G, 46 SCRIBD Cari @) TWI WZ Practical Visual Inspection: (Prepared for CSWIP 3.0 Exarrination) ‘THE WELDING INSTITUTE The CSWIP (Certification Scheme for Welding scheme for welding inspectors consists at pre & Inspection Personnel) examination the following categories WIP 3, w CSWIP 3.1 Welding Inspector CSWIP 3.2 Senior Welding Inspector “The CSWIP 3.0 3.1 and AWS CWI ~ CSWIP 3.1 Bridge examination contents and respective timings are given below: Exam Time CSWIP 3.0 , £.(Code provides ‘hour 45 minutes tical fillet wa a . hour 15 minutes Total time: 3 hours CSWIP 3.1 Practical butt welded butt joint in plate (Code provided) hour 15 minutes Practical butt welded butt joint in pipe (Nominated code*) Thor 4S minutes Practical assessment of2 macros (Code provided) 45 minutes “Theory Specific. (4 from 6 narrative questions) 1 hour 15 minutes ‘Theory General. (30 Multi choice questions) 30 minutes. ral. (Questions on code and general inspection) 15 minutes. Total time: Shours 48 minutes * Nominated code is supplied by the candidate AWS CWI-CSWIP 3.1 Bridge Practical butt welded but joint in pipe (Code provided) ‘hour 45 minutes. Practical assessment of | macro (Code provided) 25 minutes. “Theory Specific. (I long 9 short narrative questions) 1 hur 20 minutes ‘Total time: 3 hours 30 minutes ‘Welding Inspection of Socks WIS Section 23 Practical Viewl Inspection Rev 0-03.07 Copyright © 2007 TWL Biddle os S oO re) Gi FW sens CLM Sees Beranda Buku Buku audio Dokumen‘Welding Inspection of Seale WIS Section _ FH WELDING INSTITUTE Conditions for Visual Inspection: ‘The conditions for visual inspection ean are affected mainly by the following 1) Lighting. 2) Angle and distance of viewing. Light: 1 is essential that there is adequate lumination (lighting) present during inspection and that the access and angle of viewing are suitable. BS EN 970 states that the minimum light conditions shall be 350 lux, but recommends S00 lux (sinilar 10 ‘normal shop of office lighting). 500 lux is also the accepted minimum light level for CSWIP Welding Inspection examinations. Angle and Distance: BS EN 970 also states that viewing conditions for direct inspection shall be within 600mm af the surface and the viewing angle (lin from eye to surface) t0 bent less than 30° [twill be fairly obvious that increasing distance from an object will impaie the ability to identify smaller areas of interest with any clarity, though it can also occu that too close a distance ean detract from the overall picture of the weld. For general visual inspection of | welds there is generally an optimum viewing range of 150 ~ 500 mm where inspection can comfortably be carried out. Optical viewing devices such as magnifying lenses may bbe used duting inspection to aid observation though the level of magnification allowable is generally given in the applied standard. In BS EN 970 the limits re set from 2x ~ 5x ‘magnification. Effective viewing range 30° 11 should also be remembered that itis very good practice to carry out visual inspection Using a variety of viewing angles as some imperfections particularly mechanical damage can only’be identified when viewed in reflected light ‘This can be mast easily soen when using the plastics taining replicas supplied during the course and the CSWIP practical examination wher itis advisable to view all surfaces in reflected light, as it soften difficult o abserve slight mechanical damage such as light vindng marks, or slightly corroded surface when viewing only at 90° 23 Practical Visual Inspection PWT sitoncsown Rev M0307 Copyught © 2007 TWLAMdle at CLAP ecco Ss oO m Gi Beranda Buku Buku audio Dokumen_—————— ES TH \ELDING INSTITUTE For # candidate to make a respectable attempt at any practical inspection parts of his CSWIP examination he/she will need tobe in possession of a numberof important items atthe exam the venue: 1) Gondelose vision acuity. (Keen eyesight) 2) Specialist Gauges and useful hand tools. Toreh, mirsr, araduated seale ete 3) Nominated