Table of Contents
Task C-10 Performs fabrication
Task Descriptor
Fabrication is the creation of the components from stock material following specific instructions from a drawing or a concept. The fabrication process includes layout, cutting, forming and assembly of components. Most components are built in a shop and transported to the jobsite; however, fabrication can also occur in the field.
C-10.01 - Lays out components for fabrication
C-10.01 - Lays out components for fabrication
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-10.01.01P |
select and use tools and equipment |
tools and equipment are selected and used according to task |
| C-10.01.02P |
select and locate material and components |
material and components are selected and located according to drawings and specifications |
| C-10.01.03P |
measure material |
material is measured to ensure dimensions are according to drawings and specifications |
| C-10.01.04P |
perform mathematical calculations |
mathematical calculations are performed to obtain proper orientation, alignment and projections according to specifications |
| C-10.01.05P |
transfer dimensions and measurements |
dimensions and measurements are transferred to components and materials according to drawings and specifications |
| C-10.01.06P |
make jigs and templates |
jigs and templates are made according to task and specifications |
| C-10.01.07P |
identify and mark final product |
various sections of final product are identified and marked for site assembly and installation using various identification methods |
| C-10.01.08P |
prepare and clean material to be cut |
material to be cut is prepared and cleaned |
Range of Variables (include, but not limited to)
- material: metals, fibreglass, composites, stainless steel
- components: access ladders, platforms, davits, headers, pipe turns, offsets, ducts, cylinders, cones, pressure vessel shells, vessel internals, support structures
- dimensions: thickness, length, width, diameter, circumference, orientation, elevation, volume, area, chord length
- identification methods: match-marking, tagging, piece mark numbering, item list, heat number
Knowledge
| Reference Code |
Learning Outcomes and Objectives |
| C-10.01.01L |
demonstrate knowledge of procedure to lay out material and components for fabrication
- identify, select and use tools and equipment
- identify types of material to be used and components being fabricated
- describe identification methods for material and components
- describe various layout methods
- describe steps to develop templates using parallel lines and radial line development
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| C-10.01.02L |
demonstrate knowledge of calculations required to lay out components
- calculate dimensions of squares, rectangles and circles for layout
- calculate orientation, alignment, elevations and projections
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| C-10.01.03L |
demonstrate knowledge of drawing interpretation
- read drawings to determine materials required and lay out template or components
- read drawing and identify components listed for fabrication
- list and describe abbreviations applicable to layout and development
- lay out and fabricate components from drawings
|
| C-10.01.04L |
demonstrate knowledge of sustainability and environmental stewardship practices |
| a. |
describe practices that avoid material waste through pre-planning |
Range of Variables (include, but not limited to)
- material: metals, fibreglass, composites, stainless steel
- components: access ladders, platforms, davits, headers, pipe turns, offsets, ducts, cylinders, cones, pressure vessel shells, vessel internals, support structures
- identification methods: match-marking, tagging, piece mark numbering, item list, heat number
- layout methods: parallel-line, triangulation, radial line development, mathematical formulas, geometric construction
- dimensions: thickness, length, width, diameter, circumference, orientation, elevation, volume, area, chord length
C-10.02 - Cuts components for fabrication
C-10.02 - Cuts components for fabrication
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-10.02.01P |
select cutting method |
cutting method is selected according to material type, dimensions, work environment, task and specifications |
| C-10.02.02P |
select tools and equipment |
tools and equipment are selected according to task |
| C-10.02.03P |
set up cutting tools |
cutting tools are set up according to task and manufacturers’ specifications |
| C-10.02.04P |
measure components |
components are measured to ensure accuracy |
| C-10.02.05P |
position and secure material |
material to be cut is positioned and secured |
| C-10.02.06P |
perform cut |
cut is performed according to drawings and specifications |
Range of Variables (include, but not limited to)
- cutting method: oxy-fuel, grinding, gouging, plasma, saw, shear
Knowledge
| Reference Code |
Learning Outcomes and Objectives |
| C-10.02.01L |
demonstrate knowledge of procedures used to cut components for fabrication and their associated tools and equipment
- identify cutting tools and equipment, and describe their applications and procedures for use
- describe cutting methods
- describe process of cutting material of various thickness
- identify oxy-fuel cutting equipment
- describe procedure to set up oxy-fuel cutting equipment
