use of pqr without essential variable

[studaddy]

we have a pqr for stainless 308 l using the stt process with a backing gas [open butt pipe] the bosses son refuses to use the argon that was used to qualify and wants to use solar flux instead . my position is we have to qualify a new pqr and our welders since we are deleting an essential variable and replacing it with a paste flux . any other ideas out there ?

 

[Duwe6]

A) "Essential" means just that - change an Essential Variable, make [& test] a new PQR.

B) Solar "B" flux works fairly well for the first two or three quadrants. Then the weld heat makes the stuff flake off as the welder puts a root in the last quadrant, and then it is "sugar city". Cut out one of the fluxed welds and put it on the kid's desk.

C) What does work is s/s Tig wire with an integral flux; some are flux coated, some flux-core. My welders call it 'mud rod' because the normally 'wet', fluid weld puddle behaves like a glop of mud when using the fluxed rod to run the root. And this too is an Essential Variable.

Now comes the 'fun part' -- how do you address out-of-Code welding? If you are not willing to quit/be fired, you will always be a 'tame' inspector on a short, harsh leash. Me, I'd tell the owner that I can't sign for the out-of-Code work, than ask him if he would like to sign the papers or should his brilliant sone sign the papers. You may loose the job, but you'll sleep better if you refuse to sign for junk work.

 

[studaddy]

Thanks for the info. You must be spying on me because i have had several run ins already with piping not welded to code and as I am the only CWI in the shop I refuse to put my name on them. I already had my mind made up just wanted to know if it is allowed ANYWHERE to substitute flux paste for gas. Thanks for the reply!

 

[weldtek]

Before you take your stand, be sure you have the code backing you up. If this is per ASME Sec IX - you don't.

 

[studaddy]

Please explain your understanding of ASME SEC IX, From what i have read the backing gas is an essential variable that was used to qualify the procedure but is now being replaced with the flux. Am I looking at it wrong?

 

[stanweld]

As weldtek is telling you, QW-408.5 - addition or deletion or a change in backing gas is a nonessential variable under QW-256 for the P No.8 base metals and A-8 filler metal involved.

 

[studaddy]

Thanks for the added info. That was what i neeeded to know if i was overlooking something or had tunnel vision. Greatly appreciated

 

[jwhit]

Remember that you have to write a new procedure or addendum to cover the change to the procedure. Even though it isn't essential, it still must be documented. If it makes you feel any better, a lot of us find ourselves in the position of having others in the organization know better than we do, regardless of our training or experience.