Practical Training

Appendix 2
Plate Reports and Questions

CSWIP 3.1 Training Questions for Plate Butt Weld 3
Answers to be indicated on the Candidate Answer Template.
Weld Face
1 Maximum excess weld metal height (highest individual point measured): Which
answer best matches your assessment and would you accept or reject your findings
to the given acceptance levels?
a Equal to or less than 0mm.

b 1-4mm.
c 5-6mm.
d 7-8mm.
e Accept.
f Reject.
2 Incomplete fill: Which answer best matches your assessment of the total
accumulative length and would you accept or reject your findings to the given
acceptance levels?
a None observed.
b 40-60mm.
c 1-30mm.
d 75-100mm.
e Accept.
f Reject.
3 Slag inclusions: Which answer best matches your assessment of the total
acceptance levels?
a 60-70mm.
b 20-30mm.
c None observed.
d 5-18mm.
e Accept.
f Reject.
4 Undercut: Which answer best matches your assessment of the imperfection and
would you accept or reject your findings to the given acceptance levels?
a 50mm in length.
b Sharp but less than 1mm deep.
c None observed.
d Sharp but more than 1mm deep.
e Accept.
f Reject.
WIS5-90516b
Appendix 2 – Plate Reports and Questions A2-1 Copyright © TWI Ltd
5 Porosity in the weld: Which answer best matches your assessment of the total
accumulative area and would you accept or reject your findings to the given
acceptance levels?
a The area is between 15-25mm2.

b The area is greater than 100mm2.
c None observed.
d The area is between 70-90mm2.
e Accept.
f Reject.
6 Cracks: Which answer best matches your assessment of the total accumulative
length and would you accept or reject your findings to the given acceptance levels?
a 2-3mm transverse crack.

b 15mm longitudinal crack.
c None observed.
d 9-14mm longitudinal crack.
e Accept.
f Reject.
7 Lack of fusion: Which answer best matches your assessment of the total
acceptance levels?
a 70-90mm.
b 30-60mm.
c None observed.
d 91-100mm.
e Accept.
f Reject.
8 Arc strikes: Which answer best matches your assessment of the total number and
a 3 total.
b 4 total.
c None observed.
d 1 total.
e Accept.
f Reject.
9 Sharp areas of mechanical damage (excluding hard stamping and pop marks): Which
answer best matches your assessment of the total number of areas and would you
accept or reject your findings to the given acceptance levels.
a More than 2 areas.

b 1 area.
c None observed.
d 2 areas.
e Accept.
f Reject.
WIS5-90516b
Weld Root
10 Misalignment: Which answer best matches your assessment of the maximum value
and would you accept or reject your findings to the given acceptance levels?
a 2-3mm.
b 4-5mm.
c 0-1.
d Greater than 5mm.
e Accept.
f Reject.
11 Root penetration height (highest individual point measured): Which answer best
matches your assessment and would you accept or reject your findings to the given
acceptance levels?
a 2-3mm.
b 1-2mm.
c None.
d Greater than 5mm.
e Accept.
f Reject.
12 Lack of root penetration: Which answer best matches your assessment of the
accumulative total length and would you accept or reject your findings to the given
acceptance levels?
a 40-55mm.
b 25-35mm.
c None observed.
d 1-10mm.
e Accept.
f Reject.
13 Lack of root fusion: Which answer best matches your assessment of the accumulative
total length and would you accept or reject your findings to the given acceptance
levels?
a 30-45mm.
b 1-15mm.
c None observed.
d 16-29mm.
e Accept.
f Reject.
14 Root concavity or shrinkage: Which answer best matches your assessment of the
acceptance levels.
a 31-39mm.
b 18-22mm.
c None observed.
d 40-60mm.
e Accept.
f Reject.
WIS5-90516b
15 Root undercut: Which answer best matches your assessment of the accumulative
levels?
a 40-60mm.
b 5-8mm.
c None observed.
d 2-4mm.
e Accept.
f Reject.
16 Cracks in the root: Which answer best matches your assessment of the accumulative
levels?
a 10-17mm.
b 1-4mm.
c None observed.
d 5-8mm.
e Accept.
f Reject.
17 Sharp indications of mechanical damage in the root area weld and parent material
(excluding hard stamping): Which answer best matches your assessment of the total
number of items and would you accept or reject your findings to the given
acceptance levels?
a 2 observed.
b 1 item observed.
c None observed.
d 3 or more items observed.
e Accept.
f Reject.
18 Porosity in the weld root area: Which answer best matches your assessment of the
accumulative total area and would you accept or reject your findings to the given
acceptance levels?
a Individual pore diameter between 1-2mm.