- describe principles of oxy-fuel gas cutting process
- identify characteristics of oxygen and fuel gas cylinders
- explain purpose of manifold system
- identify fuel gases for manual and automatic oxy-fuel cutting of carbon steel, and describe their characteristics and applications
- identify regulator types, and describe their characteristics, applications, adjustments and care
- describe construction and maintenance of hoses, fittings and flashback arrestors
- describe and demonstrate setting of oxy-fuel pressures, balancing and flame adjustments
- list causes of backfires and flashbacks, and describe prevention strategies
- describe design, maintenance, selection and operation of oxy-fuel tips
- describe setup and operation of CAC-A equipment (gouger)
- describe setup and operation of PAC (plasma arc cutting) equipment
- describe cutting processes involved in cutting alloy steels and non-ferrous metals
- describe procedures to perform pipe cutting to size using pipe cutter or oxy-fuel cutting process
- describe procedure to check for leaks
- identify cutting issues
|
| C-10.02.03L |
demonstrate knowledge of procedures to thread components for fabrication and their associated tools and equipment
- identify threading tools and equipment
- describe procedures to thread pipe using manual and mechanical processes
|
Range of Variables (include, but not limited to)
- cutting method: oxy-fuel, grinding, gouging, plasma, saw, shear
- oxy-fuel cutting equipment: regulators, cylinders, torches, safety devices, cutting tips, hoses, striker, tip cleaners
- cutting issues: incorrect tip type, poor cut quality, incorrect speed, incorrect heat, incorrect tip angle, incorrect pressures, faulty and dull equipment
C-10.03 - Forms components for fabrication
C-10.03 - Forms components for fabrication
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-10.03.01P |
select and use shop equipment |
shop equipment is selected and used to form components |
| C-10.03.02P |
select and use hand and power tools |
hand and power tools are selected and used to form components |
| C-10.03.03P |
shape components |
components are shaped using forming methods according to drawings |
| C-10.03.04P |
check components |
components are checked for dimension and tolerance according to drawings |
| C-10.03.05P |
finish fabricated material |
fabricated material is finished using finishing methods |
Range of Variables (include, but not limited to)
- shop equipment: brakes, rolls, dies, ironworkers, plate shears
- forming methods: rolling, bending, braking, controlled heating
- finishing methods: buffing, cleaning, grinding, deburring
Knowledge
| Reference Code |
Learning Outcomes and Objectives |
| C-10.03.01L |
demonstrate knowledge of drawing interpretation
- interpret dimensions, symbols and abbreviations on drawings
|
| C-10.03.02L |
demonstrate knowledge of procedures to form components
- identify tools and shop equipment required to form components, and describe their characteristics and applications
- identify forming methods
- identify finishing methods
- identify jigs and templates, and describe their characteristics and applications
- identify spider bars and backing bars, and describe their characteristics and applications
|
Range of Variables (include, but not limited to)
- shop equipment: brakes, rolls, dies, ironworkers, plate shears
- forming methods: rolling, bending, braking, controlled heating
- finishing methods: buffing, cleaning, grinding, deburring
C-10.04 - Constructs components
C-10.04 - Constructs components
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-10.04.01P |
select and use tools and equipment |
tools and equipment are selected and used according to task and specifications |
| C-10.04.02P |
align and orient components |
components are aligned and oriented to fit according to match-marks, drawings and specifications |
| C-10.04.03P |
secure components |
components are secured to ensure correct alignment and to maintain their shape using various securing methods according to task |
| C-10.04.04P |
assemble components |
components are assembled using joining and fastening methods according to task |
Range of Variables (include, but not limited to)
- securing methods: clamping, dogging, bracing, lashing, tacking, spidering
- joining and fastening methods: welding, bolting, riveting, tube expanding
Knowledge
| Reference Code |
Learning Outcomes and Objectives |
| C-10.04.01L |
demonstrate knowledge of procedures to construct components and their associated tools and equipment
- interpret dimensions, symbols and abbreviations on drawings
- identify tools and equipment used to construct components, and describe their characteristics and applications
- describe securing, joining and fastening methods
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Range of Variables (include, but not limited to)
- securing methods: clamping, dogging, bracing, lashing, tacking, spidering
- joining and fastening methods: welding, bolting, riveting, tube expanding
Task C-11 - Assembles and fits vessels and components
Task Descriptor
Boilermakers assemble, align and fit vessels and components in sections or modules according to applicable codes and standards prior to final installation. They align the components and vessels at the desired location. Fitting ensures the proper placement of the vessels and components prior to fastening them in place.
