WIS5-2019-UK-BAB

WIS5 - CSWIP 3.1 Welding Inspector online Exam 1 Rev1 Section Work Pack
Copyright © TWI Ltd 2019

«Numbers»

Online Exam 1 Rev 1

THEORY SECTION 2
Work Pack
Multiple Choice

Instructions and Examination Questions

90 minutes allowed

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WIS5 - CSWIP 3.1 Welding Inspector online Exam 1 Rev1 Section Work Pack
Copyright © TWI Ltd 2019

Multiple Choice Candidate Instructions

Read these instructions carefully, if in doubt seek advice from the examination
invigilator.

You are required to answer 40 multiple choice questions. Your answers are recorded on a
separate sheet (template) provided. This template will be supplied to you by the
examination invigilator.

Below gives an example of how to complete the multiple-choice questionnaire paper.

1. Read the questions in this folder.

2. Indicate your answers with a X (cross) in the appropriate box in the template.
3. All answers to be first marked in pencil. Final answers to be in black ink.

Example Question:

1 Which welding defect do you consider to be the most serious?

a Porosity
b Slag
c Undercut
d Arc strikes

Example Answer

THEORY 2 work
pack Correct answer indicated here in
A B C D
the candidate answer template
1

THEORY 2 work
pack
A B C D

1
More than one answer given, answer null
2
and void.
3
If you want to change your pencil response
4
– use the eraser.
5
THE FINAL ANSWER SHOULD BE IN
6 BLACK INK (NO CHANGES ALLOWED)

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WIS5-2019-UK-BAB
WIS5 - CSWIP 3.1 Welding Inspector online Exam 1 Rev1 Section Work Pack
Copyright © TWI Ltd 2019

CSWIP 3.1 THEORY SECTION 2 WORK PACK

Answers to be indicated on the candidate template sheet under the heading of THEORY 2
work pack. Candidates must not mark this sheet; failure to follow these instructions could
lead to this part of the examination being void.

Inspection scenario

You are required to oversee the completion of a fabrication shown on the provided drawing.
This will require establishing that the correct welder qualifications and WPS(s) are being
used and also inspecting before, during and after welding.

1. WPS 22 states the positions which are qualified by the procedure for production
welding. Which of the following welding positions would not be permitted by the procedure

A. Overhead
B. Horizontal
C. Vertical down
D. Vertical up

2. Considering Welder qualification EX 4. Which of the following would apply to the

consumable stated?

A. The 5 in the designation is for the weld position the consumable can be used in
B. H5 represents the hydrogen gas content of the electrode
C. The 46 represents the yield strength of the wire
D. The 46 represents the yield strength of the electrode

3. WPS 34 has been approved for production welding by the client. The welder identified
by welder qualification EX 3 would be permitted to weld which of the following in production
welds following WPS 34?

A. Butt welds with a maximum arc energy of 0.6Kj/mm

B. Fillet welds with a maximum arc energy of 0.6kj/mm
C. Fillet welds welded in the PA position
D. The welding qualification EX 3 should not be used with WPS 34

4. The weld identified as W3 will be subjected to cyclic loading when in service. Which of
the following would improve the fatigue life of the welded joint?

A. Using a back-step welding technique

B. Using a fillet weld instead of a butt weld
C. Depositing a larger weld bead
D. Having a smooth weld profile

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WIS5 - CSWIP 3.1 Welding Inspector online Exam 1 Rev1 Section Work Pack
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5. Considering W6. Which WPS would not be suitable for welding the joint identified
but would produce the highest deposition rates?

A. WPS 22
B. WPS 34
C. WPS 11
D. WPS 18

6. Which of the following would apply to Welder qualification test certificate EX 3:

A. The certificate should have recorded results for Root and side bends
B. The material would require tensile testing and is not recorded on the certificate
C. Welder qualification tests require macro examination and results have been omitted
D. The certificate indicates the correct testing methods to qualify the welder

7. WPS 11 states the polarity to be used for welding. Which of the following would
apply?

A. The polarity stated would provide good results with the given joint design
B. Polarity is never an essential variable for a WPS and can ignored
C. The polarity stated will give less penetration and less deposition
D. A root run should always be carried out using AC on the given joint design

8. W8 is to be completed in production, which WPS would be suitable for this joint?

A. WPS 22
B. WPS 11
C. WPS 34
D. None of the WPS could be used to complete the production weld

9. The weld identified as W5 is to be made in production. A concession has been made

to change the material thickness to 12mm. WPS are available to cover the range, how
many of the welder qualifications would still be valid?

A. Four
B. None
C. Two
D. One

10. WPS 11 has no value recorded for ROL, how could the omission of ROL influence
weld quality?

A. ROL is only applicable for globular transfer so will not influence weld quality
B. The travel speed could be used to provide similar control measure for the process
C. ROL is only used when pipes are rotated
D. The heat input would subsequently exceed the values given. Resulting in lower
toughness values for the weld

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WIS5 - CSWIP 3.1 Welding Inspector online Exam 1 Rev1 Section Work Pack
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11. The weld which is to be made between F2 and F3, is deemed as critical. Considering
the material and limited access. Which of the following NDT techniques would be the most
suitable to identify internal weld defects?

