Table of Contents
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 when needed as per codes and jurisdictional 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
D-13.01 - Inspects vessels and components for defects
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Skills
Reference Code |
Performance Criteria |
Evidence of Attainment |
D-13.01.01P |
verify permit requirements are met |
permit requirements are met before proceeding with task according to site-specific specifications |
D-13.01.02P |
clean surfaces |
surfaces are cleaned for inspection by washing, grinding, chipping or buffing according to job specifications |
D-13.01.03P |
identify vessel defects |
visual inspection is performed to identify vessel defects according to specifications |
D-13.01.04P |
identify component defects |
visual inspection is performed to identify component defects according to engineered drawings |
D-13.01.05P |
request non-destructive testing to verify material integrity |
material integrity is identified according to non-destructive testing results |
D-13.01.06P |
report deficiencies and defects |
deficiencies and defects are reported according to company policies and jurisdictional regulations |
Range of Variables (include, but not limited to)
- permit requirements: gas tests, hot and cold work, confined space entry, blanket permit, lock-out and tag-out
- vessel defects: dents, cracks, corrosion, gouges, weld defects, arc strikes, flat spots, crowning, wear
- component defects: missing hardware, dents, cracks, corrosion, gouges, undercut, arc strikes, flat spots, distortion, crowning, foreign objects
- non-destructive testing: ultrasound, magnetic particle inspection (MPI), hydrostatic, air testing, vacuum box testing, x-ray, phased array, liquid penetrant inspection (LPI), positive material identification (PMI), light oil testing
Knowledge
Reference Code |
Learning Outcomes and Objectives |
D-13.01.01L |
demonstrate knowledge of vessels and components, their characteristics, applications and operation
- identify vessels and components, and describe their characteristics and applications
- describe operating principles of vessels and components
- interpret information pertaining to vessels and components found on drawings and specifications
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D-13.01.02L |
demonstrate knowledge of procedures to inspect vessels and components for defects
- identify tools and equipment used to inspect vessels and components, and describe their characteristics and applications
- identify vessel defects and component defects
- explain causes of vessel defects and component defects
- describe procedures to inspect vessels and components
- identify composition of vessels, components and gaskets
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D-13.01.03L |
demonstrate knowledge of training and certification requirements to inspect vessels and components for defects
- identify training and certification requirements to inspect vessels and components for defects and how to report them
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D-13.01.04L |
demonstrate knowledge of regulatory requirements pertaining to inspections of vessels and components for defects and how to report them
- identify codes, standards and regulations pertaining to inspections of vessels and components for defects and how to report them
|
Range of Variables (include, but not limited to)
- vessels: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters, air heaters, settler
- components: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching, expansion joints, pipes, elbows
- vessel defects: dents, cracks, corrosion, gouges, weld defects, arc strikes, flat spots, crowning, wear
- component defects: missing hardware, dents, cracks, corrosion, gouges, undercut, arc strikes, flat spots, distortion, crowning, foreign objects
D-13.02 - Prepares vessels and components for servicing
D-13.02 - Prepares vessels and components for servicing
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Skills
Reference Code |
Performance Criteria |
Evidence of Attainment |
D-13.02.01P |
locate vessels and components to be serviced |
vessels and components to be serviced are located according to client job specifications |
D-13.02.02P |
identify site access and requirements |
site access and requirements are identified according to site-specific location |
D-13.02.03P |
empty, de-energize and depressurize, isolate and purge vessels |
vessels are emptied, de-energized and depressurized, isolated and purged before maintenance begins according to job specifications, site-specifications, company policies and procedures, and jurisdictional regulations |
D-13.02.04P |
create access or openings to work area |
access or openings to work area are created according to job scope |
D-13.02.05P |
identify site modification requirements |
site modification requirements are identified according to job scope |
D-13.02.06P |
select material, tools and equipment |
material, tools and equipment are selected according to task |
D-13.02.07P |
set up material, tools and equipment |
material, tools and equipment are set up in designated location according to job specifications |
D-13.02.08P |
pre-assemble components |
components to be installed are pre-assembled according to engineer-approved drawings and specifications |