b Individual pore diameter between 2-3mm.
c None observed.
d Individual pore diameter greater than 3mm.
e Accept.
f Reject.
19 Burn-through in the root area: Which answer best matches your assessment of the
total number of areas and would you accept or reject your findings to the given
acceptance levels?
a 1.
b 2.
c None observed.
d 3.
e Accept.
f Reject.
WIS5-90516b
20 Angular distortion: Which answer best matches your assessment and would you
accept or reject your findings to the given acceptance levels (measure from the weld
centreline to the plate edge).
a 3-4mm.
b 5-6mm.
c None observed.
d 1-2mm.
e Accept.
f Reject.
WIS5-90516b
WIS5-90516b
WIS5-90516b
RETEST RETEST 10 YR 10 YR CANDIDATE TO FILL ALL BOXES INDICATED IN BLUE
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
O O O O O O O O O O O O
INVIGILATOR NAME: INVIGILATOR SIGNATURE:
VERSION _
O O O O O O O
EXAM DATE: EVENT CODE
GENERAL THEORY TECHNOLOGY THEORY
A B C D A B C D A B C D CANDIDATE NAME: CANDIDATE SIGNATURE:
1 1 31
I agree with the terms and conditions of Tick Date of Birth
2 2 32 this examination Box D D M M Y Y
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
O O O O O O O O O O O O O O O O O O O O A B C D E F
4 4 34 _
O O O O O O O O O O _
O O O O O O O O O O
_
O O O O O O O O O O 1
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
7 7 37 BOOKING REFERENCE OFFICE USE ONLY CANDIDATE NUMBER FOR OFFICE USE ONLY
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
VERSION _
O O O O O O O
1 1 31
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
4 4 34 _
O O O O O O O O O O
_
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
Weld Face

b 1-4mm.
c 5-6mm.
d 7-8mm.
e Accept.
f Reject.
acceptance levels?
a None observed.
b 30-50mm.
c 1-25mm.
d 100-120mm.
e Accept.
f Reject.
acceptance levels?
a 12-18mm.
b 8-10mm.
c None observed.
d 2-6mm.
e Accept.
f Reject.
a 10-20mm in length.
c None observed.
e Accept.
f Reject.
WIS5-90516b
acceptance levels?
a The area is between 0.5-5mm2.

b The pore is greater than 45-60mm2.
c None observed.
d The pore is between 20-30mm2.
e Accept.
f Reject.

c None observed.
e Accept.
f Reject.
acceptance levels?
a 30-39mm.
b 40-55mm.
c None observed.
d 5-10mm.
e Accept.
f Reject.
a 2.
b 3.
c None observed.
d 1.
e Accept.
f Reject.
a 4 areas.
b 1-2 areas.
c None observed.
d 3 areas.
e Accept.
f Reject.
WIS5-90516b
Weld Root
a 0.5-1mm.
b 1.5-2mm.
c None observed.
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?
a 3-5mm.
b 1-2mm.
c None.
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?
a 35-40mm.
b 20-25mm.
c None observed.
d 1-10mm.
e Accept.
f Reject.
levels?
a 28-35mm.
b 1-10mm.
c None observed.
d 15-23mm.
e Accept.
f Reject.
14 Root concavity or root shrinkage: Which answer best matches your assessment of
the accumulative total length and would you accept or reject your findings to the
given acceptance levels.
a 31-39mm.
b 18-22mm.
c None observed.
d 40-75mm.
e Accept.
f Reject.
WIS5-90516b
levels?
a 15-30mm.
b 5-8mm.
c None observed.
d 40-50mm.
e Accept.
f Reject.
levels?
a 10-17mm.
b 1-4mm.
c None observed.
d 5-8mm.
e Accept.
f Reject.
(excluding hard stamping): Which answer best matches your assessment of the
accumulative total and would you accept or reject your findings to the given
acceptance levels?
a 2-3 items observed.

b 1 item observed.
c None observed.
e Accept.
f Reject.
acceptance levels?

c None observed.
e Accept.
f Reject.
accumulative total number of areas and would you accept or reject your findings to
the given acceptance levels?
a 1.
b 2.
c None observed.
d 3.
e Accept.
f Reject.
WIS5-90516b
20 With refrence to cluster porosity which answer best matches your assessment and
would you accept or reject your findings to the given acceptance levels.
a 20-30mm2.
b 31-40mm2.
c None observed.
d 12-18mm2.
e Accept.
f Reject.
WIS5-90516b
WIS5-90516b
WIS5-90516b
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
VERSION _
O O O O O O O
1 1 31
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
4 4 34 _
O O O O O O O O O O
_
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
VERSION _
O O O O O O O
1 1 31
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
4 4 34 _
O O O O O O O O O O
_
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
Weld Face
1 Excess weld metal height (highest individual point measured): Which answer best
acceptance levels?

