Welding InspectionDuties/Terms

Course Reference WIS 5

TWI

M.S.Rogers

CSWIP ExaminationsTWI

Level 1: 3.0 Visual Welding Inspector

Level 2: 3.1 Welding Inspector

Level 3: 3.2 Senior Welding Inspector

M.S.Rogers

CSWIP Examination Requirements Theory part A2: General welding theory &

product technology 30 multiple-choice questions. Theory part B2: Specific welding technology. 4

questions from 6. Oral: Specific oral based on nominated code Practical part A2: Inspection of a plate butt weld Practical part B2: Inspection of a pipe butt weld Practical part C2: Inspection of a set of

destructive test samples, two macros test to ISO 5817

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M.S.Rogers

Main Responsibilities

Code compliance

Workmanship control

Documentation control

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Personal Attributes

Honesty

Integrity

Knowledgeable

Good communicator

Physically fit.

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M.S.Rogers

Duties of a Welding Inspector

Before Welding.before assembly.after assembly.

During welding.

After welding.

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M.S.Rogers

Duties Before Welding Check all documentation

Check all consumables

Check materials, dimensions and condition

Preheating, method and temperature

Check fit and set-up.

Ensure no undue stress is applied to the joint

Check welding equipment

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M.S.Rogers

During Welding Check amperage, voltage, polarity

Ensure the correct technique, run sequence.

Check run out lengths, time lapses.

Cleaning between passes

Interpass temperatures

Consumable control

Maintenance of records and reports

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M.S.Rogers

After Welding Post cleaning

Visual inspection of completed welded joint

Check weld contour and with

PWHT

Dimensional accuracy

Weld reports

Tie up with NDT

Monitor any repairs

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Welding Inspectors Equipment Measuring device e.g flexible tape, steel rule

Temperature indicating crayons

Welding gauges e.g. TWI multi-purpose gauge

Voltmeter

Ammeter

Magnifying glass

Torch/flash light

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M.S.Rogers

TWI Multi-purpose Welding Inspectors Gauge

TWI

M.S.Rogers605040

0 1/4 1/2 3/41

05

1015

20

IN

MM

MM 15

1/2

MMIN

605040

0 1/4 1/2 3/4 10

510

1520

IN

MM

15

1/2

IN

MM

MisalignmentThe 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

Angle of preparationThe scale reads from 0o to 60o in steps of 5o. The angle is read against the chamfered edge of the segment

605040

0 1/4 1/2 3/4 10

510

1520

IN

MM

MM15

1/2

MMIN

TWI

M.S.Rogers

UndercutThe scale reads from 0 in the negative up to 5m. The segment is rotated until the pointer reaches the full depth of the undercut.

Excess weld metalThe scale is used to read off these dimensions up to a maximum of 25mm and 1 inch

605040

0 1/4 1/2 3/41

05

1015

20

IN

MM

MM 15

1/2MMIN

TWI Multi-purpose Welding Inspectors Gauge

TWI

M.S.Rogers

Fillet throat thicknessThe 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 leg lengthThe scale is used to read off these dimensions up to a maximum of 25mm and 1 inch.

60 50 40

01/41/23/41

05

1015

20

IN

MM

MM15

1/2

MM

IN

6050400 1/4 1/2 3/4

10

510

1520

IN

MM

MM15

1/2

MM

IN

TWI Multi-purpose Welding Inspectors Gauge

TWI

M.S.Rogers

HI-LO Welding GaugeHI

-LO

Sin

gle

Purp

ose

Wel

ding

Gau

ge1

2

3

4

5

6

Root gap dimension

Internal alignment

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M.S.Rogers

Amp/Volt Meter

Terminology Joint Types

Edge Corner Lap

TeeCruciform

Butt

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Terminology Joint Welds

Compound Fillet Butt

Edge Spot Plug

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Types of Joint PreparationIncluded angle

Root GapRoot Face

Angle of bevel

Root FaceRoot Gap

Included angle

Root Radius

Single -V Butt Single - U Butt

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Types of Joint Preparation

Root GapRoot Face Root FaceRoot Gap

Root Radius

Single Bevel Butt Single J Butt

Angle of bevel

Angle of bevel

Land

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Weld Zone Terminology

Weld zone

Weld metal Heat affected zone

RootFusion zone Weld Junction

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Butt Weld Features

Weld cap widthExcess cap height

Excess root penetration Root bead width

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M.S.Rogers

Fillet Weld Features

Horizontal leg length

Ver

tical

leg

leng

th

Design throat thickness

Weld face

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M.S.Rogers

TWI BS 499: part 2. Welding Symbols Dimensions

a = Actual throat thicknessz = Design throat thicknessb = Leg lengthb = Material thicknessz = 0.7 of b

zb

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a

Fillet Weld Profiles

Mitre fillet

Concave fillet

Convex fillet

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M.S.Rogers

Welding Positions

Flat position

UK (USA) 1G rotatedISO/EN PA

UK (USA): 1G ISO/EN: PA

UK (USA) 2G FixedISO/EN PC

UK (USA): 2G ISO/EN: PC

Horizontal vertical position

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Welding Positions

Vertical downUK (USA) 3GISO/EN PG

UK (USA) 3G ISO/EN PF

Vertical up

UK (USA) 4G ISO/EN PE

Overhead PositionUK (USA) 5G ISO/EN PF, PG

Vertical PositionPipe fixed Horizontal

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Welding Positions

45o

Inclined position fixedUK (USA) 6GEN/ISO H-LO45

Inclined position RotatedUK (USA) 1FREN/ISO L 45/PA

45o

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