CSWIP Practical Plate Answers

CSWIP 3.
1 Welding Inspection
Practical Plate Inspection
TWI Training & Examination

Services
Course Reference WIS 5
Copyright © 2006, TWI Ltd World Centre for Materials Joining Technology
Page 1 of 3 EXAMPLE PLATE REPORT
Name: [Block capitals] Mr. I C Plenty Signature: I C Plenty Test piece ident: 001
Code/Specification used: TWI 09-09-03 Welding process: MMA/SMAW Joint type: Single V Butt
Welding position: Flat /PA Length & thickness of plate: 300mm x 10 mm Date 22/08/2003
MEASURE
WELD FACE
A B C
Lack of sidewall
fusion Gas pore Undercut smooth
1.5 Ø 1.5 max
FROM
87 236
22 230
30
THIS
51 8 153 40
Arc Strike
Slag
Centreline 241
inclusion
DATUM
crack
NOTES: Cap height : 4mm.
Weld width: 12-14mm
Toe blend: Poor
Misalignment: 2mm
EDGE
Angular Distortion 3mm in 50mm

Spatter along weld length or scale on the plate surface
Page 2 of 3
MEASURE EXAMPLE PLATE REPORT
WELD ROOT
A B C
Root concavity
2 deep Lack of root
Fusion
FROM
23 247
10 20
THIS
128 50
Incomplete root
penetration
DATUM
NOTES: Penetration height : 4mm.

Linear Misalignment: 2mm
Angular Distortion: 3mm in 50mm
Any scale on plate surface
EDGE
EXAMPLE WELD INSPECTION REPORT/SENTENCE SHEET
PRINT FULL NAME I C Plenty

SPECIMEN NUMBER 001
EXTERNAL DEFECTS Defects Noted Code or Specification Reference
Defect Type Pipe/Plate Accumulative Maximum Section/ Accept/Reject

Section Total Allowance Table No 5
1 2 3 4
Excess weld metal height A-C 4mm 2mm 15 Reject
Excess weld metal appearance A-C Poor blend Smooth 8 Reject
Incomplete filling A-C 22mm None 5 Reject
Inadequate weld width (PIPE) A-C N/A ------------ ---------- Accept
Slag Inclusions A-C 70mm long 50mm 9 Reject
Undercut A-C 1.5mm depth 1mm 6 Reject
Surface Porosity A-C 1.5mm  1mm 2 Reject
Cracks/Crack-like defects A-C 40mm NONE 1 Reject*
Lack of fusion A-C 22mm NONE 3 Reject
Arc strikes A-C 3 NONE 7 Reject***

Mechanical damage A-C NONE ------------ ----------- Accept
Laps/Laminations A-C NONE ------------ ----------- Accept
Misalignment (Linear) A-C 2mm 2mm 15 Accept
Longitudinal seams (PIPE) A-C N/A ------------ ---------- Accept
Root Defects
Misalignment A-C 2mm 2mm 9 Accept
Excessive Root Penetration A-C 4mm 2mm 15 Reject
Incomplete Root Penetration A-C 50mm NONE 13 Reject
Lack of Root Fusion A-C 20mm NONE 11 Reject
Root Concavity A-C 2mm depth 1mm 10 Reject
Root Undercut A-C NONE ------------ ---------- Accept
Cracks/Crack-like defects A-C NONE ------------ ---------- Accept
Slag inclusions A-C NONE ------------ 9 Accept
Porosity A-C NONE ------------ 2 Accept
Laps/Laminations A-C NONE ------------ ---------- Accept
This *pipe/plate has been examined to the requirements of code/specification TWI-N/WIS-PI

.........................................
and is accepted/rejected accordingly.
Comments:
* Request MPI testing to confirm crack and length.
** Large amount of spatter on weld face. Recommend this is removed and re inspected.
*** Recommend arc strikes are ground flush prior to MPI testing for cracks.
I C Plenty
Signature.........................................................
22nd August 2003
Date................................................. ....................................
*Delete which is not applicable. Use the other side for any comments.
Inspection Practice Specification
Number TWI 09-09-03
All dimensions are given in mm
No Imperfection Comments Allowance
1 Cracks All types of cracks Not permitted
2 Porosity/Gas pores/elongated Cluster Max dimension of area L = 13mm Max

Gas cavities (wormholes) pipes Single pore Max dimension L = 1mm Max
3 Solid Inclusions Non metallic. Individual size Maximum 1mm
4 Solid Inclusions Metallic. Individual size Not permitted
5 Lack of Fusion Side wall/Root/Inter-run Not permitted
6 Incomplete Root Penetration Not permitted
7 Overlap/Cold lap Weld face/Root Not permitted
8 Incompletely filled groove Not permitted
9 Linear Misalignment 0.2t Maximum 4mm
10 Angular Misalignment Maximum 10º
11 Undercut Smoothly blended 10%t Maximum d 1mm
12 Arc Strikes Area to be tested by MPI Seek advice
13 Laminations Not permitted
14 Mechanical Damage Not permitted
15 Cap Height Shall fall below plate surface 0 –3mm h Maximum
16 Penetration Bead 0 –2mm h Maximum
17 Toe Blend Smooth
18 Spatter Clean & Re-inspect Refer to manufacturer
19 Weld Appearance All runs shall blend smoothly Regular
20 Root concavity 10%t Maximum
Plate Sample 6A Cap
Welding Process MMA (SMAW)
?
Incomplete Filled Groove
?
Porosity Lack of
?
fusion
Slag Cap Undercut Cap Undercut
?
Inclusion ?
Intermittent ?
Intermittent
Cap Undercut
Intermittent ? ?
Arc Strike
?
Arc Strike
Note: spatter and surface slag requires removal, arc strikes