b 1-4mm.
c 5-6mm.
d 7-8mm.
e Accept.
f Reject.
acceptance levels?
a None observed.
b 16-29mm.
c 1-15mm.
d 40-50mm.
e Accept.
f Reject.
acceptance levels?
a 60-70mm.
b 20-30mm.
c None observed.
d 5-12mm.
e Accept.
f Reject.
c None observed.
e Accept.
f Reject.
WIS5-90516b
acceptance levels?
a 1-15mm2.
b Greater than 100mm2.
c None observed.
d The area is between 70-90mm2.
e Accept.
f Reject.

c None observed.
e Accept.
f Reject.
acceptance levels?
a 40-60mm.
b 20-39mm.
c None observed.
d 5-10mm.
e Accept.
f Reject.
a 3.
b 4.
c None observed.
d 1.
e Accept.
f Reject.
9 Sharp areas of mechanical damage (excluding hard stamping and pop marks):
Which answer best matches your assessment of the total number of areas and would
you accept or reject your findings to the given acceptance levels.
a 4.
b 1-2.
c None observed.
d 3.
e Accept.
f Reject.
WIS5-90516b
Weld Root
a 1-2mm.
b 3-4mm.
c None observed.
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?
a 2-3mm.
b 0.5-1.5mm.
c None.
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?
a 30-40mm.
b 20-25mm.
c None observed.
d 1-10mm.
e Accept.
f Reject.
13 Lack of root fusion: Which answer best matches your assessment of the
acceptance levels?
a 28-40mm.
b 1-10mm.
c None observed.
d 15-23mm.
e Accept.
f Reject.
14 Root concavity or shrinkage: Which answer best matches your assessment of the
acceptance levels.
a 31-39mm.
b 18-25mm.
c None observed.
d 40-75mm.
e Accept.
f Reject.
WIS5-90516b
levels?
a 15-30mm.
b 5-8mm.
c None observed.
d 1-2mm.
e Accept.
f Reject.
levels?
a 10-17mm.
b 1-4mm.
c None observed.
d 5-8mm.
e Accept
f Reject.
(excluding hard stamping): Which answer best matches your assessment of the total
number of items and would you accept or reject your findings to the given
acceptance levels?
a 2 items observed.
b 1 item observed.
c None observed.
e Accept.
f Reject.
acceptance levels?

b Individual pore diameter between 0-0.5mm.
c None observed.
e Accept.
f Reject.
total number of areas and would you accept or reject your findings to the given
acceptance levels?
a 1.
b 2.
c None observed.
d 3.
e Accept.
f Reject.
WIS5-90516b
20 Angular distortion: Which answer best matches your assessment and would you
accept or reject your findings to the given acceptance levels (measure from the weld
centreline to the plate edge).
a 2-4mm.
b 6-8mm.
c None observed.
d 0.5-1mm.
e Accept.
f Reject.
WIS5-90516b
WIS5-90516b
WIS5-90516b
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
VERSION _
O O O O O O O
1 1 31
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
4 4 34 _
O O O O O O O O O O
_
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
VERSION _
O O O O O O O
1 1 31
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
4 4 34 _
O O O O O O O O O O
_
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
Acceptance levels
Acceptance levels plate and pipe
Defect type macro only
number
Table
Remarks Maximum allowance Remarks
At no point shall the excess weld

metal fall below the outside Excess weld metal will not exceed H = 2mm
Excess weld
1 surface of the parent material. in any area on the parent material, showing As for plate and pipe
metal
All weld runs shall blend smooth transition at weld toes.
smoothly.
Slag inclusions are defined as
non-metallic inclusions trapped The length of the slag inclusion shall not
Slag/silica Slag and silica not
2 in the weld metal or between exceed 50mm continuous or intermittent.
inclusions permitted
the weld metal and the parent Accumulative totals shall not exceed 50mm
material.
No sharp indications Smooth blend required.
Undercut is defined as a grove
The length of any undercut shall not exceed
melted into the parent metal,
50mm continuous or intermittent. No sharp indications
3 Undercut at the toes of the weld excess
Accumulative totals shall not exceed 50mm. Smooth blend required
metal, root or adjacent weld
Max D = 1mm for the cap weld metal.
metal.
Root undercut not permitted.
Trapped gas, in weld metal, Individual pores ≤ 1.5 max.
Cluster porosity not
Porosity or elongated, individual pores, Cluster porosity maximum 502mm total area.
4 permitted. Individual
Gas Cavities cluster porosity, piping or Elongated, piping or wormholes
pores acceptable.
wormhole porosity. 15mm max. L continuous or intermittent.
Cracks or Transverse, longitudinal, star or

