BOILERMAKING by mikeholy

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									                                    National Center for Construction Education & Research
                                           P. O. Box 141104, Gainesville, FL 32614-1104
                                Tel: (352) 334-0920 Fax: (352) 334-0931 E-mail: info@nccer.org

                                                                                BOILERMAKING
                                                                       Materials and Equipment


Level One

MODULE 34101 - INTRODUCTION TO BOILERMAKING
 Overhead projector and screen
 Whiteboard/chalkboard
 Safety equipment
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets

MODULE 34102 - BOILERMAKING SAFETY
 Overhead projector and screen
 Whiteboard/chalkboard
 Safety equipment
 Safety harness
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets




                                                                                                 1
MODULE 34103 - BOILERMAKING TOOLS
    Overhead projector and screen
    Whiteboard/chalkboard
    Safety equipment
    Hydrometer
    Appropriate Personal Protective Equipment
    Assorted pipe wrenches
    Pipe vise
    Pipe jack stand
    Spirit level
    Framing level
    Torpedo level
    String line level
    Equipment to build a tubing water level
    Framing square
    Combination square
    Center finder
    Various pipe line-up clamps
    Hi-Lo gauge
    Wraparound
    Drift pin
    Various two-hole pins
    Flange spreader
    Hacksaw
    Assorted hacksaw blades
    Tubing cutter
    Pipe reamer
    Pipe threading machine
    Hand pipe and bolt threader
    Thread gauge
    Pipe extractors
    Pipe tap
    Lever compression tube bender
    Come-along
    Air hose and quick disconnect
    Tube beveler
    Tube roller
    Panel saw
    Circular saw
    Die-grinder
    Pencil grinder
    Various grinding wheels
    Impact wrench
    Impact sockets
    Air tugger
    Step-down transformer
    Chop saw

2
MODULE 34103 - BOILERMAKING TOOLS (Continued)
 Portable band saw
 Electric grinder
 Reciprocating saw
 Electric drill
 Magnetic base drill
 Hydro swedge
 Porta-power
 Hydraulic torque wrench
 Hydraulic flange spreader
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets




                                                3
MODULE 34104 - BASIC MATERIALS
    Overhead projector and screen
    Whiteboard/chalkboard
    Safety equipment
    Appropriate Personal Protective Equipment
    Trainee Task Module
    Transparencies
    Markers/chalk
    Module Examination
    Performance Profile Sheets

MODULE 34105 - OXYFUEL CUTTING
    Overhead projector and screen
    Whiteboard/chalkboard
    Appropriate Personal Protective Equipment
    Leather gauntlet-type gloves
    Oxyfuel cutting equipment
    Tip cleaners
    Cutting goggles
    Chipping hammer
    Pliers
    Tape measure
    Soapstone
    Friction lighter
    Framing squares
    Combination squares with protractor
    10-inch crescent wrench
    Various sizes of cutting tips for
    14-gauge to 1-inch plate
    Washing tips
    Gouging tips
    Trainee Task Module
    Transparencies
    Steel plate:
    Thin (16 to 10 gauge)
    Thick (1/4 to 1 inch)
    Markers/Chalk
    Module Examination
    Performance Profile Sheets




4
MODULE 34106 - CUTTING AND FITTING GASKETS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Ball peen hammers
 Gasket cutters
 Layout boards
 Utility knives
 Torque wrenches
 Adhesives
 Sealers
 Lubricants
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Bluing ink
 Various gaskets
 Various gasket materials




                                             5
MODULE 34107 - WELDING BASICS
    Overhead projector and screen
    Whiteboard/chalkboard
    Safety equipment
    Appropriate Personal Protective Equipment
    SMAW equipment
    GTAW equipment
    GMAW equipment
    FCAW equipment
    AAC equipment
    Welding helmets
    Hearing protection
    Welding leathers
    Welding gloves
    Handheld grinder
    Compressed air supply
    Rubber hose
    Appropriate ventilation equipment for welding
    Trainee Task Module
    Transparencies
    Markers/chalk
    Module Examination
    Performance Profile Sheets
    Assorted SMAW electrodes
    Assorted GTAW filler metal
    Assorted GMAW electrode material
    Assorted FCAW electrode material
    Assorted AAC electrodes
    Scrap metal plate
    Scrap metal pipe/tube




