C 67 15 3 reject
Arc Strikes B-C 1 none 7 reject
Mechanical Damage A-C 1 area not defined 14 reject *
Laps/Laminations A-C none - - accept
Misalignment A-C 1 max 10% t (= 1.1) 15 accept
Longitudinal Seams (pipe) N/A - - - accept
TWI Multi-Purpose Welding Gauge
IN
1/4 1/2 3/4
0
Angle of preparation
The scale reads from 0o to 60o in steps of
5o. The angle is read against the
chamfered edge of the segment
IN
1/4 1/2 3/4
0
Misalignment
The scale is used to measure misalignment of
components by placing the edge of the gauge
on the lower one and rotating the segment until
the pointer contacts the higher piece
IN
1/4 1/2 3/4
0
Undercut
The scale reads from 0 in the negative
up to 5m. The segment is rotated until
the pointer reaches the full depth of the
undercut.
IN
1/4 1/2 3/4
0
Excess weld metal

The scale is used to read off these
dimensions up to a maximum of 25mm
and 1 inch
IN
1/4 1/2 3/4
0
Fillet weld leg length

The scale is used to read off
these dimensions up to a
maximum of 25mm and 1 inch.
3/4 1/2 0
1/4
IN
Fillet throat thickness

The sliding pointer reads up to 20mm and
3/4 inch. In measuring throat thickness it is
assumed that the fillet weld has normal root
penetration
Fillet Weld Gauges
10mm
G.A.L.
L S.T.D.
16mm
Leg Length Gauge
10mm
G.A.L.
S.T.D.
16mm
Throat Thickness Gauge

HI-LO Welding Gauge
6
Root gap
dimension
HI-LO Single Purpose Welding Gauge
Internal
alignment
Plate / Pipe Inspection
Plate Inspection Examination
Remember in the CSWIP 3.1 Welding Inspectors

examination your are required to conduct a practical
examination of a plate test weld, complete a thumb
print sketch and a final report on your findings
 Time allowed 1 hour and 15 minutes
 The code is provided
Plate Inspection Points
1) Use a pencil for the arrow lines, but make all

written comments and measurements in ink
only
2) Report everything that you can observe
3) Do not forget to compare and sentence your

report
4) Do not forget to date & sign your report
5) Make any observations, such as

recommendations for further investigation for
crack-like imperfections.
Plate Thumb Print Report
After you have observed an imperfection and

determined its type, you must be able to take
measurements and complete the thumb print report
sketch
The first thumb print report sketch should be in the
form of a repair map of the weld. (i.e. All
observations are Identified Sized and Located)
The thumb print report sketch used in CSWIP exam

will look like the following example.
Name (Block capitals) Joe BLOGGS Signature Joe Bloggs Test piece identification Example 1
Code used PH6/WI/00 Welding process MMA (SMAW) Joint type Single V Butt
Welding position Flat 1G/PA Length & thickness L=300mm D = 12.5mm Date
16/07/02
Mechanical
damage 23
D=2
140
Cap undercut D = Porosity max dia 1.5 32
10 1.0 63 24
30
5 42
53 Poor stop/start 130
Incomplete filled groove +
Lack of side wall fusion
Note: all dimensions in mm

# Excessive cap height full weld length H = 5mm max
Plate Inspection Final Report
After you have completed your thumb print report

sketch of your test plate the next step is to complete
your final report again the report must be completed in
ink (no pencil).
The report must be completed to your thumb print
sketch, do not leave any boxes empty, every box must
be completed or dashed out. You must also make any
comments you feel are necessary regarding any
defects observed.
The report form used in CSWIP will look like the

following example.
EXTERNAL DEFECTS Defects Noted Code or Specification Reference