5 Not permitted Not permitted
Laminations crater cracks.
Incomplete fusion between Surface breaking lack of side wall fusion,

Lack of fusion the weld metal and base lack of inter-run fusion continuous or
6 Laps material, incomplete fusion intermittent not to exceed 15mm. Not permitted
Cold lap between weld metal. Accumulative totals not to exceed 15mm
(lack of inter-run fusion) over a 300mm length of weld.
Damage to the parent material
or weld metal, from an
unintentional touch down of the
7 Arc strikes Not permitted Not permitted
electrode or arcing from poor
connections in the welding
circuit.
No stray tack welds permitted
Parent material must be smoothly blended
Mechanical or weld metal, internal or
8 General corrosion permitted. Max. D = Not permitted
damage external resulting from
1.5mm.
any activities.
Only 1 location allowed
Mismatch between the
9 Misalignment Max H = 1.5mm As for plate and pipe
welded or unwelded joint.
Excess weld metal, above the

10 Penetration base material in the root of the Max H ≤ 3mm As for plate and pipe
joint.
The absence of weld metal in
Lack of root
11 the root area, two root faces Not permitted Not permitted
penetration
showing.
Lack of root Inadequate cross penetration of Lack of root fusion, not to exceed 50mm total
12 Not permitted
fusion (one) root face. continuous or accumulative.
Excessive penetration, collapse

13 Burn through Not permitted Not permitted
of the weld root
Angular Distortion due to weld
14 5mm max. Plate only Accept
distortion contraction
Weld metal below the surface of 50mm maximum length
15 Root concavity Accept
both parent metals 3mm maximum depth
WIS5-90516b
Practical Sessions Objective
When these presentation have been completed

you will have a greater understanding of the
examination requirement and how to identify
and plot weld defects around real life welds and
the classroom specimens on which you will be
Practical Plate Inspection examined.
Copyright © TWI Ltd Copyright © TWI Ltd
Example of Weld Face Example of Plate Root

EXAMPLE PLATE REPORT
Candidates Name……………………………….. Specification……………………………..
MEASURE
Candidates signature…………………………… Welding process………………………..

A B
Welding Position………………………..
MEASURE
Root
WELD FACE concavity Lack of root
2mm deep Fusion
FROM
A Undercut
B 23
Gas pore 10 24
Lack of sidewall smooth 20
7
FROM
fusion 1.5 Ø 1.5 max

87 230 236 30
22
THIS
12 50
THIS
8
Incomplete root
51 8 15 40 Arc
penetration
DATUM
3 Strike
Slag
DATUM
Centreline 24
inclusion
crack 1
EDGE
EDGE
NOTES: Penetration Height = Toe Blend = Weld Width =

NOTES: Excess Weld Metal = Linear Misalignment = Toe Blend = Weld Width =
Plate Inspection Examination
2. Compare to acceptance standard.
1. Read the Questions and compare

Any Questions
with your thumb print.
3. Mark the answer in the OMR grid

in pencil and accept or reject
accordingly. When you are sure
about your answer mark the OMR
grid in BLACK PEN.
?
A2-1
Appendix 3
Pipe Reports and Questions

CSWIP 3.1 Training Questions for Pipe Butt Weld 3
Weld Face

b 1-4mm.
c 4-5mm.
d 7-8mm.
e Accept.
f Reject.
acceptance levels?
a None observed.
b 65-80mm.
c 10-25mm.
d 100-120mm.
e Accept.
f Reject.
acceptance levels?
a 60-70mm.
b 20-30mm.
c None observed.
d 5-12mm.
e Accept.
f Reject.
a 50mm in length.
c None observed.
e Accept.
f Reject.
WIS5-90516b
Appendix 3 Pipe Reports and Questions A3-1 Copyright © TWI Ltd
acceptance levels?
a 0-5mm2.
b Greater than 100mm2.
c None observed.
d 70-90mm2.
e Accept.
f Reject.