Specification if applicable. Pencil/pen, anda watch 4) All examination report forms for the practical exams i.e. Macro’Pipe/Plate (Supplied to the candidate by the CSWIP exam invigilator) 1) Good Close Vision Acuity To effectively camy out visual inspection a qualified CSWIP 3.1 Weldi should possess close vision acuity of an aeceptable minimum level, thus atest certificate ‘of close vision acuity must be provided before examination in any CSWIP Welding, Inspection, or NDT subject. It is also sometimes very imponané for an inspector 10 distinguish between contrasting colours in order to effectively incerpeet results ef colour contrast penetrant, luorescent penetrant and fluorescent magnetic particle inspection twsis. Therefore all candidates for CSWIP examinations mus also submit a colour blindness test cenifiate for the effected colours. Any vision certification dated over 6 months previous to the exam date will not be acceptable to the CSWIP management board as any proof of the welding inspectors current vision abilities. All inspectors should be avvare of the sudden decay of human visual abilities and should make every clfort to attend a vision test at least twice yearly. Inspectors who use optical devi should regulaly check that ther aided eyesight has not further deteriorated below limit Inspector 2) Spectalist Gauges A number of specialist gauges are available to measure the various clements that need to ‘he measured in a welded fabrication including 4) Hi—Lo gauges, for measuring mismatch between pipe walls ») Fillet weld profile gauges, for measuring fillet weld face profile and sizes. ©) Angle gauges, for measuring weld preparation ang. 4d) Multifunctional weld gauges, used to measure many Weld values. Pages 23.41 23.5 Types of gaug their measuring ranges al aecuracy are also detailed in BS EN 970 3) Nominated Specification Al specificetion’s required forthe CSWIP 3.0 Visual Welding Inspector examination are supplied by the examining contre This is similar in style to specification TVit 09.0206 found on page 23.7 and included for the purposes of practical inspection practice. Welding epeston of Secs WH Be TWH sennccen Section 25 Practieal Visual Inspection Day Sass Rev ML.07 Copsrght © 2007 TEMA Eat Ss Berand, oO m Gi ja Buku Buku audio Dokumen(a5) A = §} SCRIBD | Cari TWI Ml. THE TWI CAMBRIDGE MULTI-PURPOSE WELDING GAUGE ‘THE WELDING INSTITUTE A tool used in the closeestimation of weld dimensions (ccurucy linittions) Adjusting serews, Linearseale (Root face/gap) Radial Seale, Linear Seale (Fillet throat) Lingar and radial seales are given in mm and inches, with angels measured in degrees. ry Angle of Preparation This scale reads 0” to 60” in 5° stops leis read against the chamfered Fillet Weld Actual Throat Thickness Tire small sliding pointer reads up to 20mm, oF % inch. When measuring the throat itis supposed that the fillet weld has “nominal” design throat thickness, as ‘effective’ design throat thickness cannot be measured in this manner Excess weld metal can be readily calculated by measuring the Leg Length, then ‘multiplying by 07 “This valucis subtracted from the measured Throat Thickness ~ Excess Weld Metal. Example: Fors measured Leg Length of 10mm and Throat Thickness of § mm Row MEOR07 Copyright = 2007 TWL Vale Oo S oO re) Gi Beranda Buku Buku audio Dokumen= §} SCRIBD | Cari ‘THE WELDING INSTITUTE Fillet Weld Leg Length ‘The gauge may be used to measure fillet weld leg lengths <25mm as shown, Limear Misalignment ‘The gauge may be used to measure rmisaligament of members by placing the cedge 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 but welds, by placing the edge of the ‘gauge on the plate ané rotating the segment until the pointed finger contacts the excess. weld ‘metal orroot bead at its highest point, Undereut “The gauge may be used to measure undercut by placing the edge of the gauge on the plate and rotating the segment until the pointed finger contacts the furthest depth ofthe undercut ‘The reading is taken