C-11.01 - Aligns vessels and components
C-11.01 - Aligns vessels and components
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-11.01.01P |
select and use alignment tools and equipment |
alignment tools and equipment are selected and used according to task |
| C-11.01.02P |
identify reference point |
reference point is identified according to drawings and specifications |
| C-11.01.03P |
set vessels and components |
vessels and components are set at desired location according to engineer-approved drawings and specifications |
| C-11.01.04P |
check elevation, orientation and projection of vessels and components |
elevation, orientation and projection of vessels and components are checked to confirm placement according to engineer-approved drawings and specifications |
Range of Variables (include, but not limited to)
- alignment tools and equipment: transits, water levels, plumb bobs, dogs/wedges, lugs, shims, key plates, strongbacks, key channels, u-bars, bull pins, key plate nuts
- reference point: benchmarks or elevation marks, datum line, work points
- vessels: drums, exchangers, towers, tanks, boilers
- components: manways, cleanout doors, water or fluid draw-off elbows, draw-off sumps, inlets/outlets, overflow venting, walkways, stairways, ladders, nozzles, support structures, vessel internals
Knowledge
| Reference Code |
Learning Outcomes and Objectives |
| C-11.01.01L |
demonstrate knowledge of procedures to align vessels and components
- identify alignment tools and equipment, and describe their applications and procedures for use
- describe layout and fit-up of vessels and components
- describe preparation, fit-up and alignment of seams
- describe orientation, elevation, projection and datum reference methods and procedures
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| C-11.01.02L |
demonstrate knowledge of drawing interpretation
- interpret information from drawings, specifications and codes
- identify reference points according to drawings and specifications
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Range of Variables (include, but not limited to)
- vessels: drums, exchangers, towers, tanks, boilers
- components: manways, cleanout doors, water or fluid draw-off elbows, draw-off sumps, inlets/outlets, overflow venting, walkways, stairways, ladders, nozzles, support structures, vessel internals
- alignment tools and equipment: transits, water levels, plumb bobs, dogs/wedges, lugs, shims, key plates, strongbacks, key channels, u-bars, bull pins, key plate nuts
- reference point: benchmarks or elevation marks, datum line, work points
C-11.02 - Fits vessels and components
C-11.02 - Fits vessels and components
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-11.02.01P |
select and use tools and equipment |
tools and equipment are selected and used according to task |
| C-11.02.02P |
inventory and assemble components |
components are inventoried and assembled according to drawings and specifications |
| C-11.02.03P |
check components |
components are checked for fit and function by measuring and pre-assembly according to drawings |
| C-11.02.04P |
measure, match-mark and cross reference elevation, orientation and projection of components |
elevation, orientation and projection of components are measured, match-marked and cross-referenced according to drawings and specifications |
| C-11.02.05P |
attach components |
components are attached using attachment methods |
Range of Variables (include, but not limited to)
- tools and equipment: levels, dogs, wedges, hammers, rigging, key plates, pry bars, strongbacks
- attachment methods: bolting, clipping, tacking, welding, tube expansion, riveting, chemical bonding
Knowledge
| Reference Code |
Learning Outcomes and Objectives |
| C-11.02.01L |
demonstrate knowledge of procedures to fit vessels and components
- identify tools and equipment used to fit vessels and components, and describe their characteristics and applications
- identify and describe assembly requirements and procedures
- describe fitting methods and procedures
- describe attachment methods
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Range of Variables (include, but not limited to)
- tools and equipment: levels, dogs, wedges, hammers, rigging, key plates, pry bars, strongbacks
- attachment methods: bolting, clipping, tacking, welding, tube expansion, riveting, chemical bonding
Task C-12 Fastens components
Task Descriptor
Boilermakers use several techniques to fasten components during construction. This is a required task in order to complete the final installation.
