Boilermaker Training

Lesson 1 • Trade Roles and Career Pathways

Defines apprentice, journeyman, and foreman roles within the trade hierarchy. Outlines certification milestones and advancement criteria.

Lesson 2 • Regulatory and Code Framework

Introduces pressure vessel codes, inspection standards, and regulatory bodies governing boilermaker work. Establishes compliance as a non-negotiable professional baseline.

Lesson 3 • Personal Protective Equipment Basics

Identifies required PPE for boilermaker environments and correct usage protocols. Builds the habit of PPE selection before any hands-on task.

Lesson 1 • Weld Symbols and Specifications

Decodes standard weld symbols including joint type, groove angle, and finish requirements. Prepares learners to execute welds exactly as specified on drawings.

Lesson 2 • Dimensions, Tolerances, and Notes

Explains how to read linear dimensions, geometric tolerances, and general notes on fabrication drawings. Connects accurate reading to precise material layout.

Lesson 3 • Sketching and Field Markup

Teaches freehand sketching and field markup techniques for communicating changes and as-built conditions. Supports accurate documentation during fabrication and repair.

Lesson 4 • Drawing Types and Conventions

Distinguishes orthographic, isometric, and detail drawings used in vessel fabrication. Establishes standard drawing conventions as the language of the trade.

Lesson 1 • Layout Tools and Precision Marking

Introduces scribers, dividers, trammel points, and squares used for accurate layout on plate and pipe. Precision marking directly affects fit-up quality and weld integrity.

Lesson 2 • Geometry for Vessel Fabrication

Applies circle, arc, and polygon geometry to shell, head, and nozzle calculations. Connects geometric principles directly to material cutting and forming decisions.

Lesson 3 • Trigonometry in Boilermaker Work

Uses sine, cosine, and tangent functions to solve angular layout problems for pipe and vessel connections. Enables precise angle determination without trial-and-error fitting.

Lesson 4 • Trade Math Fundamentals

Reviews fractions, decimals, unit conversion, and basic algebra as applied to boilermaker calculations. Establishes numerical fluency required for all subsequent layout work.

Lesson 1 • Ferrous and Non-Ferrous Metals

Distinguishes carbon steel, alloy steel, stainless steel, and non-ferrous metals used in boiler construction. Material identification skills prevent costly substitution errors.

Lesson 2 • Material Identification and Testing

Applies spark testing, hardness testing, and mill certification review to verify material identity. Field identification skills prevent use of incorrect or substandard materials.

Lesson 3 • Effects of Heat on Metal

Describes how welding heat causes grain growth, heat-affected zones, and residual stress in boiler materials. Understanding these effects guides preheat and post-weld heat treatment decisions.

Lesson 4 • Mechanical and Physical Properties

Explains tensile strength, yield strength, hardness, and ductility as they relate to pressure vessel design limits. Connects material properties to safe operating parameters.

Lesson 1 • Distortion Control During Fit-Up

Applies strongbacks, clamps, and sequencing strategies to minimise weld distortion before welding begins. Distortion control at fit-up reduces costly rework after welding.

Lesson 2 • Plate and Pipe Forming

Explains roll bending, press braking, and cold and hot forming of boiler components. Forming operations must maintain material integrity and dimensional accuracy.

Lesson 3 • Thermal Cutting Processes

Covers oxyfuel, plasma arc, and air carbon arc cutting as applied to boiler plate and pipe. Correct process selection and technique produce clean, code-acceptable cut edges.

Lesson 4 • Mechanical Cutting and Grinding

Applies shearing, sawing, and grinding to prepare plate and pipe edges for welding. Mechanical methods are used where thermal cutting would affect material properties.

Lesson 1 • Shielded Metal Arc Welding

Develops SMAW technique for all positions on plate and pipe using low-hydrogen and cellulosic electrodes. SMAW remains the most widely used process in field boilermaker work.

Lesson 2 • Flux-Cored Arc Welding

Covers FCAW setup, wire selection, and technique for high-deposition boiler shell and structural welds. FCAW increases productivity on large-diameter vessel fabrication.

Lesson 3 • Welder Qualification Testing

Prepares learners for performance qualification tests on plate and pipe in required positions. Qualification records demonstrate competency to employers and inspection authorities.

Lesson 4 • Gas Tungsten Arc Welding

Applies GTAW to root pass welding on pipe and thin-wall pressure vessel components. GTAW root passes provide the highest quality fusion for critical pressure boundaries.

Lesson 1 • Shell and Head Assembly

Sequences the assembly of cylindrical shells, dished heads, and nozzle reinforcements into a complete vessel. Correct assembly sequence minimises distortion and alignment errors.

Lesson 2 • Rigging and Heavy Lifting

Applies rigging principles to the safe lifting and positioning of large vessel components and assembled units. Correct rigging prevents equipment damage and life-threatening drops.

Lesson 3 • Tube and Tube Sheet Installation

Covers tube rolling, seal welding, and tube sheet layout for fire-tube and water-tube boiler configurations. Tube-to-tube-sheet joints are critical pressure boundary connections.

Lesson 4 • Hydrostatic and Pneumatic Testing

Conducts pressure tests to verify vessel integrity before commissioning per applicable code requirements. Test results are documented and retained as permanent quality records.

Lesson 1 • Corrosion and Erosion Assessment

Identifies pitting, general corrosion, erosion, and stress corrosion cracking in boiler pressure parts. Accurate assessment determines whether repair or replacement is required.

Lesson 2 • Visual and Surface Inspection

Applies systematic visual inspection and dye penetrant testing to identify surface defects in boiler components. Surface inspection is the first and most frequent quality check in service.

Lesson 3 • Repair Welding Procedures

Executes defect removal, weld buildup, and insert plate repairs under applicable repair codes. Repair welding requires the same qualification rigour as original fabrication.

Lesson 4 • Preventive Maintenance Programmes

Establishes inspection intervals, maintenance tasks, and record-keeping systems for boiler reliability. Proactive maintenance extends service life and prevents unplanned shutdowns.