c None observed.
e Accept.
f Reject.
acceptance levels?
a 68-80mm.
b 45-60mm.
c None observed.
d 30-40mm.
e Accept.
f Reject.
a 3.
b 4.
c None observed.
d 1.
e Accept.
f Reject.
9 Sharp indications of mechanical damage (excluding hard stamping and pop marks):
you accept or reject your findings to the given acceptance levels?
a More than 2.
b 1.
c None observed.
d 2.
e Accept.
f Reject.
WIS5-90516b
Weld Root
a 1-2mm.
b 3-4mm.
c None observed.
d Greater than 5mm.
e Accept.
f Reject.
11 Root penetration height (Highest individual point measured): Which answer best
acceptance levels?
a 3-5mm.
b 1-2mm.
c None.
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?
a 40-60mm.
b 20-35mm.
c None observed.
d 0-10mm.
e Accept.
f Reject.
levels?
a 28-35mm.
b 0-15mm.
c None observed.
d 15-23mm.
e Accept.
f Reject.
the accumulative total length and would you accept or reject your findings to the
given acceptance levels.
a 31-39mm.
b 8-16mm.
c None observed.
d 40-60mm.
e Accept.
f Reject.
WIS5-90516b
levels?
a 15-30mm.
b 5-8mm.
c None observed.
d 0-2mm.
e Accept.
f Reject.
levels?
a 10-17mm.
b 0-4mm.
c None observed.
d 5-8mm.
e Accept.
f Reject.
17 Sharp areas of mechanical damage in the root area weld and parent material
accumulative total and would you accept or reject your findings to the given
acceptance levels?
a 2-3 items observed.

b 1 item observed.
c None observed.
d 4-5 items observed.
e Accept.
f Reject.
18 Porosity in the weld root area: Which of the following answers best matches your
assessment of the accumulative total area and would you accept or reject your
findings to the given acceptance levels?

c None observed.
e Accept.
f Reject.
19 Burn through in the root area: Which answer best matches your assessment of the
a 1.
b 2.
c None observed.
d 3.
e Accept.
f Reject.
WIS5-90516b
20 Porosity: Which answer best matches your assessment and would you accept or
reject your findings to the given acceptance levels (measure from the weld centreline
to the plate edge)?
a 30-50mm2.
b 60-80mm2.
c None observed.
d 10-20mm2.
e Accept.
f Reject.
WIS5-90516b
Visual Inspection Pipe Report
Name [Block capitals]
Signature Pipe Ident#
Code/Specification used Welding Process Joint type
Welding position OutsideØ and Thickness Date
Weld face
A B C
Notes:
Excess weld metal height = Misalignment = Weld width = Toe blend =
C D A
Notes:
Excess weld metal height = Misalignment = Toe blend = Weld width =
WIS5-90516b
Pipe Root Face
A B C
Notes:
Excess penetration height = Toe blend =
C D A
Notes: Visual Inspection Pipe Report

WIS5-90516b
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
VERSION _
O O O O O O O
1 1 31
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
4 4 34 _
O O O O O O O O O O
_
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
VERSION _
O O O O O O O
1 1 31
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
4 4 34 _
O O O O O O O O O O
_
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
Weld Face

b 3-4mm.
c 5-6mm.
d 7-8mm.
e Accept.
f Reject.
acceptance levels?
a None observed.
b 80-100mm.
c 135-150mm.
d 110-130mm.
e Accept.
f Reject.
acceptance levels?
a 60-70mm.
b 20-50mm.
c None observed.
d 2-6mm.
e Accept.
f Reject.
c None observed.
e Accept.
f Reject.
WIS5-90516b
acceptance levels?
a 35-45mm2.
b Greater than 55-80mm2.
c None observed.
d 20-30mm2.
e Accept.
f Reject.

c None observed.
e Accept.
f Reject.
acceptance levels?
a 110-130mm.
b 95-105mm.
c None observed.
d 65-85mm.
e Accept.
f Reject.
a 2.
b 3.
c None observed.
d 1.
e Accept.
f Reject.
a 4.
b 2.
c None observed.
d 3.
e Accept.
f Reject.
WIS5-90516b
Weld Root
a 1-2mm.
b 3-4mm.
c None observed.
d Greater than 5mm.
e Accept.
f Reject
acceptance levels?
a 3-5mm.
b 1-2mm.
c None.
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?
a 35-40mm.
b 20-25mm.
c None observed.
d 0-10mm.
e Accept.
f Reject.
levels?
a 28-35mm.
b 0-10mm.
c None observed.
d 15-23mm.
e Accept.
f Reject.
the accumulative total and would you accept or reject your findings to the given
acceptance levels?
a 8-12mm.
b 18-22mm.
c None observed.
d 20-40mm.
e Accept.
f Reject.
WIS5-90516b
total l and would you accept or reject your findings to the given acceptance levels?
a 15-25mm.
b 35-45mm.
c None observed.
d 50-60mm.
e Accept.
f Reject.
levels?
a 10-17mm.
b 0-4mm.
c None observed.
d 5-8mm.
e Accept.
f Reject.
17 Sharp areas of mechanical damage in the root area weld and parent material
accumulative total number of items and would you accept or reject your findings to
a 2-3.
b 1 item.
c None observed.
d More than 4 items.
e Accept.
f Reject.
acceptance levels?