Plate/Pipe Accumulative Maximum Section Accept
Defect Type Section Total Allowable No Reject
Reinforcement (Height) A-C L = 300 H=2.5 max 2.0 mm 14 Reject
Reinforcement (Appear) A - C L=300 Not smooth Smooth 14 Reject
Incomplete filling A-B L=24 None 13 Reject
Inadequate weld width A-C None Accept
Slag Inclusions A-C None Accept
Undercut A-B L=24 D=1.5 sharp 10% t 2 Reject
Surface Porosity A-C None Accept
Cracks/Cracklike Defect A - B L=8mm None 6 Reject
Lack of fusion A-C None Accept
Arc Strike A-B 2 Areas None 4 Reject
Mechanical Damage A-B 2 Areas smooth Seek Advice 15 Refer
Laminations A-C None Accept
Misalignment A-C None Accept
Longitudinal Seams A-C None Pipe only Accept
ROOT DEFECTS
Misalignment A-C None Accept
Excessive Penetration B - C L=24 D=2.5mm 2.0 mm 1 Reject
Lack of Penetration B-C L=10 25 mm 11 Accept
Lack of Root Fusion A-C None Accept
Root Concavity A-C None Accept
Root Undercut A-B L= 27 D=0.5 sharp 10% t 2 Accept
Crack/Cracklike Defect A - C None Accept
Slag Inclusions A-C None Accept
Porosity A-C None Accept
This Pipe/plate has been examined to the requirements of

BW/VI/00
[code/specification] ……………………
And is accepted/rejected accordingly.
MSRogers
Signature …………………………………. 14/9/02
Date ………………………..
Use the other side for comments
Pipe Inspection
Remember in the CSWIP 3.1 Welding Inspectors

examination your are required to conduct a
practical examination of a pipe test weld, complete
a thumb print sketch and a final report on your
findings
 Time allowed 1 hour and 45 minutes
 The code is nominated e.g API 1104
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A B C
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Complete as per plate report form
Pipe Code API 1104
Reinforcement Height: 7.8.2 page 20 Misalignment: 7.2 page 19
Reinforcement Appear: 7.8.2 page 20 Longitudinal seams:Not referenced
Incomplete groove: 7.8.2 page 20 Excess penetration: Not referenced
Inadequate weld width: 7.8.2 page 20 Lack of penetration: 9.3.1/9.3.2 page 21
Slag inclusions: 9.3.8 page 22 Lack of root fusion: 9.3.4 page 22
Undercut: 9.3.11 page 24 Concave root: 9.3.6 page 22
Porosity: 9.3.9 page 24 Burn through: 9.3.7 page 22
Cracks: 9.3.10 page 24
Lack of fusion: 9.3.4 page 22
Arc strikes/arc burns: A.5.3 page 55
Mechanical damage: Not referenced
Lamination: Not referenced

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23-WIS5 Visual Inspection 2006-1

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CSWIP 3.

TWI Training & Examination

Welding Position: Flat /PA Length &Thickness of Plate:

WELD FACE mechanical 236

(+ incomplete fill) 1.5 max

# IMPERFECTION REMARKS LIMITS FOR

excess penetration bead height

PRINT FULL NAME

EXTERNAL DEFECTS Defects Noted Code or Specification Reference

Excess weld metal

Fillet weld leg length

Fillet throat thickness

Leg Length Gauge

Throat Thickness Gauge

Remember in the CSWIP 3.1 Welding Inspectors

 Time allowed 1 hour and 15 minutes

 The code is provided

1) Use a pencil for the arrow lines, but make all

3) Do not forget to compare and sentence your

5) Make any observations, such as

After you have observed an imperfection and

The thumb print report sketch used in CSWIP exam

Note: all dimensions in mm

After you have completed your thumb print report

The report form used in CSWIP will look like the

EXTERNAL DEFECTS Defects Noted Code or Specification Reference

This Pipe/plate has been examined to the requirements of

Remember in the CSWIP 3.1 Welding Inspectors

 Time allowed 1 hour and 45 minutes

 The code is nominated e.g API 1104

Complete as per plate report form

Reinforcement Appear: 7.8.2 page 20 Longitudinal seams:Not referenced

Incomplete groove: 7.8.2 page 20 Excess penetration: Not referenced

Inadequate weld width: 7.8.2 page 20 Lack of penetration: 9.3.1/9.3.2 page 21

Slag inclusions: 9.3.8 page 22 Lack of root fusion: 9.3.4 page 22

Undercut: 9.3.11 page 24 Concave root: 9.3.6 page 22

Porosity: 9.3.9 page 24 Burn through: 9.3.7 page 22

Cracks: 9.3.10 page 24

Lack of fusion: 9.3.4 page 22

Arc strikes/arc burns: A.5.3 page 55

Mechanical damage: Not referenced

Lamination: Not referenced

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