Major Work Activity D – Performs repairs, maintenance, upgrading and testing

Task D-13 Services vessels and components

Task Descriptor

Boilermakers help to ensure the proper operation of vessels and components by verifying their integrity, repairing or replacing them as needed as per code regulations. Modifying and upgrading existing systems entails replacing components and materials to improve performance or reliability, and can be done during scheduled and unscheduled maintenance. Sometimes, vessels and components cannot be repaired and need to be replaced.

Boilermakers need to know when rigging, fitting and cranes are needed to accomplish the tasks.

Inspecting and testing are important to identify defective and worn components to ensure that the system has been constructed or repaired properly.

D-13.01 Inspects vessels and components for defects

Essential Skills

Document Use, Thinking, Oral Communication

Range of Variables

permit requirements include: gas tests, hot and cold work, confined space entry, blanket permit, lock-out tag-out

vessel defects include: dents, cracks, corrosion, gouges, weld defects, arc strikes, flat spots, crowning, wear

component defects include: missing hardware, dents, cracks, corrosion, gouges, undercut, arc strikes, flat spots, dog legs, crowning, foreign objects

non-destructive testing includes: ultrasound, magnetic particle inspection (MPI), hydrostatic, air testing, vacuum box testing, x-ray, phased array, liquid penetrant inspection (LPI), positive material identification (PMI), diesel testing

Range of Variables

vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters

components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints

vessel defects include: dents, cracks, corrosion, gouges, weld defects, arc strikes, flat spots, crowning, wear

component defects include: missing hardware, dents, cracks, corrosion, gouges, undercut, arc strikes, flat spots, dog legs, crowning, foreign objects

material includes: mild steel, stainless steel, galvanized steel, aluminum, alloy

D-13.02 Prepares vessels and components for servicing

Essential Skills

Document use, Thinking, Working with Others

Range of Variables

modification requirements include: demolition, component removal and adjustments, site leveling, scaffold erection, lighting, power, ventilation

equipment includes: scaffolding, maintenance decks, temporary work platforms, needle beams, welding machines, compressors, air movers, tripods, cranes, trolley beams

Range of Variables

vessel isolation procedures include: hot bolting, odd bolting, line-break, blanking/blinding, purging

fastening methods include: bolting, welding, expanding, riveting

D-13.03 Repairs vessels and components

Essential Skills

Working with Others, Thinking, Numeracy

Range of Variables

tools and equipment include: see appendix (tools and equipment)

vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters

components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints

preparation methods include: cleaning, grinding, chipping, buffing, welding, sand blasting, cutting, milling, gouging, water jet cutting, blanking/blinding

hoisting/lifting and moving equipment includes: chainfall, come-along, Tirfor™, shackles, slings, crane, tugger, rope, gin wheel, lugs, engineered high line

job situation includes: material of vessel or component, size of repair area, work area accessibility, product stored in vessel, job specification, QC requirements

fitting tools include: dogs and wedges, screw dogs, bull pins, key plates, hickey bars, pinch bars, U-bars, drift pin, sledge hammer, finger bars, welder, level

fastening methods include: bolting, welding, gluing, riveting, tack welding

Range of Variables

preparation methods include: cleaning, grinding, chipping, buffing, welding, sand blasting, cutting, milling, gouging, water jet cutting, blanking/blinding

vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters

components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints

hoisting/lifting and moving equipment includes: chainfall, come-along, Tirfor™, shackles, slings, crane, tugger, rope, gin wheel, lugs, engineered high line

fitting tools include: dogs and wedges, screw dogs, bull pins, key plates, hickey bars, pinch bars, U-bars, drift pin, sledge hammer, finger bars, welder, level

fastening methods include: bolting, welding, gluing, riveting, tack welding

D-13.04 Performs preventative maintenance and upgrades

Essential Skills

Thinking, Oral Communication, Working with Others

Range of Variables

tools and equipment include: chipping guns, buffers, grinders, bundle puller

contaminants include: lead, asbestos, silica, kaol

vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters

components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints

cleaning methods include: scraping, buffing, chipping, high pressure washing (chemical, water), media blasting, grinding, sweeping, vacuuming

Range of Variables

vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters

components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints

cleaning methods include: scraping, buffing, chipping, high pressure washing (chemical, water), sandblasting, grinding, sweeping, vacuuming

tube defects include: wear, dents, bends, corrosion, leaks, cracks, legs, rupture

D-13.05 Tests materials, vessels and components

Essential Skills

Thinking, Document Use, Digital Technology

Range of Variables

tools and equipment include: wrenches, impact wrenches, gauges, air lines, manifolds, waterlines, purge cables, cleaning pigs, borescopes, pressure gauges, pumps, hydraulic torqueing and tensioning equipment

surface defects include: poor surface weld integrity, misalignment, improper fit up, thread protrusion, missing hardware, hardware not identified, undercut

components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints

testing equipment includes: test blinds, pumps, gauges, vent lines, trees, vacuum box, magnets, films, LPI fluid, radiation source, digital equipment

advanced testing procedures may include (depending on work location and training of tradesperson): liquid penetrant inspection (LPI), magnetic particle inspection (MPI), ultrasonic test (UT), radiographic test, phased array ultrasonic testing (PAUT), pneumatic test, hydrostatic test

defects include: cracks, undercut, pinholes, cold laps, thinning of material

internal weld or structure defects include: lack of fusion, porosity, lamination, inclusions, material makeup, lack of penetration, excessive penetration

Range of Variables

destructive testing includes: tensile test, impact test, bend test

non-destructive testing includes: visual, magnetic particle, radiographic, ultrasonic, dye penetrant, hydrostatic, vacuum box, pneumatic

vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters

components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints

Task D-14 Removes vessels and components

Task Descriptor

Boilermakers remove vessels and components to be repaired or replaced. Removing equipment, vessels and components allows easier access and facilitates maintenance and repairs. Obsolete vessels and components also need to be dismantled, demolished or removed.

D-14.01 Dismantles vessels and components

Essential Skills

Working with Others, Thinking, Document Use

Range of Variables

vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters

components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints

tools and equipment include: CAC-A (gougers), torches, wrenches, impact wrenches, hydraulic nut splitters, mechanical lifting devices, cranes

procedures include: installing lifting lugs, pre-cutting, removing obstructions

Range of Variables

vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters

components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints

safe work practices include: tie off tools, follow rigging plan, plan access to the work, establish lift zone around vessel, ensure isolation points of vessels or equipment to be removed

factors include: steel strength, rust, corrosion, weight of vessel (buildup of residue, fly ash, water retention)

D-14.02 Removes materials

Essential Skills

Document Use, Working with Others, Thinking

Range of Variables

tools and equipment include: torches, gougers, hammers, rigging equipment, mobile equipment, oxygen lances