Range of Variables (include, but not limited to)
- vessels: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters, air heaters, settler
- components: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching, expansion joints, pipes, elbows
- modification requirements: demolition, component removal and adjustments, site levelling, scaffold erection, lighting, power, ventilation
- tools and equipment: scaffolding, maintenance decks, temporary work platforms, needle beams, welding machines, compressors, air movers, tripods, cranes, trolley beams, air lines, electrical cords, hand tools, power tools
Knowledge
Reference Code |
Learning Outcomes and Objectives |
D-13.02.01L |
demonstrate knowledge of vessels and components, their characteristics, applications and operation
- identify vessels and components, and describe their characteristics and applications
- describe operating principles of vessels and components
- interpret information pertaining to vessels and components found on drawings and specifications
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D-13.02.02L |
demonstrate knowledge of procedures used to prepare vessels and components for servicing
- identify materials, tools and equipment used to service vessels and components, and describe their characteristics and applications
- identify vessels and components to be serviced
- describe vessel isolation procedures
- identify fasteners and fastening methods required to complete task
- interpret required changes detailed in engineer-approved drawings and specifications of vessels and components
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D-13.02.03L |
demonstrate knowledge of regulatory requirements pertaining to preparing vessels and components for servicing
- identify codes, standards and regulations pertaining to preparing vessels and components for servicing
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Range of Variables (include, but not limited to)
- vessels: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters, air heaters, settler
- components: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching, expansion joints, pipes, elbows
- tools and equipment: scaffolding, maintenance decks, temporary work platforms, needle beams, welding machines, compressors, air movers, tripods, cranes, trolley beams, air lines, electrical cords, hand tools, power tools
- vessel isolation procedures: hot bolting, odd bolting, line-break, blanking/blinding, purging
- fastening methods: bolting, welding, expanding, riveting
D-13.03 - Repairs vessels and components
D-13.03 - Repairs vessels and components
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Skills
Reference Code |
Performance Criteria |
Evidence of Attainment |
D-13.03.01P |
select and use tools and equipment |
tools and equipment are selected and used according to task |
D-13.03.02P |
prepare work area |
work area is prepared for installation of new vessels and components |
D-13.03.03P |
prepare parent material and repair pieces |
parent material and repair pieces are prepared using preparation methods |
D-13.03.04P |
install components |
components are installed according to factors |
D-13.03.05P |
perform orientation, alignment and fitting of components |
components are oriented, aligned and fit to existing vessels and components using fitting tools and methods according to engineer-approved drawings and specifications |
D-13.03.06P |
fasten components |
components are fastened to existing vessels and components using fastening methods |
D-13.03.07P |
reinstall components removed during repair preparation |
components removed during repair preparation are reinstalled |
Range of Variables (include, but not limited to)
- vessels: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters, air heaters, settler
- components: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching, expansion joints, pipes, elbows
- preparation methods: cleaning, grinding, chipping, buffing, welding, media blasting, cutting, milling, gouging, water jet cutting, blanking/blinding
- factors: material of vessel or component, size of repair area, work area accessibility, product stored in vessel, job scope, quality control (QC) requirements
- fitting tools: dogs and wedges, screw dogs, bull pins, key plates, hickey bars, pinch bars, U-bars, drift pin, sledgehammers, finger bars, welding equipment, level
- fastening methods: bolting, welding, gluing, riveting, tack welding
Knowledge
Reference Code |
Learning Outcomes and Objectives |
D-13.03.01L |
demonstrate knowledge of vessels and components, their characteristics, applications and operation
- identify vessels and components, and describe their characteristics and applications
- describe operating principles of vessels and components
- interpret information pertaining to vessels and components found on drawings and specifications
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D-13.03.02L |
demonstrate knowledge of procedures to repair vessels and components
- identify tools and equipment used to repair vessels and components, and describe their characteristics and applications
- describe preparation methods
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D-13.03.03L |
demonstrate knowledge of procedures to fit material to vessels and components for repair
