Boilermaking Training

Lesson 1 • Jobsite Safety Fundamentals

Establishes core safety practices required before any hands-on work begins. Covers personal protective equipment, hazard recognition, and emergency response basics.

Lesson 2 • Trade History and Industry Overview

Covers the evolution of boilermaking from early steam systems to modern pressure vessels. Establishes context for why precision and safety standards govern the trade.

Lesson 3 • Metals and Materials Identification

Teaches identification of carbon steel, alloy steel, and stainless steel used in pressure vessels. Material selection affects fabrication methods and code compliance.

Lesson 4 • Workplace Roles and Responsibilities

Defines the boilermaker's role within construction and maintenance crews. Clarifies how responsibilities differ across fabrication shops and field sites.

Lesson 1 • Drawing Types and Conventions

Explains orthographic, isometric, and detail drawings used in boilermaking fabrication. Understanding drawing types allows correct interpretation before any layout begins.

Lesson 2 • Template and Pattern Development

Teaches flat-pattern development for cylinders, cones, and transition pieces. Templates ensure repeatable accuracy when cutting multiple identical parts.

Lesson 3 • Tolerances and Fit-Up Standards

Defines dimensional tolerances and acceptable fit-up gaps required by fabrication codes. Students apply tolerance concepts to verify layout before cutting.

Lesson 4 • Measurement and Precision Layout

Covers use of rules, squares, calipers, and scribers to transfer drawing dimensions onto plate and pipe. Precision layout prevents cumulative error in assembled components.

Lesson 1 • Plate and Pipe Rolling

Explains three-roll and four-roll plate rolling to form cylindrical shells and cones. Correct roll setup prevents flat spots and ensures accurate shell diameter.

Lesson 2 • Oxyfuel Cutting Fundamentals

Introduces oxyfuel equipment setup, flame adjustment, and straight-line cutting on carbon steel plate. Correct technique produces clean, square cuts that minimize grinding.

Lesson 3 • Plasma Arc Cutting

Covers plasma arc cutting of carbon steel, stainless steel, and aluminum plate and pipe. Plasma cutting expands material range and improves cut speed over oxyfuel.

Lesson 4 • Mechanical Cutting and Grinding

Teaches use of band saws, cold saws, angle grinders, and abrasive wheels for precise cuts. Mechanical methods are preferred where heat-affected zones must be minimized.

Lesson 1 • Preheat, Interpass, and Post-Weld Heat Treatment

Covers preheat requirements, interpass temperature control, and post-weld heat treatment for pressure vessel steels. Thermal control prevents hydrogen cracking and residual stress failures.

Lesson 2 • Flux-Cored and MIG Welding

Introduces FCAW and GMAW for high-deposition fill and cap passes on structural and vessel work. Wire feed processes increase productivity on large-volume fabrication.

Lesson 3 • Submerged Arc Welding

Explains SAW equipment, flux handling, and automated welding of longitudinal and circumferential seams. SAW delivers high deposition rates and consistent quality on long straight seams.

Lesson 4 • Gas Tungsten Arc Welding

Teaches GTAW root pass technique on pipe and tube critical to boiler and heat exchanger work. Clean, full-penetration root passes are mandatory for pressure-rated joints.

Lesson 1 • Vessel Assembly and Alignment

Covers multi-course assembly, peaking and banding checks, and final dimensional verification. Alignment errors compound through assembly and must be corrected before final welding.

Lesson 2 • Shell Course Fabrication

Covers rolling, fit-up, and welding of cylindrical shell courses to dimensional tolerances. Shell roundness and seam alignment directly affect vessel integrity and inspection results.

Lesson 3 • Nozzle and Fitting Installation

Teaches layout, cutting, and welding of nozzles, manways, and reinforcing pads on vessel shells. Correct nozzle orientation and reinforcement ensure structural adequacy under pressure.

Lesson 4 • Head Forming and Attachment

Explains ellipsoidal, hemispherical, and flat head types, their forming methods, and attachment welds. Head selection and weld quality are critical to vessel pressure rating.

Lesson 1 • Crane and Hoist Operations

Covers overhead crane, mobile crane, and chain hoist operation relevant to boilermaking erection. Boilermakers must communicate effectively with crane operators during all lifts.

Lesson 2 • Lift Planning and Permit Requirements

Covers critical lift criteria, lift plan documentation, and pre-lift safety meetings. Formal lift planning is required by safety regulations for all heavy and complex lifts.

Lesson 3 • Load Calculation and Center of Gravity

Teaches weight estimation, center-of-gravity location, and sling angle effects on rigging loads. Accurate load data prevents overloading slings and crane hooks.

Lesson 4 • Rigging Hardware and Slings

Identifies wire rope, chain, and synthetic slings, shackles, hooks, and lifting lugs used in boilermaking. Correct hardware selection is the first step in any safe lift plan.

Lesson 1 • Boiler Casing and Insulation

Explains installation of outer casing panels, insulation blankets, and lagging on boiler exteriors. Proper insulation reduces heat loss and protects personnel from burn hazards.

Lesson 2 • Boiler Types and Components

Distinguishes fire-tube, water-tube, and heat recovery boiler designs and their major components. Component knowledge guides correct repair and replacement decisions.

Lesson 3 • Tube Installation and Expanding

Covers tube rolling, seal welding, and replacement procedures for fire-tube and water-tube boilers. Proper tube expansion prevents leaks and maintains heat transfer efficiency.

Lesson 4 • In-Service Inspection and Repair

Covers boiler inspection intervals, common failure modes, and repair welding under applicable codes. Timely repair prevents catastrophic failure and extends boiler service life.

Lesson 1 • Nondestructive Examination Methods

Introduces radiographic, ultrasonic, magnetic particle, and liquid penetrant examination methods. NDE detects internal and surface defects without damaging the component.

Lesson 2 • Welding Procedure and Welder Qualification

Explains welding procedure specifications, procedure qualification records, and welder performance qualification. Qualified procedures and welders are mandatory for code-stamped work.

Lesson 3 • Documentation and Quality Records

Teaches preparation and control of material certifications, weld maps, inspection reports, and data reports. Complete records are required for code stamp issuance and future inspections.

Lesson 4 • Fabrication Codes and Standards Overview

Introduces pressure vessel and boiler fabrication codes, their scope, and how they govern design and construction. Code compliance is a legal and contractual requirement on all pressure work.