c None observed.
e Accept.
f Reject.
a 1.
b 2.
c None observed.
d 3.
e Accept.
f Reject.
WIS5-90516b
20 Cluster porosity: Which answer best matches your assessment and would you accept
or reject your findings to the given acceptance levels. (measure from the weld
centreline to the plate edge)?
a 3-5mm2.
b 6-8mm2.
c None observed.
d 1-2mm2.
e Accept.
f Reject.
WIS5-90516b
Weld face
A B C
Notes:
C D A
Notes:
WIS5-90516b
Pipe Root Face
A B C
Notes:
C D A
Notes: Visual Inspection Pipe Report

WIS5-90516b
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
VERSION _
O O O O O O O
1 1 31
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
4 4 34 _
O O O O O O O O O O
_
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
VERSION _
O O O O O O O
1 1 31
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
4 4 34 _
O O O O O O O O O O
_
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
Answers to be indicated on the Candidate Answer Template
Weld Face
1 Excess weld metal height (highest individual point measured): Which answer best
acceptance levels?

b 3-4mm.
c 5-6mm.
d 7-8mm.
e Accept.
f Reject.
acceptance levels?
a None observed.
b 40-55mm.
c 30-40mm.
d 60-70mm.
e Accept.
f Reject.
acceptance levels?
a 60-70mm.
b 20-50mm.
c None observed.
d 5-12mm.
e Accept.
f Reject.
a Smooth intermittent.
c None observed.
e Accept.
f Reject.
WIS5-90516b
acceptance levels?
a 0-20mm2.
b Greater than 30-50mm2.
c None observed.
d 60-70mm2.
e Accept.
f Reject.

c None observed.
e Accept.
f Reject.
acceptance levels?
a 30-40mm.
b 45-55mm.
c None observed.
d 60-70mm.
e Accept.
f Reject.
a 2.
b 4.
c None observed.
d 1.
e Accept.
f Reject.
9 Sharp indications of mechanical damage (excluding hard stamping and pop marks):
you accept or reject your findings to the given acceptance levels?
a 4.
b 1-2.
c None observed.
d 3.
e Accept.
f Reject.
WIS5-90516b
Weld Root
a 1-2mm.
b 3-4mm.
c None observed.
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?
a 3-5mm.
b 1-2mm.
c None .
d Greater than 5mm.
e Accept.
f Reject.
acceptance levels?
a 30-40mm.
b 21-29mm.
c None observed.
d 41-50mm.
e Accept.
f Reject.
levels?
a 28-35mm.
b 0-10mm.
c None observed.
d 15-26mm.
e Accept.
f Reject.
the accumulative total and would you accept or reject your findings to the given
acceptance levels?
a 31-39mm.
b 18-22mm.
c None observed.
d 40-60mm.
e Accept.
f Reject.
WIS5-90516b
total and would you accept or reject your findings to the given acceptance levels?
a 35-45mm.
b 20-30mm.
c None observed.
d 50-60mm.
e Accept.
f Reject.
levels?
a 10-17mm.
b 0-4mm.
c None observed.
d 5-8mm.
e Accept.
f Reject.
accumulative total number of items and would you accept or reject your findings to
a 2-3.
b 1.
c None observed.
d 4-5.
e Accept.
f Reject.
18 Porosity in the weld root area: Which of the following answers best matches your
assessment of the accumulative total area and would you accept or reject your
findings to the given acceptance levels?