C-12.01 - Bolts components
C-12.01 - Bolts components
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-12.01.01P |
select bolting hardware |
bolting hardware types, grades and sizes for application are selected according to drawings and job specifications |
| C-12.01.02P |
prepare components |
components are prepared prior to fastening using preparation methods according to job specifications |
| C-12.01.03P |
select approved gasket |
approved gasket is selected according to job specifications |
| C-12.01.04P |
select approved lubrication |
approved lubrication is selected according to job specifications |
| C-12.01.05P |
install hardware |
hardware is installed according to job specifications |
| C-12.01.06P |
select and use manual, pneumatic and hydraulic torquing and tensioning equipment |
manual, pneumatic and hydraulic torquing and tensioning equipment are selected and used according to job requirements and manufacturers' specifications |
| C-12.01.07P |
ensure final fit |
final fit is ensured before tightening bolts on vessels and components according to specifications |
| C-12.01.08P |
torque or tension bolts |
bolts are torqued or tensioned according to specifications |
Range of Variables (include, but not limited to)
- preparation methods: approved lubrication, cleaning, buffing
- hardware: gaskets, bolts, nuts, washers, studs, rivets
Knowledge
| Reference Code |
Learning Outcomes and Objectives |
| C-12.01.01L |
demonstrate knowledge of techniques used to bolt components
- identify types, grades and sizes of bolts
- identify types, material grade, service and pressure/heat rating of gaskets
- identify types, size and pressure rating of flanges
- identify types of lubricants
- identify types of torquing and tensioning equipment
- describe bolting and torquing sequence
|
Range of Variables (include, but not limited to)
- torquing and tensioning equipment: pneumatic torque wrench, hydraulic torque wrench, electric torque wrench, hydraulic tensioning system, pumps, manual torque wrench, multiplier
C-12.02 - Expands tubes
C-12.02 - Expands tubes
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-12.02.01P |
calculate initial measurements of components |
initial measurements of components are calculated to determine final expansion |
| C-12.02.02P |
select and use expansion tools and equipment |
expansion tools and equipment are selected and used according to task and specifications |
| C-12.02.03P |
disassemble, clean, lubricate and reassemble rolling components |
rolling components are disassembled, cleaned, lubricated and reassembled to prevent damage to equipment according to job specifications |
| C-12.02.04P |
prepare surface |
surface is prepared using tube reamer, grooving tool and tube brushes to buff and clean according to job specifications |
| C-12.02.05P |
roll tubes |
tubes are rolled according to job specifications |
| C-12.02.06P |
measure final expansion |
final expansion is verified with initial calculations to confirm job specifications using measuring instruments |
Range of Variables (include, but not limited to)
- expansion tools and equipment: rolling guns, mandrels and rolls, compressor
- measuring instruments: outside micrometers, inside micrometers, gauges, telescopic gauges
Knowledge
| Reference Code |
Learning Outcomes and Objectives |
| C-12.02.01L |
demonstrate knowledge of techniques used to expand tubes and their associated tools and equipment
- identify expansion tools and equipment, and describe their characteristics and applications
- identify measuring instruments, and describe their characteristics and applications
- define expansion theory and describe techniques to expand tubes
- describe process of tube rolling
- list and describe factors to consider in tube expanding
- list and describe steps associated with tube installation
- list and describe recommended tube expansion sequences with reference to tube sheet layout, area and shape
- describe how to measure inside diameter of tubes
- describe recommended percentage wall reduction for ferrous and non-ferrous materials
- identify recommended lubricants, and describe their characteristics and applications
- identify optimum depth of expansion
- describe reason for grooved seats
- identify factors affecting quality of expanded joint
- describe operational relationship of mandrel and rolls
- describe purpose and process of bell rolling/flaring