- identify fitting tools, and describe their characteristics and applications
- identify methods used to fit new components
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D-13.03.04L |
demonstrate knowledge of procedures to fasten material to vessels and components for repair
- identify fastening methods used to fasten new components
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D-13.03.05L |
demonstrate knowledge of regulatory requirements pertaining to repairing of vessels and components
- identify codes, standards and regulations pertaining to repairing of vessels and components
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Range of Variables (include, but not limited to)
- vessels: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters, air heaters, settler
- components: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching, expansion joints, pipes, elbows
- preparation methods: cleaning, grinding, chipping, buffing, welding, media blasting, cutting, milling, gouging, water jet cutting, blanking/blinding
- fitting tools: dogs and wedges, screw dogs, bull pins, key plates, hickey bars, pinch bars, U-bars, drift pin, sledgehammers, finger bars, welding equipment, level
- fastening methods: bolting, welding, gluing, riveting, tack welding
D-13.04 - Performs preventative maintenance and upgrades
D-13.04 - Performs preventative maintenance and upgrades
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Skills
Reference Code |
Performance Criteria |
Evidence of Attainment |
D-13.04.01P |
select and use tools and equipment |
tools and equipment are selected and used according to task |
D-13.04.02P |
remove contaminants and corrosion on vessels and components |
contaminants and corrosion on vessels and components are removed using cleaning methods according to specifications |
D-13.04.03P |
repair defects on vessels and components |
defects are repaired according to specifications |
D-13.04.04P |
reinstall or replace components |
components are reinstalled or replaced according to specifications |
D-13.04.05P |
tighten loose components and replace missing hardware |
loose components are tightened and missing hardware are replaced according to specifications |
Range of Variables (include, but not limited to)
- contaminants: lead paint, asbestos, silica, insulation
- vessels: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters, air heaters, settler
- components: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching, expansion joints, pipes, elbows
- cleaning methods: scraping, buffing, chipping, high pressure washing (e.g., chemical, water), media blasting, grinding, sweeping, vacuuming
Knowledge
Reference Code |
Learning Outcomes and Objectives |
D-13.04.01L |
demonstrate knowledge of vessels and components, their characteristics, applications and operation
- identify vessels and components, and describe their characteristics and applications
- describe operating principles of vessels and components
- interpret information pertaining to vessels and components found on drawings and specifications
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D-13.04.02L |
demonstrate knowledge of preventative maintenance and upgrade procedures
- identify tools and equipment used to perform preventative maintenance and upgrades, and describe their characteristics and applications
- identify vessels and components to be maintained
- describe preventative maintenance procedures
- describe upgrading procedures
- describe cleaning methods
- identify compatible materials when selecting replacement hardware or components
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D-13.04.03L |
demonstrate knowledge of regulatory requirements pertaining to performing preventative maintenance and upgrades
- identify codes, standards and regulations pertaining to performing preventative maintenance and upgrades
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D-13.04.04L |
demonstrate knowledge of sustainability and environmental stewardship practices
- identify practices that contribute to environmental protection
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Range of Variables (include, but not limited to)
- vessels: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters, air heaters, settler
- components: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching, expansion joints, pipes, elbows
- cleaning methods: scraping, buffing, chipping, high pressure washing (e.g., chemical, water), media blasting, grinding, sweeping, vacuuming
D-13.05 - Tests materials, vessels and components
D-13.05 - Tests materials, vessels and components
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Skills
Reference Code |
Performance Criteria |
Evidence of Attainment |
D-13.05.01P |
select and use tools and equipment |
tools and equipment are selected and used according to task |
D-13.05.02P |
perform visual test (VT) |
VT is performed to confirm work is free of visible defects and deficiencies |
D-13.05.03P |
prepare components for testing |
components are prepared for testing by purging, attaching testing equipment and venting |
D-13.05.04P |
perform advanced testing procedures |
advanced testing procedures are performed according to jurisdictional regulations, and company policies and procedures to confirm existence and location of defects, and internal weld or structure defects |
