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MODULE 34101 INTRODUCTION TO BOILERMAKING

Task Number Item Date(s) Recorded By

This is a knowledge-based module; there is no performance testing.

MODULE 34102 BOILERMAKING SAFETY


34102-1 Properly put on a safety harness

34102-2 Upon a tour of a boiler facility, develop a list ofthe following noted during the tour:

Good safety practices being utilized Potential hazards Good work habits being performed Proximity work being performed

MODULE 34103 BOILERMAKING TOOLS



1

BOILERMAKING

On-the-Job Training

National Center for Construction Education & Research

P. O. Box 141104, Gainesville, FL 32614-1104

Tel: (352) 334-0920 Fax: (352) 334-0931 E-mail: [email protected]

Level One

NCCER

13614 Progress Blvd., Alachua, FL 32615Tel: (888) 622-3720 E-mail: [email protected]


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MODULE 34104 BASIC MATERIALS


34104-1 Given examples of different material markings,properly identify the product.

34104-2 Given samples of the following products, measurethe sample and record the correct ASTM marking

for each sample: Plate steel Sheet steel Bar steel (various shapes) Angle steel Channel steel Beam steel Pipe (with table provided) Tubing (round product, not structural)

MODULE 34105 OXYFUEL CUTTING


34105-1 Set up oxyfuel equipment.

34105-2 Light and adjust an oxyfuel torch.

34105-3 Shut down oxyfuel cutting equipment.

34105-4 Disassemble oxyfuel equipment.

34105-5 Change empty cylinders.

34105-6 Perform straight line and square shape cutting.

34105-7 Perform piercing and slot cutting.

34105-8 Perform bevel cutting.

34105-9 Perform washing.

34105-10 Perform gouging.

34105-11 Heat metal with a rosebud until red hot.

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MODULE 34106 CUTTING AND FITTING GASKETS


34106-1 Perform a takeoff from a flange.

34106-2 Lay out the gasket on gasket material.

34106-3 Cut the gasket inside and outside diameters to

the proper size plus or minus1

64 of an inch.

34106-4 Cut the bolt holes to the proper size plus or minus164 of an inch.

34106-5 Install the gasket and flange bolts.

34106-6 Tighten the flange bolts to the proper torque and inthe proper sequence.

MODULE 34107 WELDING BASICS


34107-1 Identify a welding rod and/or filler metal byits associated markings.

34107-2 Set up a shielding gas purge on a section of pipingor tubing.

34107-3 Prepare a flat plate for welding with a bevel groove joint.

34107-4 Run an SMAW bead in the flat position.

3


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MODULE 34201 INTRODUCTION TO BOILER COMPONENTS



MODULE 34202 WELDING SYMBOLS



MODULE 34203 DRAWINGS AND DETAIL SHEETS


34203-1 Identify the parts of a drawing: Title block Scales and measurements Symbols and abbreviations Notes Revision block Coordinates Drawing index Line list

34203-2 Identify the following types of drawings: Plot plans

Structural drawings P&IDs Isometric drawings Spool drawings Orthographic drawings Elevation and section drawings Equipment arrangement drawings Pipe support drawings and detail sheets

34203-3 Make field sketches: Orthographic Oblique Isometric

4

Level Two


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MODULE 34204 IDENTIFYING AND INSTALLING VALVES


34204-1 Install valves with threaded ends.

34204-2 Install valves with welded ends.

34204-3 Install valves with flanged ends.

MODULE 34205 BASE METAL PREPARATION


34205-1 Prepare the base metal for welding and cutting.

34205-2 Select the proper joint design.

34205-3 Cut and fit the base metal joints for welding.

MODULE 34206 PLASMA ARC CUTTING (PAC)


34206-1 Set up plasma arc cutting equipment.

34206-2 Set the amperage and gas pressures or flow ratesfor the type and thickness of metal to be cut.

34206-3 Pierce and cut slots in metal using plasma arccutting equipment.

34206-4 Square cut metal using plasma arc cutting equipment.

34206-5 Bevel cut metal using plasma arc equipment.

34206-6 Dismantle and store the equipment.

34206-7 Clean the work area.

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MODULE 34207 AIR CARBON ARC CUTTING AND GOUGING


34207-1 Select and install air carbon arc cutting electrodes.

34207-2 Set up the work area and the air carbon arccutting equipment.

