CWI Code Book Application Questions and Answers — Questions and Answers
Question 1: A fabricator has a Welding Procedure Specification (WPS) qualified on 1/2-inch thick plate. According to AWS D1.1, what is the maximum thickness of base metal this WPS is qualified to weld in production?
- 1/2 inch
- 3/4 inch
- 1 inch (Correct answer)
- Unlimited thickness
Correct answer: 1 inch
According to AWS D1.1 Table 6.2 (or its current equivalent), a Procedure Qualification Record (PQR) test performed on a 1/2-inch thick plate qualifies the WPS for a maximum production thickness of 2T, where T is the thickness of the test coupon. In this case, 2 * (1/2 inch) = 1 inch.
Question 2: According to the visual inspection acceptance criteria for statically loaded non-tubular connections in AWS D1.1, which of the following describes the allowable limit for undercut on base metal that is 3/4-inch thick?
- Undercut shall not exceed 1/16 inch for any length of weld.
- Undercut is unacceptable in any amount.
- Undercut shall not exceed 1/32 inch. (Correct answer)
- Undercut shall not exceed 10% of the base metal thickness.
Correct answer: Undercut shall not exceed 1/32 inch.
AWS D1.1 Table 8.1 (or its current equivalent for visual inspection) states that for material less than 1 inch thick, undercut shall not exceed 1/32 inch (1 mm). An exception allows for deeper undercut up to 1/16 inch for a very short accumulated length, but the general requirement is 1/32 inch.
Question 3: A welder successfully qualifies by performing a CJP groove weld test on a 3/8-inch thick plate in the 3G (vertical-up) position per AWS D1.1. This qualification allows the welder to perform which of the following production welds?
- CJP groove welds in the 4G (overhead) position.
- Fillet welds on 1-inch thick plate.
- Fillet welds in the 1F, 2F, and 3F positions. (Correct answer)
- CJP groove welds on 1/8-inch to unlimited thickness plate.
Correct answer: Fillet welds in the 1F, 2F, and 3F positions.
Per AWS D1.1 Table 6.10 (or current equivalent), a welder performance qualification test in the 3G position on plate qualifies the welder for groove welds in the flat (1G), horizontal (2G), and vertical (3G) positions, and for fillet welds in the flat (1F), horizontal (2F), and vertical (3F) positions. It does not qualify for the 4G position. The thickness qualified on a 3/8-inch plate is from 1/8-inch up to 2T (3/4-inch), not unlimited or 1-inch.
Question 4: When applying ASME Section IX, a change to which of the following is considered an essential variable for a Shielded Metal Arc Welding (SMAW) WPS, requiring the procedure to be requalified?
- A change in groove design.
- A change from stringer to weave bead technique.
- A change in the base metal P-Number. (Correct answer)
- A change in the brand of an E7018 electrode.
Correct answer: A change in the base metal P-Number.
According to ASME Section IX, QW-250 and QW-403, a change in the P-Number of the base metal is an essential variable for most welding processes, including SMAW. This change is considered to affect the mechanical properties of the weldment and mandates a new Procedure Qualification Record (PQR). Changes in groove design or technique are typically nonessential variables, and a change in brand of electrode within the same AWS classification is not an essential variable.
Question 5: A CWI is monitoring the welding of a 1.5-inch thick steel plate where the qualified WPS, based on AWS D1.1, requires a minimum preheat and interpass temperature of 225°F. What is the correct protocol for measuring this temperature?
- The temperature must be measured on the weld bead immediately after the arc is extinguished.
- The temperature must be at or above 225°F in an area approximately 3 inches from the joint, just before initiating an arc. (Correct answer)
- The temperature must be measured 12 inches away from the joint to get an average reading.
- Preheat is only required for the first pass; interpass temperature does not need to be monitored.
Correct answer: The temperature must be at or above 225°F in an area approximately 3 inches from the joint, just before initiating an arc.
AWS D1.1 specifies that preheat and interpass temperatures shall be measured on the base metal at a distance equal to the plate thickness or 3 inches, whichever is less, from the point of welding. The temperature must be checked just prior to initiating the arc for each pass to ensure it is at or above the minimum specified value.
Question 6: A project's specifications mandate that all pipeline welding inspection must adhere to API 1104. An inspector performing radiographic testing (RT) identifies several indications. In which section of API 1104 would the inspector find the specific limits for the size and distribution of these indications to determine if the weld is acceptable?
- Section 5, Qualification of Welding Procedures for Welds Containing Weld-Deposited Filler Metal
- Section 6, Qualification of Welders
- Section 11, Procedures for Nondestructive Testing
- Section 9, Acceptance Standards for Nondestructive Testing (Correct answer)
Correct answer: Section 9, Acceptance Standards for Nondestructive Testing
API 1104 is structured with specific sections for different aspects of welding and inspection. Section 9, "Acceptance Standards for Nondestructive Testing," contains the detailed criteria for accepting or rejecting welds based on the results of NDT methods, including radiography. Section 11 describes the procedures for performing NDT but does not contain the acceptance criteria.
CWI Code Book Application Questions and Answers
A fabricator has a Welding Procedure Specification (WPS) qualified on 1/2-inch thick plate.
According to AWS D1.1, what is the maximum thickness of base metal this WPS is qualified to weld in production?