Wis5 Terms

Welding Inspection
Duties & Terms

Course Reference WIS 5
19 Sep 02 M.S.Rogers
CSWIP Examinations
 Level 1: 3.0 Visual Welding Inspector
 Level 2: 3.1 Welding Inspector
 Level 3: 3.2 Senior Welding Inspector
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
Main Responsibilities
Code compliance
Workmanship control
Documentation control
Personal Attributes
Honesty
Integrity
Knowledgeable
Good communicator
Physically fit.
Duties of a Welding Inspector
Before Welding.
before assembly.
after assembly.
During welding.
After welding.
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
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
After Welding
 Post cleaning
 Visual inspection of completed welded joint
 Check weld contour and width
 PWHT
 Dimensional accuracy
 Weld reports
 Tie up with NDT
 Monitor any repairs
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
TWI Multi-purpose Welding
Inspectors Gauge
IN IN
0 1/4 1/2 3/4 1/4 1/2 3/4
0
Angle of preparation Misalignment

The scale reads from 0o to 60o in The scale is used to measure
steps of 5o. The angle is read misalignment of components by
against the chamfered edge of the placing the edge of the gauge on
segment the lower one and rotating the
segment until the pointer contacts
the higher piece
Inspectors Gauge
IN IN
1/4 1/2 3/4 1/4 1/2 3/4
0 0
Undercut Excess weld metal

The scale reads from 0 in the The scale is used to read off these
negative up to 5m. The segment is dimensions up to a maximum of
rotated until the pointer reaches 25mm and 1 inch
the full depth of the undercut.
Inspectors Gauge
IN
1/4 1/2 3/4
0
3/4 1/2 0
1/4
IN
Fillet weld leg length Fillet throat thickness

The scale is used to read off these The sliding pointer reads up to
dimensions up to a maximum of 20mm and 3/4 inch. In measuring
25mm and 1 inch. throat thickness it is assumed that
the fillet weld has normal root
penetration
HI-LO Welding Gauge
1
Internal Root gap

alignment dimension
HI-LO Single Purpose Welding Gauge
Amp/Volt Meter
Amp Meter
Volt Meter
Tongue
Tester
Terminology Joint Types
Edge Corner Lap
Tee Butt
Cruciform
Terminology Joint Welds
Compound Fillet Butt
Edge Spot Plug
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
Types of Joint Preparation
Angle of Angle of
bevel bevel
Root
Radius
Root Face Root Gap Root Face

Root Gap Land
Single Bevel Butt Single J Butt

Weld Zone Terminology
Weld zone
Weld metal Heat affected

zone
Fusion zone Root Weld Junction
Butt Weld Features
Weld cap width

Excess cap height
or weld reinforcement
Excess root penetration Root bead width
Terminology
Butt Weld Features Exercise
2 2 9
8 9 6
2
3 2
4
1
7 53 4
1
2 2 7
10
Terminology
Butt Weld Features Exercise Answers
1. Weld metal 6. Cap width
2. Weld toes (cap and 7. Plate thickness

root)
8. Weld length
3. Weld zone
9. Parent material
4. Cap reinforcement
10. Weld root
5. Weld junction
M.S.Roers
Fillet Weld Features
Vertical leg length
Design throat
thickness
Horizontal leg length

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
b a
Fillet Weld Profiles
Mitre fillet Convex fillet
Concave fillet
Welding Positions
Flat position
UK (USA) 1G rotated UK (USA): 1G

ISO/EN PA ISO/EN: PA
Horizontal
vertical
position
UK (USA) 2G Fixed UK (USA): 2G

ISO/EN PC ISO/EN: PC
Welding Positions
Vertical Vertical
up down
UK (USA) 3G UK (USA) 3G
ISO/EN PF ISO/EN PG
Vertical Position
Overhead Position Pipe fixed Horizontal
UK (USA) 4G UK (USA) 5G
ISO/EN PE ISO/EN PF, PG
Welding Positions
45o 45o
Inclined position fixed Inclined position Rotated

UK (USA) 6G UK (USA) 1FR
EN/ISO H-LO45 EN/ISO L 45/PA

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Welding Inspection

Duties & Terms

 Level 2: 3.1 Welding Inspector

 Level 3: 3.2 Senior Welding Inspector

 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

 Ensure the correct technique, run sequence.

 Check run out lengths, time lapses.

 Cleaning between passes

 Maintenance of records and reports

Angle of preparation Misalignment

Undercut Excess weld metal

Fillet weld leg length Fillet throat thickness

Internal Root gap

Edge Corner Lap

Compound Fillet Butt

Edge Spot Plug

Root Face Root Face

Single -V Butt Single - U Butt

Root Face Root Gap Root Face

Single Bevel Butt Single J Butt

Weld metal Heat affected

Fusion zone Root Weld Junction

Weld cap width

Excess root penetration Root bead width

2. Weld toes (cap and 7. Plate thickness

Horizontal leg length

a = Actual throat thickness

Mitre fillet Convex fillet

UK (USA) 1G rotated UK (USA): 1G

UK (USA) 2G Fixed UK (USA): 2G

Inclined position fixed Inclined position Rotated

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