6
Level Two
MODULE 34201 - INTRODUCTION TO BOILER COMPONENTS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Pencils/paper

MODULE 34202 - WELDING SYMBOLS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Pencils/paper
 Welding Symbols wall chart
 Lincoln Electric Stick Electrode Welding Guide M-600

MODULE 34203 - DRAWINGS AND DETAIL SHEETS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Straightedges or rulers
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Pencils/paper
 Elevation and section drawings
 Equipment arrangement drawings
 Isometric drawings
 Orthographic drawings
 P&IDs
 Pipe support drawings and detail sheets
 Plot plans
 Spool drawings
 Structural drawings



                                                        7
MODULE 34204 - IDENTIFYING AND INSTALLING VALVES
    Overhead projector and screen
    Whiteboard/chalkboard
    Appropriate Personal Protective Equipment
    Angle valves
    Ball check valves
    Ball valves
    Butterfly check valves
    Butterfly valves
    Chain operators
    Channel-lock pliers
    Control valves
    Diaphragm valves
    Drift pins
    Electric motor-driven actuators
    Flanged valves
    Flanged end valves
    Foot valves
    Framing levels
    Framing squares
    Gate valves with various types of bonnets and stems
    Gear operators
    Globe valves
    Jack stands
    Knife gate valves
    Lift check valves
    Measuring tapes
    Needle valves
    Oxygen cylinder
    Pipe jacks
    Pipe threading machine or manual threader
    Pipe vises
    Pipe wrenches
    Plug valves
    Pneumatic and hydraulic actuators
    Pressure-relief valves
    Safety valves
    Spud wrenches
    Swing check valves
    Thread-cutting dies
    Threaded end valves
    Three-way valves
    Torpedo levels
    Torque wrenches
    Try squares
    Welded end valves
    Y-type valves

8
MODULE 34204 - IDENTIFYING AND INSTALLING VALVES (Continued)
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Bolts
 Carbon steel pipe
 Cleaning solvent
 Flanged piping
 Gaskets
 Nuts
 Pipe joint compound
 Soapstones
 Teflon® tape
 Thread-cutting oil
 Pencils/paper




                                                               9
MODULE 34205 - BASE METAL PREPARATION
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Leather gauntlet-type gloves
 Cutting goggles
 Chipping hammer
 Pliers
 Tape measure
 Soapstone
 File
 Framing square
 Combination square with protractor head
 Hand scrapers and wire brushes
 Power grinder with grinding and wire brush attachments
 Mechanical plate beveling equipment
 Mechanical pipe beveling equipment
 Oxyfuel cutting equipment
 Motorized oxyfuel carriage
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Sample MSDS for chemicals used to clean metals
 Mild steel plate
 Mild steel pipe
 Pencils/paper




10
MODULE 34206 - PLASMA ARC CUTTING (PAC)
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Leather welding gloves
 Leather jacket or sleeves
 Welding shield
 Ear plugs
 Chipping hammer
 Wire brush
 Pliers
 Respirator
 Tape measure
 Soapstone
 Plasma arc cutting unit with cutting torch and appropriate gas sources
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Scrap steel sheet or plate, 12 gauge to 1⁄2-inch thick
 Scrap aluminum plate, 3⁄16 - to 1⁄2-inch thick (if available)
 Pencil/paper




                                                                          11
MODULE 34207 - AIR CARBON ARC CUTTING AND GOUGING
 Overhead projector and screen
 Appropriate Personal Protective Equipment
 Whiteboard/chalkboard
 Leather welding gloves
 Leather jacket or sleeves
 Welding shield
 Ear plugs
 Chipping hammer
 Wire brush
 Pliers
 Soapstone
 DC welding machine, minimum 400 amp for light duty or 600 amp for medium duty
 Air carbon arc torch and cable
 Compressed air source, minimum 16 cfm at 80 psig for light and medium duty cutting or
 minimum 50 cfm at 100 psig for heavy duty cutting
 Air hose
 Trainee Task Module
 Transparencies
 Markers/chalk
 Scrap steel plate
      1
        ⁄2-inch thick minimum
      8-inches long minimum
 Module Examination
 Performance Profile Sheets
 Pencils/paper
 Scrap steel shapes containing bolts, rivets, protruding welds, eyes, clips, or other protrusions to be washed
 Selection of carbon electrodes up to 3⁄8 inch