require blending and crack detection
Plate Sample 6A Root
Excess
?
Penetration
Excess
?
Penetration
?
Gas Pore
Root Undercut
?
Linear Misalignment
?
Surface Slag Lack of Root
?
Fusion ?
Note: Spatter and surface slag require removal
Plate Sample 6B Cap
?
?Porosity Lack of Sidewall
?
Lack of Sidewall Fusion Fusion?
?
Surface Slag
Overlap and Excess Cap Height Full Weld Length ?
Note: Surface slag requires removal and poor toe blending

full weld length
Plate Sample 6B Root
? ?
Slag Inclusion
Crater Pipe
?
Lack of Root Fusion
?
Lack of Root ?
Lack of Root Fusion
Penetration
Plate Sample 6C Cap
Welding Process FCAW
Incomplete
?
Cap Undercut
Filled Groove +
Lack of
Sidewall
?
Surface slag & Spatter ?
Fusion Longitudinal
?
Crack
?
Slag Inclusion
?
Incomplete Filled
Groove + Lack of
Sidewall Fusion + Cap
Undercut Intermittent
Note: Spatter and surface slag requires removal
Plate Sample 6C Root
Welding Process FCAW
Mechanical Damage
?
Burn Through
? Poor Stop/Start + Lack of
?
Root Penetration
?Excess Penetration
?
Lack of Root Fusion
Lack of Root Fusion

?
Plate Sample 6D Cap
?
Porosity
Incomplete
?
Filled Groove
Excess Cap Cap Lack of Sidewall Cap
Height ? ?
Undercut ?
Fusion ?
Undercut
Overlap between Capping Passes
Note: Excess cap height and poor cap profile throughout.
Plate Sample 6D Root
?
Mechanical Damage
?
Lack of Root Fusion
Lack of Root Fusion

?
Plate Sample 6E Cap
Lack of
?
Sidewall
Fusion
?
Cap Undercut Intermittent ?
Cap Undercut Intermittent
?
Excess Cap Height
?
?
Plate Sample 6E Root
?
Poor Stop/Start + Crater Pipe ?
Lack of Root Fusion
?
Lack of Root Fusion
?
Root Undercut
?
Excess Root Penetration
?
Excess Root
Penetration
Crater Pipe ?Lack of Root
fusion
?
Plate Sample 6F Cap
Mechanical
Damage
?
?
Lack of Sidewall fusion Crater pipe ?
Poor Toe Blend Lack of Sidewall Fusion + Incomplete Filled Groove

? ?
?
Tack Weld
? Arc
Strikes
Note: Arc strikes require blending and crack detection
Plate Sample 6F Root
Poor Stop/Start + Lack of Root

?
Penetration + Crater Pipe ?
Blow Hole
?
Arc Strikes Lack of Lack of
Mechanical Damage +
?
Lack of Root Fusion
Root
?
Fusion
Root?
Fusion
Lack of Root Fusion

Arc Strikes
? ? Arc Strikes
?
Note: Arc strikes require blending and crack detection
Plate Sample 6G Cap
?
Parent Material Damage
?
Arc Strikes
?
Arc Strikes
Lack of Sidewall Fusion +
?
Poor Toe Blend + Excess Cap Height

?
Porosity
?
Note: Arc strikes require blending and crack detection, Seek
advise on parent material damage
Plate Sample 6G Root
Parent material
?
gas cavities
?
Plate corrosion
?
Poor Stop/Start
?
Lack of Root Fusion
Crater pipe ? slag

Surface
?
Surface Slag
?
Linear Misalignment
?
Note: Surface slag requires removal, plate corrosion requires

wire brushing
Plate Sample 6H Cap
?
Incomplete Filled Groove ? ?
?
Arc Strikes
Arc Strikes Slag Inclusion ?
Arc Strikes
Cap Undercut
Arc Strikes
?
Cap Undercut Intermittent
?
? Arc Strikes
?
Note: Parent plate damage throughout, seek advice. Arc

strikes require blending and crack detection.
Plate Sample 6H Root
?
Crater pipe ?
Excessive root penetration ?
Linear misalignment +
lack of root fusion
Lack of root fusion
? Poor stop/start ? ?
Lack of root fusion Arc strikes
?
Arc strikes

Plate Sample 6I Cap
?
?
Cap undercut
Spatter
Arc strikes
?
Poor toe blend full weld length

?
Note: Arc strikes require blending and crack detection.

