TWI Welding Inspection Duties/Terms Course Reference WIS 5 M.S.Rogers

CSWIP Examinations Level 1: 3.0 Visual Welding Inspector TWI CSWIP Examinations 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 TWI 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 M.S.Rogers

Main Responsibilities TWI Main Responsibilities Code compliance Workmanship control Documentation control M.S.Rogers

Personal Attributes Honesty Integrity Knowledgeable Good communicator TWI Personal Attributes Honesty Integrity Knowledgeable Good communicator Physically fit. M.S.Rogers

Duties of a Welding Inspector TWI Duties of a Welding Inspector Before Welding. before assembly. after assembly. During welding. After welding. M.S.Rogers

Duties Before Welding Check all documentation Check all consumables TWI 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 M.S.Rogers

During Welding Check amperage, voltage, polarity TWI 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 M.S.Rogers

After Welding Post cleaning TWI 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 M.S.Rogers

Welding Inspectors Equipment TWI 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 M.S.Rogers

TWI Multi-purpose Welding Inspectors Gauge 60 50 40 1/4 1/2 3/4 1 5 10 15 20 IN MM 60 50 40 1/4 1/2 3/4 1 5 10 15 20 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 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 M.S.Rogers

TWI Multi-purpose Welding Inspectors Gauge 60 50 40 1/4 1/2 3/4 1 5 10 15 20 IN MM 1/4 1/2 3/4 1 5 MM IN MM 1/2 10 MM 15 20 15 40 50 60 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. Excess weld metal The scale is used to read off these dimensions up to a maximum of 25mm and 1 inch M.S.Rogers

TWI Multi-purpose Welding Inspectors Gauge 60 50 40 1/4 1/2 3/4 1 5 10 15 20 IN MM 60 50 40 1/4 1/2 3/4 1 5 10 15 20 IN MM Fillet weld leg length The scale is used to read off these dimensions up to a maximum of 25mm and 1 inch. 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 M.S.Rogers

HI-LO Single Purpose Welding Gauge TWI HI-LO Welding Gauge HI-LO Single Purpose Welding Gauge 1 2 3 4 5 6 Internal alignment Root gap dimension M.S.Rogers

TWI Amp/Volt Meter M.S.Rogers

Terminology Joint Types TWI Edge Corner Lap Tee Butt Cruciform M.S.Rogers

Terminology Joint Welds TWI Terminology Joint Welds Compound Fillet Butt Spot Edge Plug M.S.Rogers

Types of Joint Preparation TWI Types of Joint Preparation Included angle Included angle Angle of bevel Root Radius Root Face Root Face Root Gap Root Gap Single -V Butt Single - U Butt M.S.Rogers

Types of Joint Preparation TWI Types of Joint Preparation Angle of bevel Angle of bevel Root Radius Root Face Root Face Root Gap Root Gap Land Single Bevel Butt Single J Butt M.S.Rogers

Weld Zone Terminology Heat affected zone Weld Junction Weld zone TWI Weld Zone Terminology Weld zone Weld metal Heat affected zone Weld Junction Fusion zone Root M.S.Rogers

Excess root penetration TWI Butt Weld Features Weld cap width Excess cap height Excess root penetration Root bead width M.S.Rogers

Fillet Weld Features Weld face Vertical leg length TWI Fillet Weld Features Weld face Vertical leg length Design throat thickness Horizontal leg length M.S.Rogers

BS 499: part 2. Welding Symbols Dimensions TWI BS 499: part 2. Welding Symbols Dimensions a = Actual throat thickness z = Design throat thickness b = Leg length b = Material thickness z = 0.7 of b z a b M.S.Rogers

Fillet Weld Profiles Mitre fillet Convex fillet Concave fillet TWI M.S.Rogers

Horizontal vertical position TWI Welding Positions Flat position UK (USA): 1G ISO/EN: PA UK (USA) 1G rotated ISO/EN PA Horizontal vertical position UK (USA): 2G ISO/EN: PC UK (USA) 2G Fixed ISO/EN PC M.S.Rogers

Welding Positions Vertical up Vertical down UK (USA) 3G UK (USA) 3G TWI Welding Positions UK (USA) 3G ISO/EN PF Vertical up Vertical down UK (USA) 3G ISO/EN PG UK (USA) 5G ISO/EN PF, PG Vertical Position Pipe fixed Horizontal UK (USA) 4G ISO/EN PE Overhead Position M.S.Rogers

Inclined position fixed Inclined position Rotated TWI Welding Positions 45o 45o Inclined position fixed UK (USA) 6G EN/ISO H-LO45 Inclined position Rotated UK (USA) 1FR EN/ISO L 45/PA M.S.Rogers