A. MPI using an AC yoke

B. UT using a compression probe and ½ skip scanning pattern
C. UT using an angle probe with a full skip scanning pattern
D. RT using DWSI

12. WPS 22 is to be used for production welding. Which of the following would be
permissible?

A. The joint bevel angles could be increased

B. The procedure would also cover process 121
C. PWHT should be added after welding to reduce both distortion and residual stress
D. A double sided V butt with staggered weld patterns could be used

13. Considering the four welder qualifications. Which of the following would be
applicable to production welding and qualification range?

A. Only the welder identified in qualification EX4 can weld in all positions
B. All welders would be permitted to weld in the PB and PF positions
C. None of the welders would be permitted to weld in the PF position
D. Only two of the welders would be able to weld in the overhead position

14. The Welder identified in qualification EX4, is to perform production welding using
WPS 18. Which of the following would describe the consumables recorded on the
qualification and the WPS.

A. The WPS uses an electrode with a yield of 70,000 PSI

B. The WPS has an electrode with a value indicating it can be used at -10°F
C. The welder qualification was carried out using an electrode that can be used only
above 50°C
D. The welder qualification was carried out using an electrode with a yield of 460 n/mm²

15. Referring to Joint W3. What would be the most suitable radiographic technique?

A. DWDI
B. DWSI
C. SWSI
D. SWSI panoramic

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WIS5 - CSWIP 3.1 Welding Inspector online Exam 1 Rev1 Section Work Pack
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16. WPS 34 states that “a” has no restriction. The design specification for the component
also states no weld shall fail to meet a minimum leg length of 0.7 of t. Which of the
following throat thickness dimensions would fail to meet the minimum leg acceptable for
the joint identified as W7?

A. 5.2mm
B. 7mm
C. 16.5mm
D. 4.8mm

17. Referring to Welder qualification EX1. Which of the following statements would apply?

A. Fracture testing would only be required if the welded component was intended to
be used in low temperature conditions.
B. Bend tests are required for fillet welds only, so the test results can be ignored
C. Destructive testing is always an additional test specified by the client. Results can
be ignored if the client does not specify that testing.
D. Bend tests are conducted in addition to NDT, as some processes are more prone
to lack of fusion.

18. WPS 11 states a shielding gas for the welding process. Considering modes of metal
transfer which of the following would apply?

A. Full spray transfer is achievable with the stated gas

B. Full spray transfer would not be achievable due to the lack of Argon
C. The gas stated should only be used for pulse transfer
D. The pre-heat used and the flux stated always determine the mode of metal transfer
when using process FCAW.

19. Referring to WPS 11, what is the minimum and maximum heat input for
the capping runs?

A. 1.42 to 2.13 kJ per mm

B. 0.85 to 1.28 kJ per mm
C. 1.13 to 1.70 kJ per mm
D. 0.57 to 1.18 kJ per mm

20. Referring to WPS 18. If the minimum and maximum ROL values recorded for one
minute of welding were 80mm and 110mm. What would be the minimum arc energy for
the root run?

A. 1.3 kJ per mm
B. 1.04 kJ per mm
C. 1.8 kJ per mm
D. The value cannot be calculated from the information given

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WIS5 - CSWIP 3.1 Welding Inspector online Exam 1 Rev1 Section Work Pack
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21. The client sates that previous vendor inspections, have highlighted difficulties working
with the component identified as F1. Which of the following should be considered to avoid
chromium carbide formation

A. Use higher heat inputs during welding

B. Increase the preheat temperature for the material prior to welding
C. These will not form as 316L is being used
D. The material should have the passivation layer removed prior to welding

22. Why is the use of an oxyacetylene cutting torch not recommended for pre-heating?

A. It will increase the toughness of a material

B. It can decrease the risk of cracking
C. It may cause hard spots on the material due to localised heating
D. Its use is still widely recommended and used within industry

23. During pre-weld inspection you notice welding consumables not approved for
production, are set ready to use for tack welding. Which of the following would be a suitable
course of action?

A. Allow the consumables to be used as tack welds never form part of the final weld
B. As long as a qualified welder completes the tack welding any consumable can be
used
C. Carry out a destructive test on one of the tack welds to make sure it’s of sound
quality
D. The consumables should not be used for any welding operations if they have not
been approved. Do not permit welding operations to commence.

24. A pressure retaining component has a weld symbol indicating a full penetration butt
weld. The fabricator is proposing a concession and suggests a change to a part penetration
butt weld. Considering quality is paramount, which of the following should be considered
during the decision making process.

A. The change should be permitted as it will speed up weld production

B. The weld could suffer from lack of penetration and the subsequent repair will slow
production down, reject the concession.
C. The weld could offer similar properties, if access was available for a sealing run and
back grinding, investigate the request further
D. A decrease in deposition rate would always be associated with such a change, reject
the concession

25. Prior to welding you notice the included angle of a vee butt has been reduced from 70°
to 55°. Which of the following could explain such a change?