Spatter requires removal.
Plate Sample 6I Root
Arc strike
? ?
Lack of root penetration
Burn through Poor stop/start ?
?
Linear misalignment
? Lack of root penetration
?
Lack of root fusion
?
?
Mechanical damage ?
Lack of root fusion
+ poor stop/start

Plate Sample 6J Cap
Suspect crater cracking

?
Cap undercut
?
Arc strikes
?
Cap undercut
?
Porosity
Cap undercut intermittent

Cap undercut ?
?
Note: Material damage throughout, seek advice. Arc strikes

require blending and crack detection.
Plate Sample 6J Root
?
Mechanical damage
? fusion
Lack of root
?
lack of root fusion
Lack of root penetration

?
lack of root fusion ?
Note: Material damage seek advice on course of action.
Plate Sample T4 Cap
Mechanical damage
?
?
Cap undercut ?
Cap undercut
Spatter/irregular cap profile

?
Note: Grinding marks throughout seek advice on course of

action.
Copyright © 2006,Excess
TWI Ltd cap World
heightCentre for Materials
and poor Joining
cap profile Technology
throughout.
Plate Sample T4 Root
? ?
Arc strike
Root undercut
intermittent
?
Lack of penetration intermittent
Ground flush root

?
Plate Sample H8 Cap
?
Surface slag
?
Arc strikes damage
?
Mechanical
?

?
?
Mechanical
damage
Note: Mechanical damage seek advice on course of action.

Excess cap height and poor cap profile throughout. Arc
strikes require blending and crack detection.
Plate Sample H8 Root
? ?
Lack of root
Arc strike fusion
? ?
? Lack of root Spatter
?
Lack of root
fusion
Lack of root
fusion
fusion
Root undercut intermittent

Spatter
? ?
Note: Arc strikes require blending and crack detection.

Spatter requires removal
Any Questions

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CSWIP 3.

Practical Plate Inspection

TWI Training & Examination

Course Reference WIS 5

Angular Distortion 3mm in 50mm

NOTES: Penetration height : 4mm.

PRINT FULL NAME I C Plenty

Defect Type Pipe/Plate Accumulative Maximum Section/ Accept/Reject

Inadequate weld width (PIPE) A-C N/A ------------ ---------- Accept

Slag Inclusions A-C 70mm long 50mm 9 Reject

Undercut A-C 1.5mm depth 1mm 6 Reject

Surface Porosity A-C 1.5mm  1mm 2 Reject

Cracks/Crack-like defects A-C 40mm NONE 1 Reject*

Lack of fusion A-C 22mm NONE 3 Reject

Arc strikes A-C 3 NONE 7 Reject***

Laps/Laminations A-C NONE ------------ ----------- Accept

Misalignment (Linear) A-C 2mm 2mm 15 Accept

Longitudinal seams (PIPE) A-C N/A ------------ ---------- Accept

Misalignment A-C 2mm 2mm 9 Accept

Excessive Root Penetration A-C 4mm 2mm 15 Reject

Incomplete Root Penetration A-C 50mm NONE 13 Reject

Lack of Root Fusion A-C 20mm NONE 11 Reject

Root Concavity A-C 2mm depth 1mm 10 Reject

Root Undercut A-C NONE ------------ ---------- Accept

Cracks/Crack-like defects A-C NONE ------------ ---------- Accept

Slag inclusions A-C NONE ------------ 9 Accept

Porosity A-C NONE ------------ 2 Accept

Laps/Laminations A-C NONE ------------ ---------- Accept

This *pipe/plate has been examined to the requirements of code/specification TWI-N/WIS-PI

2 Porosity/Gas pores/elongated Cluster Max dimension of area L = 13mm Max

Note: spatter and surface slag requires removal, arc strikes

Note: Spatter and surface slag require removal

Overlap and Excess Cap Height Full Weld Length ?

Note: Surface slag requires removal and poor toe blending

Note: Spatter and surface slag requires removal

Lack of Root Fusion

Overlap between Capping Passes

Note: Excess cap height and poor cap profile throughout.

Lack of Root Fusion

Poor Toe Blend Lack of Sidewall Fusion + Incomplete Filled Groove

Note: Arc strikes require blending and crack detection

Poor Stop/Start + Lack of Root

Lack of Root Fusion

Poor Toe Blend + Excess Cap Height

Crater pipe ? slag

Note: Surface slag requires removal, plate corrosion requires

Note: Parent plate damage throughout, seek advice. Arc

Lack of root fusion

Note: Arc strikes require blending and crack detection, Seek

Poor toe blend full weld length

Note: Arc strikes require blending and crack detection.

Note: Arc strikes require blending and crack detection, Seek

Suspect crater cracking

Cap undercut intermittent

Note: Material damage throughout, seek advice. Arc strikes

Lack of root penetration

Note: Material damage seek advice on course of action.

Spatter/irregular cap profile

Note: Grinding marks throughout seek advice on course of

Ground flush root

Cap undercut intermittent

Note: Mechanical damage seek advice on course of action.

Root undercut intermittent

Note: Arc strikes require blending and crack detection.