MODULE 34208 - TUBE WELDING PREPARATION AND FITTING
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Carbon steel pipe
 Butt weld fittings
 Butt weld flanges
 Stainless steel pipe
 Piping drawings
 Pencils/paper




12
MODULE 34209 - PIPE HANGERS AND SUPPORTS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Adjustable ring hangers
 Adjustable clevis hangers
 Double-bolt pipe clamps
 Trapeze hangers
 Job-fabricated pipe hangers
 Turnbuckles
 Threaded rods
 Rod attachments
 Beam clamps
 C-clamps
 Welded beam attachments
 U-bolts
 Expansion cases
 Pipe roll supports
 Pipe saddles
 Extension riser clamps
 Wall support clamps
 Job-fabricated supports
 Redhead® drill kit
 Torpedo levels
 Soapstones
 Measuring tapes
 Channel-lock pliers
 Angle irons
 Connecting units and attachments
 Screwdrivers
 Concrete inserts
 1
   ⁄2-inch hammer drill
 1
   ⁄4-inch drill motor
 Extension cord(s)
 Adjustable wrenches
 Masonry drill bits
 Standard drill bits
 Welded beam attachments
 Support brackets
 Trainee Task Module
 Transparencies
 Markers/chalk
 Eyebolts
 Expanding concrete fasteners
 Redhead® fasteners
 Toggle bolts
 Grout
 Pipe support drawings
 Module Examination
 Performance Profile Sheets
 Pencils/paper
                                             13
MODULE 34210 - FASTENERS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Concrete pad
 Wrenches and pliers of the appropriate type and size for the fasteners used
 Core drill
 3
   ⁄8 -inch drill
 Drill bits of the proper type and size for the fasteners used
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Machine screws
 Machine bolts
 Cap screws
 Set screws
 Stud bolts
 Thread-forming screws
 Thread-cutting screws
 Drive screws
 Eyebolts
 Toggle bolts
 Anchor bolts
 Self-tapping bolts
 Nuts
 Jam nuts
 Castellated, slotted, and self-locking nuts
 Acorn nuts
 Wing nuts
 Inserts
 Flat washers
 Lock washers
 Retainer rings
 Square keys
 Pratt and Whitney keys
 Gib head keys
 Woodruff keys
 Dowel pins
 Taper and spring pins
 Cotter pins
 Tinner’s rivets
 Blind rivets
 Annealed wire
 Bands and clips
 Staples
 Stick clips
 Studs and pins
 Contact adhesives
 Noncontact adhesives
14
MODULE 34211 - SPRING CAN SUPPORTS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Channel-lock pliers
 Combination wrenches
 Types A, B, C, D, E, F, G variable and constant spring can supports
 Crescent wrenches
 Grinder and accessories
 Hacksaws
 Ladders or scaffolding
 Rigging devices
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Detail sheets for spring can supports
 Erection materials
      Double-bolt pipe clamps
      Hex nuts
      Threaded rods
      Welded beam attachments
      Weldless eye nuts
 Copies of industry standard MSS SP-58




                                                                       15
MODULE 34212 - BUTT WELD PIPE FABRICATION
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Bottle cart
 Calculators
 Center finder
 Framing squares
 Full-face shields
 Hacksaws
 Hammers
 Hi-Lo gauge
 Hose sets
 Jack stands
 Lever-type clamps
 Oxyacetylene cutting equipment
 Pipe vises
 Portable grinders
 Soapstones
 Spirit levels
 Tape measures
 Torpedo levels
 Tripod vises
 Wraparounds
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Backing rings
 Butt weld fittings
 Butt weld flanges
 Flange welding clamps
 Various sizes of carbon steel and pipe
 Stainless steel pipe
 Steel plate
 Straight pipe welding clamps
 Pencils/paper
 Piping drawings
 Scrap angle iron
 Scrap channel iron
 Two-hole flange pins