A. The reduced angle would decrease the need for a root face
B. The reduced angle would increase the stresses caused by welding
C. The reduced angle would increase the amount of weld metal needed
D. The reduced angle would decrease welding time

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WIS5 - CSWIP 3.1 Welding Inspector online Exam 1 Rev1 Section Work Pack
Copyright © TWI Ltd 2019

26. You are observing the welding of plate butt welds in the PF position. You notice welders
are using a weave technique as opposed to a stringer. Which of the following statements
is incorrect?

A. A weave with a slow travel speed will produce a higher heat input
B. A stringer with a fast travel speed will produce a higher heat input
C. Welding in the PF position always requires the use of a weave technique
D. Some consumables and processes cannot be used for positional welding

27. The clients welding inspector has suggested repairs are increasing due to poor in
process inspection control. One of the repairs identified is solidification cracking. Which of
the following could limit its occurrence

A. Checking all weld root profiles before filling up butt welds

B. Reducing bevel angles so less weld metal is required
C. Ensure all deposited welds are within the 2:1 depth to width ratio
D. Check the materials being used are of Z% values greater than 20%

28. During the final inspection of a completed weld, you notice a tack weld which was
made to aid alignment during set up which has not been removed. What action would you
take?

A. Ignore you’re finding as a welding inspector only assesses the completed weld joint
B. Suggest the completed weld will only be assessed once the tack has been fully removed
and NDT checked
C. Instruct the welder who has welded the joint to grind out the full area, and inspect
with MPI to avoid contamination
D. The remaining tack weld will not cause any in service problems, ignore the weld and
assess the completed weld

29. The client has asked why the welder doesn’t control the arc length with process 136.
Which of the following would be the best explanation?

A. The wire feed speeds up to allow the arc length to remain constant
B. Wire feed speed remains constant, which keeps the arc length constant
C. The statement is incorrect, as all manual processes require the welder to maintain the
arc length throughout welding
D. The travel speed controls the arc length so faster welding speeds produce shorter
arcs

30. Whilst checking the width of a MMA weld, you notice that the welds have exceeded
the maximum width of 3.5 times the diameter of the electrode. What influence could this
have on the weld metal mechanical properties?

A. An increased in hardness
B. An increased amount of distortion and residual stress
C. A decreased hardness value
D. A decreased toughness

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WIS5 - CSWIP 3.1 Welding Inspector online Exam 1 Rev1 Section Work Pack
Copyright © TWI Ltd 2019

31. During welding activities you notice marks made with temperature indicating crayons
are melting. This suggests their indicating temperature has been exceeded. The welder is
still welding the joint. What action should you take?

A. Immediately stop the welding, as the maximum interpass temperature has been
exceeded
B. Reject the weld as the parameters stated on the WPS must have been exceeded
C. Minimum interpass temperature is always taken when the welder is to restart welding
therefore the marks would now be irrelevant
D. Consult the WPS, as a minimum interpass temperature between passes may also be
relevant.

32. During visual inspection you note excessive amounts of spatter on a number of
completed welds. All of which were welded with process 111. What could have caused the
spatter?

A. A decrease in the inductance being used

B. A draught causing poor shielding of the welding arc
C. The use of too short an arc length during welding
D. Contaminated material surfaces with a long arc length

33. You are inspecting pipe spools made of 308L material with a wall thickness of 25mm.
During inspection you notice a difference in colour with some of the already completed
root welds. Some of the welds appear to be grey and others shiny. What is the most likely
cause of this?

A. Exceeding the recommended levels of argon in the pipe purge

B. Not purging the pipes to the required pressure
C. Using 316L welding wire as opposed to 308L welding wire
D. Removing the purge to soon after completing the root pass and starting the filling runs

34. Joint W2 identified on the drawing requires NDT testing. What would be the best
method for finding internal non-planar defects?

A. Ultrasonics
B. Radiography
C. MPI
D. Dye penetrant

35. An ITP states all structural sections should be of Z quality. What is the reason for this?

A. To help prevent solidification cracking during welding

B. To help prevent the formation of laminations during welding
C. To ensure the material has good through thickness ductility
D. To avoid the need for tensile test results when carrying out WPS qualifications

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WIS5 - CSWIP 3.1 Welding Inspector online Exam 1 Rev1 Section Work Pack
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36. Whilst reviewing heat treatment charts for C/Mn steel you notice thermocouples have
been used to record values ranging from 120°-600°, then down from 600° to 120°. You also
note no reference is made to time. Which of the following would best explain the recorded
values.

A. With any heat treatment cycle it is critical to only record the soak temperature, the
cooling cycle can be ignored.
B. The temperatures would indicate an effective PWHT due the maximum value recorded
C. The chart should also record time, as both temperature and time are important factors
when carrying out any heat treatment
D. The temperature is the only critical value needed, due to the low heat input used in the
heat treatment

37. All lifting attachments identified through the drawing have NDT requirements. Which
of the following would be applicable if UT was to be used for NDT evaluation.