in the « seale (left of zer0) inmm or inches. Fillet weld leg length size & profile gauge Teidaginpatnot Secs WSS x3 ‘Section 23 Practical Visual Inspection TWI ws Rev SUALaT Copia © 207 TMT Mle at Msc S oO re) Gi Beranda Buku Buku audio Dokumenry = 3 SCRIBD | Cari TWI Uf 4) Visual Examination Report Forms THE WELDING INSTITUTE ‘The requirement for examination recordslinspection reports will vary accor contract and ype of fabrication and there may not always bea need fora formal recon. ‘When a record is required it may be necessary to show that items have been checked at the specified stages and that they have satisfied the acceptance criteria. The form of this record will vary; possibly a signature against an activity on an laspection Check List or (Quality Plan oran individual report foran item, For individual inspection reports, BS EN 7Olists typical details for inclusion as: a) Nameofthe component manufacturer b)-—-Examining body, ifitferent ©) Kdentification of the object examined d)—Material ©) Type ot joint 1) Material thicknoss g) Welding process h) Acceptance criteria 1) Imperfections exeeeding the acceptance criteria and thet location j) Extent of examination with reference to drasvings as appropriate k) Examination devices used 1) Result oFexamination with reference to acceptance criteria m) Namo of examiner/inspector and date of examination, ‘When itis required by contract to produce and retain permanent visual records of a weld fas examined, photographs, accurate sketches, or both should be made with any imperfections cleatly indicated. In the Visual Welding Inspector examination assessment fof welds is made using a number of forms. For the T Joint examination 2 sheets (normally 1x double sided page) For the Plate Inspection 3 sheets are issued (normally 1 and Ix single sided) Acceptanes code similar to page 23.7 is provided for exam. "T Joint 1 0f2: Details ofall weld measurements and calculated acceptance criteria, then ‘an acceptaneeirejection ofthe weld dimensions based en calculations TJolnt2 0f2: A dimeasioned list of observable imperfections and evaluation to the supplied code and final overall assessment ofthe fillet welded T joint, Plate 1of3: Deuils of weld and a dimensioned sketch of imperfections Found within plate weld face area Plate2 0f3: A dimensioned sketch of imperfections found within the plate weld root area, Note: Inspection should include surface areas ofthe plates on wei fore and weld root sick only and any observations recorded on the relevant shee. Inspection should always be made from gob to enke, Plate3 of3: A final report form containing all relevant information from sheets 182 then a comparative assessment of the recorded imperfections with the supplied acceptance criteria. Any additional comments should be made of th sdirecte. Alling shawl ‘Welling Impestonal cele WISE. omc Section 23 Praca Visual Iida ‘Rey M0307 Copyuight £12007 TWLAVYddte ast monet S oO re) Gi Beranda Buku Buku audio Dokumenoe Soe) 6.29 A = §} SCRIBD | Cari TWI Uf. ages 23.9~ 23.13 contain examples of completed inspection forms used, using the set of acceptance eriteria given below. These acceptance eriteria have also been provided for valuation of the Filet Wielokd T Joint and B utt Welckd Butt Jaint inspection practi THE WELDING INSTITUTE For Training Purposes Only WIS 5 Acceptance Levels Butt Welded Plate & Fillet Welded T Joint Inspection Practice Specification Number IW 09.09.06 All dimensions are given in millimetres ys © diameter platethickness. d= depth bh =height No| _ Imperfeetion ‘Comments ‘Allowance | 1 [Cracks Confin with ponetrant testing ‘Not permitted | 2 | Porosity Thal gs pore © ‘Maximum Lom | '3_[ Sold Inelusions ‘Non-metallic. Individual size Maximum 1mm ‘4 [Sold inlusions Metalic Not permitted | 'S_| Lack of Fusion Sidewall/Root/Inter-run Not permitted | {6_| Incomplete Root Penctation Not permitted | 7_[ OverlaiCold tap Weld fice Root Not permitted '_[Incomploely filed groove Not permitted [Linear Misaliament 