c None observed.
e Accept.
f Reject.
a 1.
b 2.
c None observed.
d 3.
e Accept.
f Reject.
WIS5-90516b
20 Cluster porosity: Which answer best matches your assessment and would you accept
or reject your findings to the given acceptance levels (measure from the weld
centreline to the plate edge)?
a 30-50mm2.
b 60-80mm2.
c None observed.
d 12-22mm2.
e Accept.
f Reject.
WIS5-90516b
Weld face
A B C
Notes:
C D A
Notes:
WIS5-90516b
Pipe Root Face
A B C
Notes:
C D A
Notes:
WIS5-90516b
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
VERSION _
O O O O O O O
1 1 31
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
4 4 34 _
O O O O O O O O O O
_
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
1 2 3 4 5 6 7 INITIAL
1 2 INITIAL RETEST
WI 3.1 EXAM _
VERSION _
O O O O O O O
1 1 31
3 3 33 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
MACRO A
_ _
4 4 34 _
O O O O O O O O O O
_
5 5 35 _
O O O O O O O O O O
_
6 6 36 _
O O O O O O O O O O
3
4
8 8 38
5
9 9 39
PLATE PIPE 6
10 10 40 A B C D E F A B C D E F
7
11 11 41 1 1
8
12 12 42 2 2
9
13 13 43 3 3
10
14 14 44 4 4
11
15 15 45 5 5
12
16 16 46 6 6
17 17 47 7 7
MACRO B
18 18 48 8 8 A B C D E F
19 19 49 9 9 1
20 20 50 10 10 2
21 21 51 11 11 3
22 22 52 12 12 4
23 23 53 13 13 5
24 24 54 14 14 6
25 25 55 15 15 7
26 26 56 16 16 8
27 27 57 17 17 9
28 28 58 18 18 10
29 29 59 19 19 11
30 30 60 20 20 12
Table numbers
Acceptance levels
Defect type Acceptance levels plate and pipe macro only
Remarks Maximum allowance Remarks
At no point shall the excess

weld metal fall below the Excess weld metal will not exceed H = 2mm
Excess weld As for plate and
1 outside surface of the parent in any area on the parent material, showing
metal pipe
material. All weld runs shall smooth transition at weld toes.
blend smoothly.
Slag inclusions are defined as
non-metallic inclusions trapped The length of the slag inclusion shall not
Slag/silica Slag and silica not
2 in the weld metal or between exceed 50mm continuous or intermittent.
inclusions permitted
the weld metal and the parent Accumulative totals shall not exceed 50mm
material.
No sharp indications Smooth blend required.
Undercut is defined as a grove
The length of any undercut shall not exceed No sharp
melted into the parent metal,
50mm continuous or intermittent. indications
3 Undercut at the toes of the weld excess
Accumulative totals shall not exceed 50mm. Smooth blend
metal, root or adjacent weld
Max D = 1mm for the cap weld metal. required
metal.
Root undercut not permitted.
Trapped gas, in weld metal, Individual pores ≤ 1.5 max. Cluster porosity not
Porosity or elongated, individual pores, Cluster porosity maximum 502mm total area. permitted.
4
Gas Cavities cluster porosity, piping or Elongated, piping or wormholes Individual pores
wormhole porosity. 15mm max. L continuous or intermittent. acceptable.
Cracks or Transverse, longitudinal, star or

5 Not permitted Not permitted
Laminations crater cracks.
Incomplete fusion between Surface breaking lack of side wall fusion,

Lack of fusion the weld metal and base lack of inter-run fusion continuous or
6 Laps material, incomplete fusion intermittent not to exceed 15mm. Not permitted
Cold lap between weld metal. Accumulative totals not to exceed 15mm
(lack of inter-run fusion) over a 300mm length of weld.
or weld metal, from an
unintentional touchdown of the
7 Arc strikes Not permitted Not permitted
electrode or arcing from poor
connections in the welding
circuit.
Damage to the parent material No stray tack welds permitted
Mechanical or weld metal, internal or Parent material must be smoothly blended
8 Not permitted
damage external resulting from General corrosion permitted. Max. D =
any activities. 1.5mm. Only 1 location allowed
Mismatch between the As for plate and
9 Misalignment Max H = 1.5mm
welded or unwelded joint. pipe
Excess weld metal, above the

As for plate and
10 Penetration base material in the root of the Max H ≤ 3mm
pipe
joint.
The absence of weld metal in

Lack of root
11 the root area, two root faces Not permitted Not permitted
penetration
showing.
Lack of root Inadequate cross penetration of Lack of root fusion, not to exceed 50mm total
12 Not permitted
fusion (one) root face. continuous or accumulative.
Excessive penetration, collapse

13 Burn through Not permitted Not permitted
of the weld root
Angular Distortion due to weld

14 5mm max. Plate only Accept
distortion contraction
Weld metal below the surface of 50mm maximum length
15 Root concavity Accept
both parent metals 3mm maximum depth
WIS5-90516b
Practical Sessions Objective
When these presentation have been completed

you will have a greater understanding of the
examination requirement and how to identify
and plot weld defects around real life welds and
the classroom specimens on which you will be
Practical Pipe Inspection examined.
Pipe Inspection Hi-Low and Root Gap Measurements