A. The weld can always be tested in the as welded condition

B. The weld surface itself should be free from any surface discontinuities
C. The weld area should always be cleaned with a solvent prior to inspection
D. The weld should be tested at an elevated temperature to identify hot cracks

38. Referring to section A identified by the drawing. You notice within the welding
documentation a weld repair has been conducted. However no reference has been made
of a repair procedure. What would be your course of action?

A. If the repair has a NDT report that is accepted ignore the missing reference
B. Make up a repair procedure number as no one will ever check
C. Report the omission to the senior welding inspector to investigate further
D. Inform the clients welding inspector so an NCR can be issued and a repair on the
repair can be carried out with a procedure

39. The client has requested part F1 on drawing is replaced with Duplex stainless steel.
What would be your main objection for this not to happen?

A. Duplex stainless steel is a mixture of 3 phases Austenite, martensite and ferrite, and
welding can cause martensite formation.
B. Duplex stainless steel is a mixture of 2 phases Austenite and martensite and welding
can lead to one phase forming over the other
C. 316L would be better suited due to its wider operating temperature range
D. The Duplex stainless steel would be better suited due to it having excellent performance
at low temperatures

40. The combination of F1 and S2 could lead to what problem if materials were not
segregated during the fabrication process?

A. Iron sulphide formation during welding

B. Intergranular corrosion could occur during service
C. Increased hardness after welding in the material identified as F1
D. Sigma phase formation in the material identified as S2

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 Certificate No:
Page 1 of 2

Welder Qualification Test Certificate

(ISO 9606-1:2017)
EX1-Online
Designation: EN ISO 9606-1,135,P,BW,FM1,s10, t10, PA,ss mb, bs
Welding Procedure WPS 2 Examining Body: TWI CL
Specification Reference No. WPS 2 Reference No:
Welders Name Bob Bruce
Identification BB
Method of Identification: Initials
Photograph
Date and Place of Birth: 18/08/76
(if required)
Employer: Private
Code/Testing Standard: BS EN ISO 9606-1:2017
Job Knowledge: Not Tested
Test Piece Range of Qualification
Welding Process(es) 135MAG 135 / 138 MAG
Transfer Mode Dip and Spray All
Product Type (plate or pipe) (P) Plate (T) Pipe/Tube & (P) Plate
Type of Weld (BW) Butt weld (BW) Butt Welds Only
Parent Material EN 10025-2 (S355J2, 1.0577) Grp 1.2 Non Essential Variable (Any)
Filler Materials Group(s) FM 1 FM 1 & FM 2
Filler Material (designation) EN ISO 14341-A G 46 5 M 3Si1 S&M
Shielding Gas ISO 14175-M21 Ar80 % 20% C02 Non Essential Variable (Any)
Auxiliaries N/A N/A
Type of Current and Polarity DC + Non Essential Variable (Any)
Material Thickness (mm) 10mm 3.0mm to 20.0mm
Deposited Thickness (mm) 10mm 3.0mm to 20.0mm
Outside Pipe Diameter (mm) N/a ≥ 500mm
Welding Positions PA PA
Weld Details ss mb ss mb,bs
Multi-layer/Single Layer ml sl & ml

Supplementary Fillet Weld Test (completed in conjunction with a butt weld) N/A

See Test Report No:

Type of Test Performed and Acceptable Not Tested Name & Signature of Engineer
Visual Testing Acceptable
Radiographic Testing Acceptable
Inspecting Authority
Fracture Test Not Tested TWI Certification Limited
Bend Test Acceptable
Date of Issue: 10/08/2019
Notch Tensile Test Not Tested
Location: Middlesbrough
Macroscopic Examination Not Tested Validity of Qualification: 01/08/2022

Date of Welding: 02/08/2019

Revalidation Valid Until Revalidation Valid Until Revalidation Valid Until

on 9.3 a) 01/08/2022 on 9.3 b) on 9.3 c)

TWI Certification Ltd is a Recognised Third Party Organisation in accordance with the Pressure Equipment Directive, details of which can be
confirmed at http://ec.europa.eu/growth/tools-databases/nando/index.cfm?fuseaction=country.notifiedbody&cou_id=826

Revalidation for qualification by examiner or examining body for the following 2 years [refer to 9.3 b)]
Confirmation of the validity by employer / welding coordinator / examiner or examining body for the following 6 months [refer 9.2)].
 Certificate No:
Page 1 of 2

