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1.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 Welding Inspection Welding Inspection Practical Course Reference WIS 5
2.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 The purpose of this session is to practice the reporting format required by CSWIP in the practical plate examination part of the CSWIP 3.1 Welding Inspectors exam Remember the responsibilities of a Welding Inspector are: Observe Report Compare PlateInspectionPracticePlateInspectionPractice
3.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 To observe welding imperfections you are required to have good close vision acuity A close vision acuity test will be given to you before your exam to establish if your vision meets the minimum standard required Its not just the project that must meet the standard!! You will also require a thorough knowledge of welding imperfections and their likely location, causes and implications ObserveObserve
4.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 TWI Multi-function weld gauge for measuring many different weld measurements. Fillet weld gauges for measuring leg lengths and throat thickness. Hi-Lo gauge for measuring misalignment and root gaps Angle gauges for measuring weld preparation angles A number of specialist welding gauges are available to measure the various elements that need to be measured in a welded fabrication including SpecialistWeldingGaugesSpecialistWeldingGauges
5.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 TWIMultipurposeWeldingTWIMultipurposeWelding GaugeGauge 60 50 40 0 1/4 1/2 3/4 1 0 5 10 15 20 IN MM 15 1/2 IN MM 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
6.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 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 60 50 40 0 1/4 1/2 3/4 1 0 5 10 15 20 IN MM MM 15 1/2 MMIN TWIMultipurposeWeldingTWIMultipurposeWelding GaugeGauge
7.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 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. 60 50 40 0 1/4 1/2 3/4 1 0 5 10 15 20 IN MM MM 15 1/2 MMIN TWIMultipurposeWeldingTWIMultipurposeWelding GaugeGauge
8.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 60 50 40 0 1/4 1/2 3/4 1 0 5 10 15 20 IN MM MM 15 1/2 MMIN Excess weld metal The scale is used to read off these dimensions up to a maximum of 25mm and 1 inch TWIMultipurposeWeldingTWIMultipurposeWelding GaugeGauge
9.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 Fillet weld leg length The scale is used to read off these dimensions up to a maximum of 25mm and 1 inch. 60 50 40 0 1/4 1/2 3/4 1 0 5 10 15 20 IN MM MM 15 1/2 MM IN TWIMultipurposeWeldingTWIMultipurposeWelding GaugeGauge
10.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 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 60 50 40 0 1/41/23/4 1 0 5 10 15 20 IN MM MM 15 1/2 MM IN TWIMultipurposeWeldingTWIMultipurposeWelding GaugeGauge
11.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 Leg Length Gauge G.A.L. S.T.D. 10mm 12m m 16mm 3mm 6mm 9m m5m m 4mm L Throat Thickness Gauge G.A.L. S.T.D. 10mm 12m m 16mm 3mm 6m m 9m m5m m 4mm T FilletWeldGaugesFilletWeldGauges
12.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 HILOWeldingGaugeHILOWeldingGauge HI-LOSinglePurposeWeldingGauge 1 2 3 4 5 6 Root gap dimension Internal alignment
13.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 M.S.Rogers PlatePipeInspectionPlatePipeInspection SectionRef23Copyright © 2003 TWI Ltd WI 3.1
14.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 PlateInspectionPracticePlateInspectionPractice 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
15.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 1) Use a pencil for the arrow lines, but make all written comments and measurements in ink only 3) Do not forget to compare and sentence your report 2) Report everything that you can observe 4) Do not forget to date & sign your report 5) Make any observations, such as recommendations for further investigation for crack-like imperfections. PlateInspectionPointsPlateInspectionPoints
16.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 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) ThumbPrintReportSketchThumbPrintReportSketch The thumb print report sketch used in CSWIP exam will look like the following example.
17.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1PlateThumbPrintReportPlateThumbPrintReport ExampleExampleName (Block capitals) Joe BLOGGS Signature Joe Bloggs Test piece identification Example 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 10 30 Cap undercut D = 1.0 53 5 Poor stop/start 24 63 Porosity Incomplete filled groove + Lack of side wall fusion 42 130 Mechanical damage D = 2 32 140 23 Note: all dimensions in mm # Excessive cap height full weld length H = 5mm max
18.