16
Level Three
MODULE 34301 - BOILER PRESSURE COMPONENTS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination

MODULE 34302 - BOILER NONPRESSURE COMPONENTS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Pencils/paper
 Module Examination

MODULE 342303 - ADVANCED TUBE WORK
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination




                                               17
MODULE 34304 - SPECIAL RIGGING
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Boom
 Snatch blocks
 Ink stand
 Sheaves
 Blocks
 Guys
 Manila rope
 U-bolts
 Guy anchors
 Frame (steel or wood) A-frame
 Hoisting engine
 Hook
 Block and tackle (manila rope)
 Lugs
 Frame (Davit)
 Balancing beam
 Shackles
 Slings
 Tag line
 Anchors
 Turnbuckles
 Caterpillar dollies
 Hydraulic jacks
 Chain hoists
 Suitable lengths of pipe
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Pencils/paper

MODULE 34305 - BRIL (BRICK, REFRACTORY, INSULATION, AND LAGGING)
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination




18
MODULE 34306 - BOILER AUXILIARIES
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination

MODULE 34307 - TOWERS AND EXCHANGERS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination

MODULE 34308 - TESTING PIPING SYSTEMS AND EQUIPMENT
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Examples of pressure gauges
 Trainee Task Module
 Transparencies
 Pencils/paper
 Markers/chalk
 Module Examination
 Performance Profile Sheets




                                                      19
Level Four
MODULE 34401 - ADVANCED TRADE MATH
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Scientific calculator
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 The Pipe Fitter’s Blue Book

MODULE 34402 - ADVANCED BLUEPRINT READING
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Calculator
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Set of drawings supplied with the Trainee Module, identified by the following numbers:
      CTE-51MP-23-2
      CTE-51MP-24-0
      CTE-51MP-38
      CTE-51MP-40-5
      CTE-51MP-62-4
      CTE-51MP-84-2
      CTE-51MP-103-3

MODULE 34403 - ADVANCED TOWERS AND EXCHANGERS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Samples of bubble caps, if available
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets




20
MODULE 34404 - ADVANCED BOILER TUBE SYSTEMS
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination




                                              21
MODULE 34405 - ADVANCED PIPE FABRICATION
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Ball peen hammer
 Sledgehammer
 Chipping hammer
 Open-end wrench
 Box-end wrench
 Combination wrench
 Socket wrench set
 Adjustable wrench
 Pipe wrench
 Slugging wrench
 Torque wrench
 Torque multiplier
 Assorted screwdrivers
 Slip joint pliers
 Locking pliers
 Parallel pliers
 Half round file
 Hand file
 Pillar file
 Square file
 Round file
 Triangular file
 Machinist’s bench vise
 Mechanic’s bench vise
 Bench and pipe vise
 Yoke pipe vise
 Adjustable drill press vise
 Chain pipe vise
 C-clamp
 Welding table clamp
 Spring clamp
 Prick punch
 Center punch
 Drift punch
 Pin punch
 Alignment punch
 Hole (gasket) punch
 Assorted chisels
 Twist drill
 Tapered hank drill
 Assorted taps
 Assorted dies
 Assorted reamers

22
MODULE 34405 - ADVANCED PIPE FABRICATION (Coninued)
 Portable drill
 Drill press
 Reciprocating saw
 Circular saw
 Hacksaw
 Wheel-and-roller pipe cutter
 Two-wheel pipe cutter
 Bench grinder
 Portable grinder
 15 feet of pipe
 10 45-degree elbows
 Soapstone
 Tape measure
 Combination try-square
 Torpedo level
 Framing square
 Trainee Module
 Transparencies
 Markers/chalk
 Module Examination
 Performance Profile Sheets
 Calculator
 Pencils and paper

MODULE 34406 - STRESS RELIEVING
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination

MODULE 34407 - QUALITY ASSURANCE
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination




                                                      23
MODULE 34408 - BOILER DESIGN
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination

MODULE 34409 - PLANNING WORK ACTIVITIES
 Overhead projector and screen
 Whiteboard/chalkboard
 Appropriate Personal Protective Equipment
 Trainee Task Module
 Transparencies
 Markers/chalk
 Module Examination




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