Welder Qualification Test Certificate

(ISO 9606-1:2017)
EX2-Online
Designation: EN ISO 9606-1,136,P,BW,FM1,B,s 25,t25,PA,PE,ss,mb,bs
Welding Procedure WPS 11 Examining Body: TWI CL
Specification Reference No. WPS Reference No:
Welders Name Stella Smith
Identification SS
Method of Identification: Initials
Photograph
Date and Place of Birth: 18/08/76
(if required)
Employer: Private
Code/Testing Standard: BS EN ISO 9606-1:2017
Job Knowledge: Not Tested
Test Piece Range of Qualification
Welding Process(es) 136 FCAW 136 FCAW
Transfer Mode Spray Spray
Product Type (plate or pipe) (P) Plate (T) Tube/Pipe & (P) Plate
Type of Weld (BW) Butt Weld (BW) Butt Welds only
Parent Material EN10028-3 P355NL2 (1.1106) Non Essential Variable (Any)
Filler Materials Group(s) FM 1 FM 1 & FM 2
Filler Material (designation) EN ISO 17632-A T 42 4 B C 2 H5 R, P, V, W, Y, Z & B
Shielding Gas ISO 14175-M21 Ar80 % 20% C02 Non Essential Variable (Any)
Auxiliaries N/A N/A
Type of Current and Polarity DC + Non Essential Variable (Any)
Material Thickness (mm) 25mm ≥ 12mm-75mm
Outside Pipe Diameter (mm) N/A Pipe ≥ 75mm rotated PA Only ≥ 500mm Fixed
Welding Positions PA and PE PA, PC & PE
Weld Details mb bS mb bs,ss
Multi-layer/Single Layer ml sl & ml

Supplementary Fillet Weld Test (completed in conjunction with a butt weld) N/A

See Test Report No:

Type of Test Performed and Acceptable Not Tested Name & Signature of Engineer
Visual Testing Acceptable
Radiographic Testing Acceptable
Inspecting Authority
Fracture Test Not Tested TWI Certification Limited
Bend Test Acceptable
Date of Issue: 10/08/2019
Notch Tensile Test Not Tested
Location: Middlesbrough
Macroscopic Examination Not Tested Validity of Qualification: 01/08/2022

Date of Welding: 02/08/2019

Revalidation Valid Until Revalidation Valid Until Revalidation Valid Until

on 9.3 a) 01/08/2022 on 9.3 b) on 9.3 c)

TWI Certification Ltd is a Recognised Third Party Organisation in accordance with the Pressure Equipment Directive, details of which can be
confirmed at http://ec.europa.eu/growth/tools-databases/nando/index.cfm?fuseaction=country.notifiedbody&cou_id=826

Revalidation for qualification by examiner or examining body for the following 2 years [refer to 9.3 b)]
Confirmation of the validity by employer / welding coordinator / examiner or examining body for the following 6 months [refer 9.2)].
 Certificate No:
Page 1 of 2

Welder Qualification Test Certificate

(ISO 9606-1: 2017)
EX3-Online
Designation: ISO 9606-1,141,T,BW,FM5,S,s12,t12,D60,H-L045,ss,gb
Welding Procedure Examining Body: TWI CL
Specification Reference No. Reference No:
Welders Name A Another
Identification AA
Method of Identification: Initials
Photograph
Date and Place of Birth: 01/10/1996
(if required)
Employer:
Code/Testing Standard: BS EN ISO 9606-1:2017
Job Knowledge: Not Tested
Test Piece Range of Qualification
Welding Process(es) TIG 141 TIG 141, 142, 143 & 145
Transfer Mode N/A N/A
Product Type (plate or pipe) (T) Pipe (T) Pipe & (P) Plate
Type of Weld (BW) Butt Weld (BW) Butt Welds Only
Parent Material EN 10088-1 316L 1.4404 Non Essential Variable (Any)
Filler Materials Group(s) FM5 FM5
Filler Material (designation) ISO 1434-A W 19 12 3 L S&M
Shielding Gas/Purge ISO 14175-I1 Ar 99.9% Non Essential Variable (Any)
Auxiliaries N/A N/A
Type of Current and Polarity DC – DC –
Material Thickness (mm) 12mm 3.0mm to 22mm
Deposited Thickness (mm) 12mm 3.0mm to 22mm
Outside Pipe Diameter (mm) 60mm ≥ 30mm
Welding Positions H-L045 All Except Vertical Down
Weld Details ss,gb ss,mb, ss,gb, & bs
Multi-layer/Single Layer ml sl & ml

Supplementary Fillet Weld Test (completed in conjunction with a butt weld) Not Performed
See Test Report No:

Type of Test Performed and Acceptable Not Tested Name & Signature of Engineer
Visual Testing Acceptable
Radiographic Testing Acceptable Name
Inspecting Authority
Fracture Test Not Tested TWI Certification Limited
Bend Test Not Tested
Date of Issue: 20/05/2019
Notch Tensile Test Not Tested
Location: Middlesbrough
Macroscopic Examination Not Tested Validity of Qualification: 11/05/2022

Date of Welding: 12/05/2019

Revalidation Valid Until Revalidation Valid Until Revalidation Valid Until

on 9.3 a) 11/05/2022 on 9.3 b) xxxxxxxxxxx on 9.3 c) xxxxxxxxxxx

TWI Certification Ltd is a Recognised Third Party Organisation in accordance with the Pressure Equipment Directive, details of which can be
confirmed at: http://ec.europa.eu/growth/tools-databases/nando/index.cfm?fuseaction=country.notifiedbody&cou_id=826