Range of Variables (include, but not limited to)
- tools and equipment: wrenches, impact wrenches, gauges, air lines, manifolds, waterlines, purge hoses, pressure gauges, pumps, hydraulic torquing and tensioning equipment
- visible defects: poor surface weld integrity, misalignment, improper fit-up, thread protrusion, missing hardware, hardware not identified, undercut
- components: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching, expansion joints, pipes, elbows
- testing equipment: test blinds, pumps, gauges, vent lines, trees, vacuum box, magnets, LPI fluid, radiation source, digital equipment
- advanced testing procedures (depending on work location and training of tradesperson): LPI, MPI, ultrasonic test (UT), radiographic test, phased array ultrasonic testing (PAUT), pneumatic test, hydrostatic test, light oil test
- defects: cracks, undercut, pinholes, cold laps, thinning or blistering of material
- internal weld or structure defects: lack of fusion, porosity, lamination, inclusions, material makeup, lack of penetration, excessive penetration, corrosion
Knowledge
Reference Code |
Learning Outcomes and Objectives |
D-13.05.01L |
demonstrate knowledge of materials, vessels and components, their characteristics, applications and operation
- identify materials, vessels and components, and describe their characteristics and applications
- describe operating principles of vessels and components
- interpret information pertaining to materials, vessels and components found on drawings and specifications
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D-13.05.02L |
demonstrate knowledge of procedures to test materials, vessels and components
- identify tools and equipment and testing equipment, and describe their characteristics and applications
- identify types of destructive testing (DT), and describe their characteristics, applications, advantages, disadvantages, limitations and associated procedures
- describe types of non-destructive testing (NDT), and describe their characteristics, applications, advantages, disadvantages, limitations and associated procedures
- explain differences between DT and NDT
- identify vessels and components to be tested
- identify and describe inspection methods, procedures and record keeping
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D-13.05.03L |
demonstrate knowledge of training and certification requirements to test materials, vessels and components
- identify training and certification requirements to test materials, vessels and components
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D-13.05.04L |
demonstrate knowledge of regulatory requirements pertaining to testing materials, vessels and components
- identify codes, standards and regulations pertaining to testing materials, vessels and components
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Range of Variables (include, but not limited to)
- vessels: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters, air heaters, settler
- components: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching, expansion joints, pipes, elbows
- tools and equipment: wrenches, impact wrenches, gauges, air lines, manifolds, waterlines, purge hoses, pressure gauges, pumps, hydraulic torquing and tensioning equipment
- testing equipment: test blinds, pumps, gauges, vent lines, trees, vacuum box, magnets, LPI fluid, radiation source, digital equipment
- destructive testing: tensile test, impact test, bend test
- non-destructive testing: visual, magnetic particle, radiographic, ultrasonic, dye penetrant, hydrostatic, vacuum box, pneumatic, PAUT, light oil test
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
D-14.01 - Dismantles vessels and components
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Skills
Reference Code |
Performance Criteria |
Evidence of Attainment |
D-14.01.01P |
prepare plan to dismantle vessels and components |
plan to dismantle vessels and components is prepared according to job scope, site conditions and sequence |
D-14.01.02P |
select and use tools and equipment |
tools and equipment are selected and used according to task |
D-14.01.03P |
select and use bundle pulling equipment |
bundle pulling equipment is selected and used according to task and manufacturers' specifications |
D-14.01.04P |
identify vessels and components to be salvaged |
vessels and components to be salvaged are numbered, match-marked or tagged according to work plan, drawings, and company policies and procedures |
D-14.01.05P |
prepare components for dismantling |
components are prepared for dismantling using procedures according to plan |
D-14.01.06P |
coordinate work with other trades |
work with other trades is coordinated to ensure efficient and safe removal of components |
D-14.01.07P |
unbolt, unfasten or cut vessels and components |
vessels and components are unbolted, unfastened or cut according to plan and site conditions |
D-14.01.08P |
separate components to be salvaged (reused or recycled) |
components to be salvaged are placed in secure area for storage and cleaning according to site-specific specifications, and company policies and procedures |
Range of Variables (include, but not limited to)
- vessels: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters, air heaters, settler
- components: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching, expansion joints, pipes, elbows
