Industrial Boilermaking Training

Lesson 1 • Workplace Safety Fundamentals

Introduces core safety principles, personal protective equipment, and hazard recognition. Safety compliance underpins every practical task in the trade.

Lesson 2 • Boilermaking Materials Introduction

Surveys metals and alloys commonly used in boiler construction. Material knowledge informs correct fabrication and joining decisions throughout the trade.

Lesson 3 • Regulatory and Code Awareness

Introduces pressure vessel codes, inspection standards, and regulatory frameworks. Understanding compliance requirements shapes every fabrication and repair decision.

Lesson 4 • Trade Tools and Equipment

Identifies hand tools, power tools, and measuring instruments used daily. Proper tool selection directly affects fabrication quality and worker safety.

Lesson 1 • Symbols, Dimensions, and Tolerances

Covers weld symbols, geometric dimensioning, and tolerance notation on fabrication drawings. Correct symbol interpretation prevents costly fabrication errors.

Lesson 2 • Layout Tools and Marking Methods

Demonstrates use of scribers, dividers, squares, and chalk lines for transferring dimensions. Accurate marking is the direct link between drawings and physical fabrication.

Lesson 3 • Plate and Shell Layout Calculations

Applies geometry and trigonometry to lay out flat plates, cylinders, and cones. Correct calculations ensure components fit together within specified tolerances.

Lesson 4 • Isometric and Piping Drawings

Introduces isometric views and piping and instrumentation diagrams used in boiler systems. These drawings guide assembly sequencing and component placement.

Lesson 1 • Forming Quality and Inspection

Applies dimensional checks and visual inspection to verify cut and formed parts. Quality verification at this stage prevents defects from propagating into final assemblies.

Lesson 2 • Oxyfuel Cutting Principles

Covers gas chemistry, equipment setup, and cutting technique for oxyfuel processes. Oxyfuel cutting is the most widely used thermal cutting method in the trade.

Lesson 3 • Plate Rolling and Bending

Teaches operation of plate rolls and press brakes to form cylindrical and angular shapes. Formed components must meet dimensional tolerances before proceeding to assembly.

Lesson 4 • Plasma and Mechanical Cutting

Introduces plasma arc cutting and mechanical methods including saws and grinders. These processes expand cutting capability for varied materials and thicknesses.

Lesson 1 • Gas Metal and Flux-Cored Arc Welding

Covers wire feed processes including GMAW and FCAW for structural and pressure work. These processes offer higher deposition rates suited to production fabrication.

Lesson 2 • Shielded Metal Arc Welding

Teaches electrode selection, machine setup, and technique for SMAW on carbon steel. SMAW remains a primary process for field repair and heavy fabrication work.

Lesson 3 • Gas Tungsten Arc Welding

Introduces GTAW for root passes and thin-wall alloy applications in boiler work. GTAW produces the highest-quality welds required for critical pressure boundaries.

Lesson 4 • Weld Inspection and Defect Correction

Applies visual inspection criteria and introduces nondestructive examination methods. Identifying and correcting defects ensures welds meet code acceptance standards.

Lesson 1 • Head Forming and Attachment

Teaches fabrication of ellipsoidal, hemispherical, and flat heads and their attachment to shells. Head geometry and weld joint design directly affect pressure rating.

Lesson 2 • Shell and Drum Fabrication

Covers rolling, fit-up, and longitudinal seam welding of cylindrical pressure vessel shells. Shell fabrication integrates all prior forming and welding competencies.

Lesson 3 • Nozzle and Fitting Installation

Covers layout, cutting, and welding of nozzles, manways, and branch connections. Correct nozzle installation maintains shell integrity and code compliance.

Lesson 4 • Tube and Tube Sheet Assembly

Addresses tube rolling, expanding, and welding into tube sheets for fire-tube and water-tube boilers. Tube-to-tube-sheet joints are critical pressure boundary connections.

Lesson 1 • Field Welding and Final Connections

Addresses field welding of pressure connections, piping tie-ins, and final closure welds. Field weld quality must match shop fabrication standards for code compliance.

Lesson 2 • Rigging and Lifting Fundamentals

Covers sling types, load calculations, and crane communication for lifting heavy components. Safe rigging is the first requirement of any boiler erection project.

Lesson 3 • Structural Steel and Casing Erection

Covers erection of boiler support steel, casing panels, and insulation framing. Structural integrity of the casing system protects pressure parts and maintains efficiency.

Lesson 4 • Foundation and Anchor Bolt Setting

Teaches survey of foundations, anchor bolt placement, and grouting procedures. Correct foundation work ensures long-term structural stability of the boiler.

Lesson 1 • Leak Detection and Repair

Applies pneumatic soap testing, dye penetrant, and ultrasonic methods to locate leaks. Identified leaks must be repaired and retested before commissioning proceeds.

Lesson 2 • Commissioning Documentation and Handover

Addresses completion of test records, code data reports, and operator handover packages. Accurate documentation is required for regulatory approval and future maintenance.

Lesson 3 • Conducting the Hydrostatic Test

Teaches pressurization sequence, hold periods, and inspection during the test. Correct test execution confirms structural integrity of all pressure-containing components.

Lesson 4 • Boiler Startup and Initial Firing

Covers dry-out procedures, initial firing sequences, and safety interlock verification. Controlled startup prevents thermal shock and validates control system function.

Lesson 1 • Tube Replacement and Repair

Teaches tube removal, replacement, and plug welding procedures for fire-tube and water-tube boilers. Tube repairs restore heat transfer efficiency and pressure boundary integrity.

Lesson 2 • Pressure Part Repair Procedures

Covers weld repair of shells, headers, and nozzles under applicable repair codes. Repair procedures must be qualified and documented to maintain code compliance.

Lesson 3 • Planned Maintenance Programs

Introduces preventive and predictive maintenance strategies for boiler systems. Structured maintenance programs reduce unplanned outages and extend equipment life.

Lesson 4 • In-Service Inspection Techniques

Covers visual, ultrasonic, and radiographic inspection of in-service pressure components. Regular inspection detects degradation before it reaches a failure threshold.