Revalidation for qualification by examiner or examining body for the following 2 years (refer to 9.3 b)
Confirmation of the validity by employer / welding coordinator / examiner or examining body for the following 6 months (refer 9.2)
 Certificate No:
Page 1 of 2

Welder Qualification Test Certificate

(ISO 9606-1: 2017)
EX4-Online
Designation: ISO 9606-1,111,P,BW,FM2,B,s15,t15,PA,ss,nb
Welding Procedure Examining Body: TWI CL
Specification Reference No. Reference No:
Welders Name B Holness
Identification BH
Method of Identification: Initials
Photograph
Date and Place of Birth: 01/10/1996
(if required)
Employer:
Code/Testing Standard: BS EN ISO 9606-1:2017
Job Knowledge: Not Tested
Test Piece Range of Qualification
Welding Process(es) MMA 111 MMA 111
Transfer Mode N/A N/A
Product Type (plate or pipe) (P) Plate (T) Pipe & (P) Plate
Type of Weld (BW) Butt Weld (BW) Butt Welds Only
Parent Material Corten (S355J2 1.0577) Non Essential Variable (Any)
Filler Materials Group(s) FM2 FM1 & FM2
Filler Material (designation) EN ISO 2560-A; E 46 5 Mn1Ni B 3 2 H5 A, RA, RB, RC, RR, R & B
Shielding Gas N/A N/A
Auxiliaries N/A N/A
Type of Current and Polarity DC + and DC- Non Essential Variable (Any)
Material Thickness (mm) 15 mm 15 to 45mm
Deposited Thickness (mm) 15 mm 15 mm to 45 mm
Outside Pipe Diameter (mm) N/a ≥ 500 mm
Welding Positions PA PA
Weld Details ss nb ss mb, ss nb, ss gb, ss fb & bs
Multi-layer/Single Layer Ml sl & ml

Supplementary Fillet Weld Test (completed in conjunction with a butt weld) Not Performed
See Test Report No:

Type of Test Performed and Acceptable Not Tested Name & Signature of Engineer
Visual Testing Acceptable
Radiographic Testing Acceptable Name
Inspecting Authority
Fracture Test Not Tested TWI Certification Limited
Bend Test Not Tested
Date of Issue: 20/05/2019
Notch Tensile Test Not Tested
Location: Middlesbrough
Macroscopic Examination Not Tested Validity of Qualification: 11/05/2022

Date of Welding: 12/05/2019

Revalidation Valid Until Revalidation Valid Until Revalidation Valid Until

on 9.3 a) 11/05/2022 on 9.3 b) xxxxxxxxxxx on 9.3 c) xxxxxxxxxxx

TWI Certification Ltd is a Recognised Third Party Organisation in accordance with the Pressure Equipment Directive, details of which can be
confirmed at: http://ec.europa.eu/growth/tools-databases/nando/index.cfm?fuseaction=country.notifiedbody&cou_id=826

Revalidation for qualification by examiner or examining body for the following 2 years (refer to 9.3 b)
Confirmation of the validity by employer / welding coordinator / examiner or examining body for the following 6 months (refer 9.2)
 WPQR No 11 WPS No 11

THIS WPS IS TO BE USED FOR WELDER TESTING ONLY!!

SPECIFICATIONS : ISO 15614-1: 2017

WELD PREP DESIGN TYPICAL WELDING SEQUENCE*

POSITION
MATERIAL SPEC. P355NL2 (1.1106) POSITION QUALIFIED PA and PE
BASE METAL

TYPE or GRADE Plate PROGRESSION Upward

ISO 15614-1 GROUP No Group 1.2 MINIMUM TEMPERATURE 125°c

PRE - HEAT
THICKNESS RANGE (mm) 12.5-50mm APPLICATION METHOD Gas Torch When Applicable

DIAMETER RANGE N/a MAX INTERPASS TEMP 250°c

FILLER METAL

TRADE NAME ROOT En ISO 17632Outershield 71 MS H METHOD OF MEASUREMENT Digital Thermometer or Tempilstick

TRADE NAME FILLER En ISO 17632 Outershield 71 MS H FIT UP METHOD Tacks and strongbacks
TECHNIQUE