- tools and equipment: CAC-A (gougers), hammers, torches, wrenches, impact wrenches, hydraulic nut splitters, mechanical lifting devices, cranes
- bundle pulling equipment: hydraulic or pneumatic bundle extractors (bundle pullers), forklifts, cranes
- procedures (dismantling): installing lifting lugs, pre-cutting, removing obstructions
Knowledge
Reference Code |
Learning Outcomes and Objectives |
D-14.01.01L |
demonstrate knowledge of vessels and components, their characteristics, applications and operation
- identify vessels and components, and describe their characteristics and applications
- describe operating principles of vessels and components
- interpret information pertaining to vessels and components found on drawings and specifications
|
D-14.01.02L |
demonstrate knowledge of dismantling procedures related to vessels and components
- identify tools and equipment used to dismantle vessels and components, and describe their procedures for use
- identify hazards and describe safe work practices when dismantling vessels and components
- describe dismantling procedures and methods
- describe demolition methods and procedures
- list and describe factors to consider when analyzing integrity of components or attachment points
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D-14.01.03L |
demonstrate knowledge of sustainability and environmental stewardship practices
- identify vessels and components that can be re-used
- describe recycling procedures
- identify practices that contribute to environmental protection
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Range of Variables (include, but not limited to)
- vessels: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters, air heaters, settler
- components: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching, expansion joints, pipes, elbows
- dismantling procedures: installing lifting lugs, pre-cutting, removing obstructions
- tools and equipment: CAC-A (gougers), hammers, torches, wrenches, impact wrenches, hydraulic nut splitters, mechanical lifting devices, cranes
- hazards: struck by material, asphyxiation, burns, explosion, falls, rigging failure, crushed, unknown weights
- safe work practices: tie off tools, follow rigging plan, plan access to work, establish lift zone around vessel, ensure isolation points of vessels or equipment to be removed, remove combustibles from work area, de-energize and isolate, identify and remove hazardous materials
- factors: steel strength, rust, corrosion, weight of vessel (buildup of residue, fly ash, water retention)
D-14.02 - Removes materials and components
D-14.02 - Removes materials and components
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Skills
Reference Code |
Performance Criteria |
Evidence of Attainment |
D-14.02.01P |
plan material, component and scrap removal |
material, component and scrap removal is planned according to material or component being removed, hazards, job requirements and site conditions |
D-14.02.02P |
select and use tools and equipment |
tools and equipment to remove materials and components are selected and used according to work plan |
D-14.02.03P |
select PPE to execute work plan |
PPE to remove materials and components is selected and used according to work plan |
D-14.02.04P |
sort and dispose of materials and components |
materials and components to be removed is sorted and disposed of according to work plan and jurisdictional requirements |
Range of Variables (include, but not limited to)
- tools and equipment: torches, gougers, hammers, rigging equipment, mobile equipment, oxygen lances
Knowledge
Reference Code |
Learning Outcomes and Objectives |
D-14.02.01L |
demonstrate knowledge of materials and components, their characteristics and applications
- identify materials and components, and describe their characteristics and applications
- interpret information pertaining to materials and components found on drawings and specifications
|
D-14.02.02L |
demonstrate knowledge of procedures to remove materials and components
- identify tools and equipment used to remove materials and components, and describe their procedures for use
- identify hazards, and describe safe work practices pertaining to removing materials and components
- describe process to plan materials and components removal
- describe procedures to remove materials and components
- describe procedures and factors for sorting materials and components to be removed
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D-14.02.03L |
demonstrate knowledge of regulatory requirements pertaining to disposal of waste materials and components
- identify regulatory requirements pertaining to disposal of waste materials and components
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D-14.02.04L |
demonstrate knowledge of sustainability and environmental stewardship practices
- identify practices that contribute to environmental protection
- describe procedures to dispose of and recycle removed materials and components
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Range of Variables (include, but not limited to)
- tools and equipment: torches, gougers, hammers, rigging equipment, mobile equipment, oxygen lances
- hazards: struck by material, asphyxiation, burns, explosion, falls, rigging failure, crushed, unknown weights