M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 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. FinalReportFinalReport
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 PlateFinalReportExamplePlateFinalReportExample Defect Type Reinforcement (Height) Reinforcement (Appear) Incomplete filling Inadequate weld width Slag Inclusions Undercut Surface Porosity Cracks/Cracklike Defect Lack of fusion Arc Strike Mechanical Damage Laminations Misalignment Longitudinal Seams Plate/Pipe Section Accumulative Total Maximum Allowable Section No Accept Reject Defects Noted Code or Specification Reference EXTERNAL DEFECTS A - C L = 300 H=2.5 max 2.0 mm 14 Reject A - C L=300 Not smooth Smooth 14 Reject A - B L=24 None 13 Reject A - C AcceptNone Accept Reject A - C A - C A - C A - B A - B None 2L=24 D=1.5 sharp 10% t AcceptNone Reject6L=8mm None AcceptNone RejectA - B 42 Areas None ReferA - B 152 Areas smooth Seek Advice A - C A - C AcceptNone A - C AcceptNone AcceptNone Pipe only
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 This Pipe/plate has been examined to the requirements of [code/specification] …………………… And is accepted/rejected accordingly. ROOT DEFECTS Misalignment Excessive Penetration Lack of Penetration Lack of Root Fusion Root Concavity Root Undercut Crack/Cracklike Defect Slag Inclusions Porosity A - C AcceptNone B - C L=24 D=2.5mm 2.0 mm 1 Reject B - C L=10 25 mm 11 Accept A - C AcceptNone A - C AcceptNone A - B AcceptL= 27 D=0.5 sharp A - C AcceptNone A - C AcceptNone A - C AcceptNone 10% t 2 BW/VI/00 Signature …………………………………. Date ……………………….. MSRogers 14/9/02 Use the other side for comments PlateFinalReportExamplePlateFinalReportExample
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 PipeInspectionPracticePipeInspectionPractice 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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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 Page 1 of 3 CSWIP VISUAL INSPECTION PIPE REPORT Name [Block capitals]____________ Signature_________Pipe Ident#________ Code/Specification used_________W elding Process_______ Joint type______ W elding position__________ Outside & Thickness_____ Date ________ A B C C D A Complete as per plate report form PipeThumbPrintReportPipeThumbPrintReport ExampleExample
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 PipeCode:API114PipeCode:API114 Reinforcement Height: 7.8.2 page 20 Reinforcement Appear: 7.8.2 page 20 Incomplete groove: 7.8.2 page 20 Inadequate weld width: 7.8.2 page 20 Slag inclusions: 9.3.8 page 22 Undercut: 9.3.11 page 22 Porosity: 9.3.9 page 24 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 Misalignment: Not referenced Longitudinal seams:Not referenced Excess penetration: Not referenced Lack of penetration: 9.3.1/9.3.2 page 21 Lack of root fusion: 9.3.5 page 21 Concave root: 9.3.6 page 22 Burn through: 9.3.7 page 22
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 MacroInspectionMacroInspection M.S.RogersSectionRef23Copyright © 2003 TWI Ltd WI 3.1
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 Remember in the CSWIP 3.1 Welding Inspectors examination your are required to conduct a visual examination of two macro samples Time allowed 45 minutes Code ISO 5817 Level stringent B MacroInspectionPracticeMacroInspectionPractice
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 PLEASE READ CAREFULLY You have been provided with one or two macro samples and the report sheets you are required to complete the following 1. Ensure that you record your name and the date on the report sheet 2. Ensure that you sign the report sheet 3. Visually inspect the specimens and report: The defects type The defects size, length, depth and height if applicable 4. Comment on each defect e.g accept, reject or refer in accordance with ISO 5817 stringent B ALL LINE DRAWING & WRITING MUST BE COMPLETED IN INK ALL MEASUREMENT IN MM / PHOTOGRAPH AT 10X MAGNIFICATION. DIVDE ALL MEASUREMENTS BY 10 AND RECORD ON REPORT PROVIDED NO LIQUID PAPER OR CORRECTION FLUID PERMITTED. CORRECTIONS MUST BE CROSSED OUT AND THE CORRECTION MADE TIME ALLOWED FOR TWO MARCS 45 MINUTES MarcoInspectionMarcoInspection InstructionsInstructions
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1Page 6 ISO 5817 : 1992
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 Acceptance levels B,C,D For the CSWIP 3.1 exam stringent B Maximum pore diameter 3mm or pore diameter shall be less than or equal to 0.3 X plate thickness Page 7 ISO 5817 : 1992 M.S.RogersCopyright © 2003 TWI Ltd SectionRef23
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 Specimen Thickness(mm) 8 15 30 60Defect Overlap Incomplete penetration Lack of sidewall fusion Gas pore Slag inclusion Elongated cavity Linear misalignment Cap undercut Crack Spatter Dimensions H = 1.5 L = 2.0 L = 2.0 D = 2.5 1.0 x 2.0 0.5 x 1.5 H = 1.8 D = 0.4 L = 1.5 D = 1.8 R R R R R R R R R R R R R A A A A A A A A A A A R R A A A A A A R R R R X X X X Using ISO 5817 determine the acceptability of the defects listed. Under the column headed specimen thickness, insert A,R and X A = Accept R = Reject X = Refer Use the acceptance category stringent B when making your assessment assume specimens to be plate butt welds ISO5817ExerciseISO5817Exercise
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 1 2 3 4 5 DEFECT SIZE ACCEPT/REJECT 1 Lack of sidewall fusion + Slag 3 x 4 mm Reject Reject Accept Accept 2 3 4 5 6 7 8 10 11 12 Lack of sidewall fusion Slag inclusion Cap undercut 3 mm 1.5 mm 0.5 mm Plate lamination 5.2 mm Refer* Excess weld metal Excess root penetration 4 mm None Accept Reject CHECK PHOTOGRAPH IDENT MATCHES FORM SUPPLIED. ALL LINE DRAWING & WRITTING MUST BE IN INK. ALL MEASUREMENTS IN MM / PHOTOGRAPH AT X10 MAGNIFICATION RECORD DEFECTS AS YOU SEE THEM THESES MACROS HAVE BEEN MASTERED FROM THE PHOTOGRAPHS INTERPRETATION DIFFICULTIES HAVE BEEN RECORDED. COMMENT ONLY IF A DEFINITE UNCERTAINTY EXISTS: i.e SLAG/GAS IN SOME CASES COMMENTS: *Materials defect acceptance dependent on application. Seek advice. Name: Mark Rogers Signature: M S Rogers Date: 20/03/03 MarcoReportExampleMarcoReportExample
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M.S.Rogers TECHNOLOGY SectionRef23Copyright © 2003
TWI Ltd WI 3.1 AnyQuestionsAnyQuestions M.S.RogersCopyright © 2003 TWI Ltd SectionRef23
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