TRADE NAME CAP En ISO 17632Outershield 71 MS H STRINGER/WEAVE BEAD Stringer

TYPE OF SHIELDING SIDE 1 ISO 14175 C1 CLEANING METHOD Wire Brushing

GAS/FLUX

COMPOSITION 100% C02 SECOND SIDE TREATMENT Back gouge

MODE OF TRANSFER

FLOW RATE L/Min 18Lpm DIP N/a

DIAMETER 12mm GLOBULAR N/a

NOZZLE

WIRE STICKOUT LENGTH N/a SPRAY N/a

TUNGSTEN TYPE & DIA N/a PULSE N/a

ELECTRICAL WELD ARC ENERGY

SIDE PASS WELDING DIA CODE CHARACTERISTICS R.O.L. SPEED
No PROCESS MM REF POLARITY AMPS ARC (mm) mm/Min KJ/mm²
AC/DC RANGE VOLTS
1 Root FCAW (136) 1.2 71 MS H DC + VE 150-180 26 - 27 N/a 120-150 1.56-2.43
1&2 Fill FCAW (136) 1.2 71 MS H DC + VE 180-220 27 - 28 N/a 130-180 1.62-2.84
1&2 Cap FCAW (136) 1.2 71 MS H DC + VE 190-200 30 - 32 N/a 180-240 1.42-2.13

ISSUED BY TWI: Notes:

1) Weld area to be cleaned of rust etc for a minimum of 25mm each side
of the joint configuration using a grinder/wire brush as required.

2) Tack welds and strongbacks where necessary.

* Number of runs dependent on material thickness

CONSUMABLE HANDLING:
As per manufacturers recommendation
DATE:
 WPQR No 18 WPS No 18

SPECIFICATIONS : ISO 15614-1: 2017

WELD PREP DESIGN TYPICAL WELDING SEQUENCE

Side 2 Side 1

POSITION
MATERIAL SPEC. BS EN 10025-1 Carbon steel POSITION QUALIFIED H-LO45
BASE METAL

TYPE or GRADE Plate S275 JR PROGRESSION All except vertical down

ISO 15614-1 GROUP No Group 1 MINIMUM TEMPERATURE 15°C

PRE - HEAT
THICKNESS RANGE (mm) 6mm -24 mm APPLICATION METHOD Gas Torch When Applicable

DIAMETER RANGE Pipe with dia. ≥44.45 MAX INTERPASS TEMP 150°C
FILLER METAL

TRADE NAME ROOT Conarc 49 C 7018 METHOD OF MEASUREMENT Digital Thermometer or Tempilstick

TRADE NAME FILLER Conarc 49 C 7018 FIT UP METHOD Tacks and strongbacks
TECHNIQUE

TRADE NAME CAP Conarc 49 C 7018 STRINGER/WEAVE BEAD Stringer

TYPE OF SHIELDING SIDE 1 N/a CLEANING METHOD Wire Brushing

GAS/FLUX

COMPOSITION N/a SECOND SIDE TREATMENT N/a

MODE OF TRANSFER

FLOW RATE L/Min N/a DIP N/a

DIAMETER N/a GLOBULAR N/a

NOZZLE

WIRE STICKOUT LENGTH As Required SPRAY Yes

TUNGSTEN TYPE & DIA N/a PULSE N/a

ELECTRICAL WELD ARC

SIDE PASS WELDING DIA CODE CHARACTERISTICS R.O.L. SPEED ENERGY
No PROCESS MM REF POLARITY AMPS ARC (mm) mm/Min KJ/mm²
AC/DC RANGE VOLTS
1 1 MMA (111) 3.2 AWS 5.1 DC + VE 100-120 24 - 26 N/a N/a N/a
1 Fill MMA (111) 4 AWS 5.1 DC + VE 120-150 25 - 28 N/a N/a N/a
1 Cap MMA (111) 4 AWS 5.1 DC + VE 120-150 25 - 28 N/a N/a N/a

ISSUED BY TWI: Notes:

1) Weld area to be cleaned of rust etc for a minimum of 25mm each side
of the joint configuration using a grinder/wire brush as required.

2) Tack welds and strongbacks where necessary.

CONSUMABLE HANDLING:
As per manufacturers recommendation
DATE:
 WPQR No 20 WPS No 22

SPECIFICATIONS : ISO 15614-1: 2017

WELD PREP DESIGN TYPICAL WELDING SEQUENCE

Side 2 Side 1

POSITION
MATERIAL SPEC. BS EN 10025-1 Carbon steel POSITION QUALIFIED PA, PC, PD & PF
BASE METAL

TYPE or GRADE Plate S275 JR PROGRESSION All except PG

ISO 15614-1 GROUP No Group 1 MINIMUM TEMPERATURE 15°C

PRE - HEAT
THICKNESS RANGE (mm) 6mm -24 mm APPLICATION METHOD Gas Torch When Applicable

DIAMETER RANGE Pipe with dia. ≥44.45 MAX INTERPASS TEMP 150°C
FILLER METAL

TRADE NAME ROOT Lincoln LMN 25 G42 4M 2Si METHOD OF MEASUREMENT Digital Thermometer or Tempilstick

TRADE NAME FILLER Lincoln LMN 25 G42 4M 2Si FIT UP METHOD Tacks and strongbacks
TECHNIQUE