0.2t Maximum dm) 10 | Angular Missignme Maximum 10 11 [Undercut Srooy barded 10%t Maxinun tam 12 [Are Surikes “Test foe cracks using MPL Seek advice for repair 13. | Laminations 14 | Mechanical Damage ‘Surlhos stale fnve ofall USaCOTE 18 | Cap Height ‘Shall not fall below plate surface Penetration Bead Burn-though not permitted Spatier (lean & Re-inspeet Refer to manufacturer Weld Appearanss All toes shall flend/ SAGO Regular along the lengih_| Root concavity 10%%t Maximum d tm | ‘Weldig fspection of Steels WIS Section 23 Practical Viswal Inspection ov 0a3-0 Cop 07 TW pe ost a S oO re) Gi Beranda Buku Buku audio Dokumenoe Soe) 6.29 A = §} SCRIBD | Cari TWI CMT Fillet Welded T Joint Practical Exam ‘THE WELDING INSTITUTE 1) Firstly, the plate reference number must be recorded in the top left tand comer of the report sheet, then thickness of the plate is measured and then entered in the top right hhand comer of the report sheet in the boxes provided. Sevondly, both fillet weld leg lengths must be measured fo find both maximum and ‘minimum leg lengths in both Vertieal and Horizontal legs. These values are entered in the boxes provided on the report sheet. Use the gauge as shown below: 3) Thirdly, the maximum and minimum throat thickness is measured and entered in the boxes provided onthe report sheet. These values are measured as shown below: 4) Having made all the above measurements they can be assessed to 8 set of values that may be simply calculate from the known plate thickness, tance 8) ‘The minimum leg length size is the plate thiekness bb) The maximum leg length size isthe plate thickness + 3mm ©) The minimum throat thickness isthe plate thickness x 0.7 4) ‘The maximum throat thickness isthe plate thickness +0. Forexample Fie plate thickness is 6mm then the following will apply a) (Plate thickness) b) Plate thickness + 3mm) 3 n (Plate thickness x 0.7) 44) ‘The maximum throat thickness isthe 6.Smim (Plate thickness +0 Smo All measurements taken must fall within the 2 tolerances calculated i.c. Leg lengths between 6mm — 9mm and throat thickness between 42 and 6.5mm — Ifany of the values aro within these tolerances they are acceptable. If any of the values fall outside of the caleulated tolerances then it becomes unaceeptable, It should be remembered that any change in thickness changes these acceptance values. ‘Actual Throat Thickness Lowest throat measurement 4.5mm. Highest throat measurement Sm Lowest leg measurement Tmm Highest leg measurement 8mm. Horizontal Leg Length Lowest leg measurement Smm Inspect only faces A B andC Highest leg measurement 1mm Wang agen Sees WSS oo Section 23 Fractal Visual Inspection cme Rou s08-0F Capi = DOT TNT MMe st CL tion S oO re) Gi Beranda Buku Buku audio Dokumen& 4 (aa) Gy 46 sll 63% 6.29 = §} SCRIBD | Cari THE WELDING INSTITUTE When completing the report sheet from the sample Weld given t should appear as follows: Example Fillet Welded T Joint Report Sheet Specimen Number E123 Material thickness: _omm 1) Measure and record the following details: VERTICAL LEG LENGTH (Max & Min) = Mas. mm Min 7mm HORIZONTAL LEG LENGTH ¢ “) = Max 10mm Min Sma ACTUALTHROAT THICKNESS ¢* *) = Max 8mm Min 4.8 mm 2) Sentence the filet weld dimensions using the following design eriteri MINIMUM LEG LENGTH: Material thickness (6mm) MAXIMUM LEG LENGTH: Material thickness + 3mm (9 rm) “MAXIMUM THROAT THICKNESS: Material thickness + 0.5mm (6.5 mm) The VERTICALLEG LENGTH ACCEPT or REJECT: Please state ACCEPT, The HORIZONTAL LEG LENGTH ACCEPT or REJECT: Please state REJECT, The THROAT THICKNESS ACCEPT or REJECT: Please state: REIECT Havingassessed the weld far its size an inspection ean then be madeon the surface to locate any imperfections. Firsily: the report sheet requests the inspector to indicate the number of locations that the following imperfections occur if any? 3) Thenumber of places that they occur should now be entered in the box as follows: UNDERCUT APPEAR? places, OVERLAP APPEAR? ‘one. LACK OF FUSION APPEAR? CRACKS