Boilermaker-Welder Training

Lesson 1 • Hazard Identification and Control

It teaches recognition of electrical, thermal, chemical, and fall hazards in industrial settings. It provides the risk-assessment mindset applied throughout the entire programme.

Lesson 2 • Personal Protective Equipment

It covers the selection, fit, and maintenance of PPE for welding and boilermaker tasks. It connects to all subsequent hands-on work by establishing baseline protection habits.

Lesson 3 • Workplace Regulations and Standards

It introduces occupational health regulations, pressure vessel codes, and welding quality standards. Learners understand compliance obligations before touching equipment.

Lesson 1 • Drawing Types and Conventions

It explains orthographic, isometric, and detail drawings used in boilermaker work. It establishes the visual literacy needed to read every subsequent fabrication print.

Lesson 2 • Applied Trade Mathematics

It applies fractions, decimals, geometry, and trigonometry to boilermaker calculations. Learners solve real problems such as pipe offsets and shell circumferences.

Lesson 3 • Measurement and Layout Tools

It covers the proper use of rules, squares, levels, and layout scribers for accurate marking. Precision layout is a prerequisite to all cutting and fitting operations.

Lesson 1 • Ferrous Metal Classifications

It covers carbon steel grades, alloy steels, and cast iron used in pressure equipment. It provides the material knowledge base for all welding procedure decisions.

Lesson 2 • Nonferrous and Specialty Metals

It examines stainless steel, chrome-moly, nickel alloys, and aluminium in industrial use. It prepares learners for advanced welding procedures on high-value materials.

Lesson 3 • Preheat, Interpass, and PWHT

It teaches temperature control requirements before, during, and after welding. Learners apply preheat charts and post-weld heat treatment cycles to prevent cracking.

Lesson 1 • Mechanical Cutting and Grinding

It covers angle grinders, abrasive wheels, band saws, and pipe bevelers for cold cutting. Mechanical methods are required where welding heat input must be avoided.

Lesson 2 • Joint Design and Fit-Up

It explains groove types, root openings, bevel angles, and land dimensions for code joints. Proper fit-up directly controls weld quality and reduces rework.

Lesson 3 • Oxyfuel Cutting Fundamentals

It covers gas pressures, tip selection, torch operation, and cutting technique for carbon steel. Oxyfuel cutting is the entry-level thermal process used across all fabrication tasks.

Lesson 1 • Pipe Welding with SMAW

It applies SMAW to pipe in 5G and 6G positions using open-root and backed techniques. Pipe welding is the primary qualification test for boilermaker-welders.

Lesson 2 • SMAW Equipment and Setup

It covers power source types, polarity, electrode holders, and cable sizing for SMAW. Correct setup is prerequisite to consistent arc performance in all positions.

Lesson 3 • Vertical and Overhead Position Welding

It advances technique to 3G and 4G positions where gravity challenges molten pool control. Mastery here qualifies learners for structural and pressure vessel work.

Lesson 4 • Flat and Horizontal Position Welding

It builds foundational arc control, travel speed, and bead placement in 1G and 2G positions. These positions establish technique before progressing to vertical and overhead.

Lesson 1 • Gas Metal Arc Welding Setup and Technique

It teaches wire feed, shielding gas, voltage, and inductance settings for GMAW. GMAW is widely used in structural and vessel fabrication for high deposition rates.

Lesson 2 • Flux-Cored Arc Welding Applications

It covers self-shielded and gas-shielded FCAW for heavy plate and out-of-position work. FCAW combines high deposition with all-position capability for boilermaker fabrication.

Lesson 3 • GTAW Pipe Root Pass Applications

It applies GTAW to open-root pipe joints in multiple positions with purge gas backing. The root pass quality determines the integrity of the entire weld joint.

Lesson 1 • Nozzle and Fitting Layout

It teaches template development, hole cutting, and nozzle orientation layout on curved surfaces. Accurate nozzle placement is critical for process piping alignment.

Lesson 2 • Structural Steel Fabrication

It applies layout, cutting, and welding to beams, columns, and platforms supporting boiler systems. Structural work requires understanding of load paths and connection details.

Lesson 3 • Shell Rolling and Head Forming

It covers plate rolling, seam alignment, and elliptical head pressing for vessel fabrication. Dimensional accuracy at this stage controls all downstream assembly tolerances.

Lesson 4 • Distortion Control and Correction

It explains the causes of weld distortion and applies sequencing, fixturing, and flame straightening. Distortion control is a key quality differentiator for experienced boilermaker-welders.

Lesson 1 • Welding Procedure Specifications

It teaches how to read, follow, and document compliance with a welding procedure specification. WPS adherence is mandatory for code-compliant pressure equipment fabrication.

Lesson 2 • Destructive Testing and Qualification

It explains bend tests, tensile tests, and macro-etch tests used in welder qualification. Learners understand how test results validate or invalidate a welding procedure.

Lesson 3 • Pressure Testing and Final Acceptance

It covers hydrostatic and pneumatic pressure testing procedures and acceptance criteria. The final pressure test is the last verification before vessel commissioning.

Lesson 4 • Visual Weld Inspection

It covers weld profile, surface discontinuities, and dimensional checks using gauges and standards. Visual inspection is the first and most frequent quality gate on every weld.