TRADE NAME CAP Lincoln LMN 25 G42 4M 2Si STRINGER/WEAVE BEAD Stringer

TYPE OF SHIELDING SIDE 1 ISO 14175 - M26 CLEANING METHOD Wire Brushing
GAS/FLUX

COMPOSITION 80% 2Ar 18% C02 02 2% SECOND SIDE TREATMENT N/a

MODE OF TRANSFER

FLOW RATE L/Min 15 to 18 DIP N/a

DIAMETER 15 to 20mm GLOBULAR N/a

NOZZLE

WIRE STICKOUT LENGTH As Required SPRAY Yes

TUNGSTEN TYPE & DIA N/a PULSE N/a

ELECTRICAL WELD HEAT

SIDE PASS WELDING DIA CODE CHARACTERISTICS R.O.L. SPEED INPUT
No PROCESS MM REF POLARITY AMPS ARC (mm) mm/Min KJ/mm²
AC/DC RANGE VOLTS
1 1 MAG (135) 1.2 ISO 14341 DC + VE 260-280 26 - 28 N/a 240 - 285 N/a
1 Fill MAG (135) 1.2 ISO 14341 DC + VE 270-290 29 - 30 N/a 300 - 320 N/a
1 Cap MAG (135) 1.2 ISO 14341 DC + VE 270-290 29 - 30 N/a 300 - 330 N/a

ISSUED BY TWI: Notes:

1) Weld area to be cleaned of rust etc for a minimum of 25mm each side
of the joint configuration using a grinder/wire brush as required.

2) Tack welds and strongbacks where necessary.

CONSUMABLE HANDLING:
As per manufacturers recommendation
DATE:
 WPQR No 34 WPS No 34

THIS WPS IS TO BE USED FOR WELDER TESTING ONLY!!

SPECIFICATIONS : ISO 15614-1: 2017

WELD PREP DESIGN TYPICAL WELDING
a = No Restriction
FILLET WELD
SEQUENCE
ONE SIDE ONLY!

2
1

POSITION
MATERIAL SPEC. Austenetic Stainless steel POSITION QUALIFIED PA
BASE METAL

TYPE or GRADE Plate PROGRESSION Flat

ISO 15614-1 GROUP No Group 8 MINIMUM TEMPERATURE 15°c

PRE - HEAT
THICKNESS RANGE (mm) 3.0 - and above APPLICATION METHOD Gas Torch When Applicable

DIAMETER RANGE N/a MAX INTERPASS TEMP 150°c

FILLER METAL

TRADE NAME PASS 1 ISO 1434-A W 19 12 3 L METHOD OF MEASUREMENT Digital Thermometer or Tempilstick

TRADE NAME PASS 2 ISO 1434-A W 19 12 3 L FIT UP METHOD Tacks

TECHNIQUE

TRADE NAME PASS 3 ISO 1434-A W 19 12 3 L STRINGER/WEAVE BEAD Stringer

TYPE OF SHIELDING SIDE 1 ISO 14715 - I CLEANING METHOD Wire Brushing

GAS/FLUX

COMPOSITION 100% AR SECOND SIDE TREATMENT N/a

MODE OF TRANSFER

FLOW RATE L/Min 10 to 12 DIP N/a

DIAMETER 15 to 20mm GLOBULAR N/a

NOZZLE

WIRE STICKOUT LENGTH As Required SPRAY N/a

TUNGSTEN TYPE & DIA Ceriated PULSE N/a

ELECTRICAL WELD HEAT

SIDE PASS WELDING DIA CODE CHARACTERISTICS R.O.L. SPEED INPUT
No PROCESS MM REF POLARITY AMPS ARC (mm) mm/Min KJ/mm²
AC/DC RANGE VOLTS
1 1 TIG (141) 1.6 ER70T1 DC - 65-85 21-24 N/a 65-75 0.76-0.98
1 2 TIG (141) 2.4 ER70T1 DC - 85-105 23-26 N/a 80-95 0.88-1.0

ISSUED BY TWI: Notes:

1) Weld area to be cleaned for a minimum of 25mm each side
of the joint configuration using a grinder/wire brush as required.

2) Tack welds and strongbacks where necessary.

CONSUMABLE HANDLING:
As per manufacturers recommendation
DATE:
 W1 F4

W8 F3

A F2
W7

W9

W5 Thickness
Part Material (mm)
S1-S2 S355 J2 UB 25mm
H1
F1-F2 316L sch 80 OD 323 mm 17mm
B F3-Concentric reducer Inlet 316L sch 80 OD 323mm
Outlet 316L sch 80 OD 203mm
17mm

F4 316L sch 80 OD 203 17mm

S1 S2 H1-H2 RSJ S275 J2 10mm

L1-L2 S355 J2 OD 80mm 20mm
W3
L2

W6 Lifting attachments To match section 10 mm

W2
1 C
2 D
3 D
4 D
5 C
6 D
7 A
8 D
9 B
10 B
11 C
12 A
13 D
14 D
15 B
16 D
17 D
18 B
19 C
20 A
21 C
22 C
23 D
24 C
25 D
26 A
27 C
28 B
29 B
30 D
31 D
32 D
33 D
34 B
35 C
36 C
37 B
38 C
39 C
40 B