34207-3 Use air carbon arc cutting equipment for washing.

34207-4 Use air carbon arc cutting equipment for gouging.

34207-5 Demonstrate storage and housekeeping activitiesfor air carbon arc cutting equipment.

MODULE 34208 TUBE WELDING PREPARATION AND FITTING


34208-1 Identify the proper techniques for gaining tube access.

34208-2 Cut and fit-up tube for welding.

MODULE 34209 PIPE HANGERS AND SUPPORTS


34209-1 Identify types of pipe hangers.

34209-2 Identify types of connecting units and attachments.

34209-3 Identify types of pipe supports.

34209-4 Read and interpret pipe support drawings and symbols.

34209-5 Install expanding concrete fasteners.

34209-6 Install Redhead fasteners.

34209-7 Install toggle bolts.

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MODULE 34210 FASTENERS


34210-1 Identify predetermined fasteners and explainhow they are used.

34210-2 Select and install threaded fasteners in a given holeof unknown dimensions.

34210-3 Select and install a nonthreaded fastener ina given hole of unknown dimensions.

34210-4 Select and install a concrete anchor.

MODULE 34211 SPRING CAN SUPPORTS


34211-1 Identify the types of spring can supports.

34211-2 Read and interpret spring can support detail sheets.

34211-3 Install spring can supports.

34211-4 Remove the travel stops from a spring can support.

34211-5 Adjust a support to the cold position.

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MODULE 34212 BUTT WELD PIPE FABRICATION


34212-1 Given several types and sizes of fittings and pipe,match the fittings to the proper pipe.

34212-2 Describe the components of a piping systemfrom an isometric drawing.

34212-3 Clean a beveled pipe end using a portable grinder.

34212-4 Calculate pipe lengths from line drawings,using the center-to-center method.

34212-5 Calculate pipe lengths from line drawings,using the center-to-face method.

34212-6 Calculate pipe lengths from line drawings,using the face-to-face method.

34212-7 Align straight pipe.

34212-8 Align a pipe to a 45-degree elbow.

34212-9 Align a pipe to a 90-degree elbow.

34212-10 Align a pipe into a 90-degree elbow.

34212-11 Align a pipe to a flange.

34212-12 Align a pipe to a tee.

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MODULE 34301 BOILER PRESSURE COMPONENTS



MODULE 34302 BOILER NONPRESSURE COMPONENTS



MODULE 34303 ADVANCED TUBE WORK



MODULE 34304 SPECIAL RIGGING


34304-1 Erect or rig the following safely and correctly: Chicago boom A-frame Balancing beam

High lines

MODULE 34305 BRIL (BRICK, REFRACTORY, INSULATION, AND LAGGING)



MODULE 34306 BOILER AUXILIARIES



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Level Three


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MODULE 34307 TOWERS AND EXCHANGERS



MODULE 34308 TESTING PIPING SYSTEMS AND EQUIPMENT


34308-1 Perform pretest requirements.

34308-2 Perform service and flow tests.

34308-3 Perform head pressure tests.

34308-4 Perform hydrostatic tests.

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MODULE 34401 ADVANCED TRADE MATH



MODULE 34402 ADVANCED BLUEPRINT READING


34402-1 Identify symbols and abbreviations on P&IDs.

34402-2 Identify piping arrangement drawings.

34402-3 Read and interpret coordinates, control points, and elevations.

34402-4 Read and interpret P&IDs, plan views, and section views.

34402-5 Identify isometric drawings.

34402-6 Read isometric drawings taken from plan views.

34402-7 Draw isometric drawings.

34402-8 Read and interpret boiler plan views, section views, and details.

MODULE 34403 ADVANCED TOWERS AND EXCHANGERS


34403-1 Properly inventory and identify tower and exchangercomponents.

34403-2 Using proper safety procedures and correct PPE, properlyremove and install a tray.

34403-3 Using proper safety procedures and correct PPE, properlyremove and install a heat exchanger.

MODULE 34404 ADVANCED BOILER TUBE SYSTEMS



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Level Four


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MODULE 34405 ADVANCED PIPE FABRICATION


34405-1 Fabricate a tank heating coil.

MODULE 34406 STRESS RELIEVING



MODULE 34407 QUALITY ASSURANCE



MODULE 34408 BOILER DESIGN



MODULE 34409 PLANNING WORK ACTIVITIES



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