1
Root gap
dimension
HI-LO Single Purpose Welding Gauge
Internal
alignment
Pipe Inspection Examination

Pipe Inspection Examination Pipe Inspection Examination
EXAMPLE PIPE REPORT
 After you have observed an imperfection and

Name: [Block capitals] ….............................. Signature: ……………….
Date…………………….
Code/Specification used: …………………… Welding process: ……………… Joint type: …………….
determined its type, you must be able to take Welding position: …………………. Outside Dia & thickness ……………
WELD FACE
Date ……………………
measurements and complete the thumb print A Lack of side B Arc Strike C
report sketch. 140
wall fusion
8 40
Under fill
12
98
 The first thumb print report sketch should be in

90 10 180 60 5
the form of a repair map of the weld. (ie all 20 15 46
Slag
observations are Identified sized and located). Lack of side Undercut Under fill
inclusion
wall fusion >1.0 mm
NOTES:
Excess Weld Metal Height = Misalignment = Weld Width = Toe Blend =
 The thumb print report sketch used in CSWIP Lack of side wall fusion
Arc Strike
C D A
exam will look like the following example. Slag / incomplete fill
12 15 3 8 2
0 8 5
 The thumb print is to used in conjunction with

the multiple choice questions during the
examination .
NOTES:
Excess Weld Metal Height = Misalignment = Weld Width = Toe Blend =
A3-1
Pipe Inspection Examination Pipe Inspection Examination
PIPE ROOT FACE
1. Read the Questions and compare 2. Compare to acceptance standard.
A Lack of B C
root fusion Burn with your thumb print.
140 through
8 40 6
2 1 90 1 180 46 5
6
0 5 0
0
Lack of Undercut Excess Poor stop
root >1.0 mm penetration start
penetratio 5mm
n
NOTES:
Excess Penetration Height = Toe Blend =
Lack of
C D root fusion
A
38 8
3. Mark the answer in the OMR grid
in pencil and accept or reject
12 accordingly. When you are sure
0 120
about your answer mark the OMR
Smooth Undercut grid in BLACK PEN.
<1.0mm
NOTES: Excess Penetration Height = Toe Blend =
Any Questions
?
Copyright © TWI Ltd
A3-2

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Appendix 2

Plate Reports and Questions

Answers to be indicated on the Candidate Answer Template.

a Equal to or less than 0mm.

a The area is between 15-25mm2.

a 2-3mm transverse crack.

a More than 2 areas.

a Individual pore diameter between 1-2mm.

Answers to be indicated on the Candidate Answer Template.

a Equal to or less than 0mm.

a The area is between 0.5-5mm2.

a 2-3mm transverse crack.

a 2-3 items observed.

a Individual pore diameter between 1-2mm.

Answers to be indicated on the Candidate Answer Template.

a Equal to or less than 0mm.

a 2-3mm transverse crack.

a Individual pore diameter between 1-2mm.

Remarks Maximum allowance Remarks

At no point shall the excess weld

Cracks or Transverse, longitudinal, star or

Incomplete fusion between Surface breaking lack of side wall fusion,

Excess weld metal, above the

Excessive penetration, collapse

When these presentation have been completed

Copyright © TWI Ltd Copyright © TWI Ltd

Example of Weld Face Example of Plate Root

Candidates signature…………………………… Welding process………………………..

fusion 1.5 Ø 1.5 max

NOTES: Penetration Height = Toe Blend = Weld Width =

Copyright © TWI Ltd Copyright © TWI Ltd

Plate Inspection Examination

2. Compare to acceptance standard.

1. Read the Questions and compare

3. Mark the answer in the OMR grid

Pipe Reports and Questions

Answers to be indicated on the Candidate Answer Template.

a Equal to or less than 0mm.

a 2-3mm transverse crack.

a 2-3 items observed.

a Individual pore diameter between 1-2mm.

Name [Block capitals]

Signature Pipe Ident#

Code/Specification used Welding Process Joint type

Welding position OutsideØ and Thickness Date

Notes: Visual Inspection Pipe Report

Answers to be indicated on the Candidate Answer Template.

a Equal to or less than 0mm.

a 2-3mm transverse crack.

a Individual pore diameter between 1-2mm.

Name [Block capitals]

Signature Pipe Ident#

Code/Specification used Welding Process Joint type

Welding position OutsideØ and Thickness Date

Notes: Visual Inspection Pipe Report

Answers to be indicated on the Candidate Answer Template

a Equal to or less than 0mm.

a 2-3mm transverse crack.

a Individual pore diameter between 1-2mm.

Name [Block capitals]

Signature Pipe Ident#

Code/Specification used Welding Process Joint type

Welding position OutsideØ and Thickness Date