- describe purpose and process of tube beading
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| C-12.02.02L |
demonstrate knowledge of techniques used to assemble tubular heat exchangers
- define terms associated with tube hole arrangement
- identify types of baffles and describe their function and installation procedures
- identify tube sheet layouts and state their preference of application
- describe different types of exchanger heads
- list and describe the uses and limitations of tube equipment
|
| C-12.02.03L |
demonstrate knowledge of calculations required to expand tube
- calculate expanded diameter (final ID) of tube
|
Range of Variables (include, but not limited to)
- expansion tools and equipment: rolling guns, mandrels and rolls, compressor
- measuring instruments: outside micrometers, inside micrometers, gauges, telescopic gauges
- exchanger heads: channel and removable cover, bonnet, channel integral with tube sheet, pull through floating head, outside packed floating head
- tube equipment: tube guide, air motor, electric motor tube end mills, tube expanders, tube pullers, fly cutters, tube cutters, tube cleaners, tube removal tools
C-12.03 - Lays up fibreglass
C-12.03 - Lays up fibreglass
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-12.03.01P |
select and use tools, equipment and PPE |
tools, equipment and PPE are selected and used according to task, jurisdictional regulations and SDS |
| C-12.03.02P |
prepare surface |
surface is prepared by grinding, sanding and cleaning |
| C-12.03.03P |
mix fibreglass resins |
fibreglass resins are mixed according to manufacturers’ and job specifications, and environmental considerations |
| C-12.03.04P |
apply lay-up techniques |
lay-up techniques are applied according to manufacturers’ specifications |
| C-12.03.05P |
identify and repair malformations |
malformations are identified and repaired according to job specifications |
| C-12.03.06P |
store and dispose of fibreglass materials |
fibreglass materials are stored and disposed of according to SDS |
Range of Variables (include, but not limited to)
- tools and equipment: power cutter (circular saw), power disc sander, extension cords, rags, heat lamps, fans, scale, thermometer, rollers and brushes
- PPE:disposable coveralls, safety goggles, full-faced respirator, chemical-resistant gloves, organic vapour cartridges, butyl rubber gloves, face shields
- lay-up techniques: rolling, brushing, spraying
- malformations:air bubbles, delamination, impurities
Knowledge
| Reference Code |
Learning Outcomes and Objectives |
| C-12.03.01L |
demonstrate knowledge of fibreglass chemicals and lay-up materials,their characteristics and applications
- identify fibreglass chemicals, and describe their characteristics and applications
- interpret information found on drawings and specifications
- identify lay-up materials, and describe their characteristics and applications
- identify types and grades of fibreglass chemicals
- identify accelerators, retarders and promoters
- identify and describe fibreglass chemicals and lay-up materials required for lay-up and repairs
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| C-12.03.02L |
demonstrate knowledge of procedures used to lay up fibreglass
- identify tools and materials used for preparation and assembly, and describe their characteristics and applications
- identify hazards and describe safe work practices pertaining to fiberglass chemicals
- identify measuring equipment, and describe their characteristics and applications
- describe procedures to lay up fibreglass
- describe mixing and curing procedures, and safety considerations for handling and mixing resins, catalysts and associated chemicals
- describe handling and storage process for chemicals required to assemble fibreglass pipe and vessels
- describe process of drilling
- describe process of bolting
- describe process of cutting
- describe process of grinding
- describe process of laminating fibreglass
- describe uses of fibreglass in tanks, silos, stacks, scrubbers, breeching and piping
|
Range of Variables (include, but not limited to)
- fibreglass chemicals: polyester resins, catalysts, promoters, acetone, methylene chloride, air dry additive, filler, methyl ethyl ketone peroxide (MEKP)
- lay-up materials: surfacing veil, matting, woven roving
- hazards: fire, explosion, dermatitis, burns, inhalation