APPEAR? ‘one POROSITY APPEAR? SOLID INCULSIONS? MISC: [ARC STRIKES ete) Spatter ‘Wlding npesion ol Secs ISS 33,9 wm Section 23 Practical Viewl Inspection iinet Rev M0307 Copyught © 2007 TWLAddle at oncast S oO re) Gi Beranda Buku Buku audio Dokumen> 3 2 Gq 46 wil 639 6.29 = §} SCRIBD | Cari ‘THE WELDING INSTITUTE 4) For the defects recorded- state the MAXIM applicable) ofeach defeet length (and DEPTH if UNDERCUT: Length: 181 Depth: 18 mm (Sharp) OVERLAP: Length Depth: LACK OF FUSION: Length: 2 Depth CRACKS Length Dept POROSITY: Length: LSmm@ Depth: N/A SOLIDINCLUSIONS; Leng 4mm. Depth: NIA MISC: [ARC STRIKES etc] Lengthy Spatter Depth: NIA 5) Then, using the code provided assess the levels of Imperfections with the allowance inthe codes follows: UNDERCUT: REJECT (Accept or Reject?) OVERLAP! ACCEPT (Accept or Reject?) LACK OF FUSION: ACCEPT. (Accept or Reject?) CRACKS: ‘ACCEPT (Accept of Reject?) POROSITY: REJECT (Accept or Reject?) SOLID INCLUSION: REJECT MISC: [ARC STRIKES ete] REJECT 1» All spatters should have been removed prior tosubmrission for inspection. Clean then resubmit for inspection. 6) Finally accept or reject the weld used for your visual inspection as follows 1S THE WELD ACCEPTABLE? xo YESINO Signature: IE lemy Name: 1€ Plenty Date: 30-03-07 This completes the practical Fillet Welded T Joint Inspection Assessment. ‘Welding Ingestion of Ses WISF B10 ‘ort ea ox Section 23 Practical Visual fspection BOY Seas ew MLO.07 Copyright © 2007 TEMA Eat S oO re) Gi Beranda Buku Buku audio Dokumen5 x ° g 5 a“ g § 3.8 z a » a z Bi a 2G 3 Length & thickness of plate: 300mm x 10mm Date 30.03.07 ew ML0.07 Copyright © Ss Beranda Js 25 30 Ls, Are Strikes 2 Q z = a a a = ar SF | . aE 3 measure frrom THis Abarum EDGE sec WINE 2 TW wenn x sul Ispet Senn it CL cscs na i i aob Buku Buku audio Dokumen‘THE WELDING INSTITUTE 10 Burn-through t Grinding Marks 50 Lack of root fusion WELD ROOT B EXAMPLE PLATE REPORT sure #rRom THis foaTum EDGE 22 TW sono Rov anai.orCop © 00" ae ost UM cs S oO re) Gi Beranda Buku Buku audio Dokumenoe ene 6.30 A = §} SCRIBD | Cari TWI CMT. THE WELDING INSTIUTE ‘Weld Report Sheet Page 3 of 3 EXAMPLE WELD INSPECTION REPORT/SENTENCESHEET PRINTFULLNAME _1€ Plenty ‘SPECIMENNUMBER 001 Face Defects EXTERNAL DEFECTS Detects Noted Code or Specification Reference Deteet Type Accumulative Maximum] Section’ ] Accopl Rajon Total Allowaace | Table N° 1 2 3 4 5 st (cai Tam Tn 1s Reet iit (Appearance) —| Poor tae Hisnd | Smooth toc Hand [1 | Reject Tacomplete filing 2 mm ot pres 3 [Reject Slag ielusions mm Timm 3 [Reject Undereut 1S men depth [1mm Li [ Reject Surface Porosity ES mmo Timm @ 2 [Reject Cracks “20m Nat prea 1 PRejeot ack of fision 22mm Natparaia S| Reject Are ates 30 on x 25 may | Tei VT 12__| Seek advise Ho ‘Meshanical damage NONE ‘Accept ‘Misalignment [2 mim ines [09 = Pm 9 Acwept Root Defects Misalignment Zam(Linear) [02 (= Sram 3 neeepe Penetration (Height) om 2 mn 16 | Reject Insomplete Root Pensiaion | $0 mmr Tarp 6D Rejest Lack of Root Fusion om ote 5 [Reet Root Conssvity 2 am depth nm ma 19 [ Reject Root Underewt ‘NONE, Accept Cracks NONE Accept ‘Mechanieal damage 30 mmx D0 mm | Net pee Ta | Rejeot Porosity NONE ee |] mm | Aceh Bare To mm Tength | Nope Te [Reject ‘This “ppmplate has been examined to the requirements of code/specification J, 02:02:06 and is weweptedrejected accordingly signeure AO Pliny ee 30 March 2007 “Delete which is not applicable. Use the other side for any comments Comments + Request Penetrant NDT testing to confirm crack and true length, ++ Largeamount of spatter on weld face. Recommend cleaning, then re-inspeetion. +++ Recommend are strikes are ground flush prior fo MPI testing for eruek detection, Seek advice on repair upon test results This completes the practical Butt Welded Plate Butt Joint Inspection Assessment “Welling inpesion of Siecle WIS3——__ 35,13 DWI sono Section 23 Practieal Vial Inspection itinerant Rev M-0.07 Copsrght © 2007 TWEMAle ast S oO re) Gi Beranda Buku Buku audio Dokumen