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
Essential Skills
Numeracy, Document Use, Thinking
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 locate material and components |
material and components are selected and located according to drawings and specifications |
| C-10.01.02P |
measure material |
material is measured to ensure dimensions are according to drawings and specifications |
| C-10.01.03P |
select and use tools |
tools are selected and used according to task at hand |
| 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 at hand 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
- dimensions include: thickness, length, width, diameter, circumference, orientation, evaluation
- tools include: measuring tools, straight edges, levels, marking tools, compass, dividers
- identification methods include: match-marking, tagging, piece mark numbering, item list, heat number
- material includes: metals, fiberglass, composites, stainless steel
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| C-10.01.01L |
demonstrate knowledge of the procedure to lay out material and components for fabrication and the associated tools and equipment |
identify, select and use measuring, checking and layout tools |
| identify types of materials to be used and components being fabricated |
| describe the various layout methods |
| avoid material waste through pre-planning |
| describe how to develop a template using parallel lines and radial line development |
| 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 and projections |
| C-10.01.03L |
demonstrate knowledge of drawing interpretation |
layout and fabricate components from drawings |
| read a drawing to determine the materials required and layout template or components |
| read a drawing and identify the components listed for fabrication |
| list and describe the abbreviations applicable to layout and development |
Range of Variables
- components include: ladders, platforms, davits, headers, pipe turns, offsets, ducts, cylinders, cones, pressure vessel shells, support structures
- layout methods include: parallel-line, triangulation, radial-line development, mathematical formulas, geometric construction
C-10.02 - Cuts components for fabrication
Essential Skills
Document Use, Numeracy, Thinking
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, task at hand and specifications |
| C-10.02.02P |
select tools and equipment |
tools and equipment are selected according to task at hand |
| C-10.02.03P |
set up cutting tools |
cutting tools are set up according to specifications |
| C-10.02.04P |
position and secure material |
material to be cut is positioned and secured |
| C-10.02.05P |
perform cut |
cut is performed according to drawings and specifications |
| C-10.02.06P |
measure components |
components are measured to ensure accuracy |
Range of Variables
- cutting method includes: oxy-fuel, grinding, gouging, plasma, saw, shear
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| C-10.02.01L |
demonstrate knowledge of procedures used to cut components for fabrication and their associated tools and equipment |
identify and describe cutting tools and equipment and list their uses and limitations |
| describe cutting using manual and mechanical processes |
| describe the process of cutting material of various thickness |
| identify and describe oxy-fuel cutting equipment |
| explain the set-up of oxy-fuel cutting equipment |
| define the principle of the oxy-fuel gas cutting process |
| identify the characteristics of oxygen and fuel gas cylinders |
| explain the purpose of a manifold system |
| identify and select fuel gases for manual and automatic oxy-fuel cutting of carbon steel |
| identify and describe regulator types, purposes, and their adjustments and care |
| describe the construction and maintenance of hoses, fittings and flashback arrestors |
| explain and demonstrate the setting of oxy-fuel pressures, balancing and flame adjustments |
| list the causes of backfires and flashbacks |
| describe the design, maintenance, selection and operation of oxy-fuel tips |
| describe the setup and operation of CAC-A (carbon arc cutting-air) equipment (gouger) |
| describe the setup and operation of PAC (plasma arc cutting) equipment |
| describe cutting processes involved in cutting alloy steels and non-ferrous metals |
| perform pipe cutting to size using a pipe cutter or oxy-fuel cutting process |
| explain the correct procedure to check for leaks |
| identify cutting issues |
| C-10.02.02L |
demonstrate knowledge of procedures used to thread components for fabrication and their associated tools and equipment |
identify and describe threading tools and equipment and list their uses and limitations |
| describe threading of pipe using manual and mechanical processes |
Range of Variables
- cutting issues include: 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
Essential Skills
Thinking, Numeracy, Working with Others
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 by using forming methods according to specifications |
| C-10.03.04P |
check components |
components are checked for dimension and tolerance according to specifications |
| C-10.03.05P |
finish fabricated material |
fabricated material is finished by buffing, cleaning and grinding |
Range of Variables
- shop equipment includes: brakes, rolls, dies
- forming methods include: rolling, bending, braking, controlled heating
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| C-10.03.01L |
demonstrate knowledge of procedures to form components and their associated tools and equipment |
identify the tools and equipment required to fabricate components |
| describe methods used to identify fabricated components and assemblies |
| identify forming methods |
| C-10.03.02L |
demonstrate knowledge of drawing interpretation |
interpret dimensions, symbols and abbreviations on drawings |
Range of Variables
- forming methods include: rolling, bending, braking, controlled heating
C-10.04 - Constructs components
Essential Skills
Working with Others, Thinking, Continuous Learning
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 at hand and specifications |
| C-10.04.02P |
align and orient components |
components are aligned and oriented to fit according to match-mark, drawings and specifications |
| C-10.04.03P |
secure components |
components are secured to ensure correct alignment and to maintain their shape by using various securing methods |
| C-10.04.04P |
join components |
components are assembled using joining methods |
Range of Variables
- tools and equipment include: squares, levels, clamps, wrenches, welding machines
- securing methods include: clamping, dogging, bracing, lashing, spiders, stiffeners
- joining methods include: welding, bolting, riveting
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| C-10.04.01L |
demonstrate knowledge of the procedures to construct components and their associated tools and equipment |
interpret dimensions, symbols and abbreviations on drawings |
| list fastening, securing and joining methods |
| identify required tools and equipment specific to fastening method and specifications |
Range of Variables
- fastening methods include: welding, bolting (torqueing, tensioning), rigging, riveting
- securing methods include: clamping, dogging, bracing, lashing, spiders
- joining methods include: welding, bolting, riveting
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
Essential Skills
Thinking, Document Use, Working with Others
C-11.01 - Aligns vessels and components
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| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-11.01.01P |
select alignment tools and equipment |
alignment tools and equipment are selected according to industry practices |
| 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 |
Range of Variables
- alignment tools and equipment include: transits, water levels, plumb bobs, dogs/wedges, lugs, shims, key plates, strongbacks, key channels, u-bars, bull pins and key nuts
- reference point includes: benchmarks or elevation marks, datum line, work points
- vessels include: drums, exchangers, towers, tanks
- components include: manway, cleanout doors, water or fluid draw-off elbow, draw-off sump, inlet outlet, overflow venting, walkway, stairway, ladders, nozzles, support structures
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| C-11.01.01L |
demonstrate knowledge of the procedures to align vessels and components and their associated tools and equipment |
identify alignment tools and equipment and their functions and limitations |
| describe the layout and fit-up of bottom, shell, roof and openings |
| describe the preparation, fit-up and alignment of horizontal and vertical seams |
| describe orientation, elevation and projection methods and procedures |
| C-11.01.02L |
demonstrate knowledge of drawing interpretation |
interpret information from approved drawings and specifications |
| identify reference points according to approved drawings and specifications |
Range of Variables
- vessels include: drums, exchangers, towers, tanks
- components include: manway, cleanout doors, water or fluid draw-off elbow, draw-off sump, inlet outlet, overflow venting, walkway, stairway, ladders, nozzles, support structures
- alignment tools and equipment include: transits, water levels, plumb bobs, dogs, lugs, shims, key plates, strongbacks, key channels, wedges, u-bars
C-11.02 - Fits vessels and components
Essential Skills
Document Use, Numeracy, Working with Others
C-11.02 - Fits vessels and components
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| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-11.02.01P |
inventory and assemble components |
components are inventoried and assembled according to approved drawings and specifications |
| C-11.02.02P |
check components |
components are checked for fit and function by measuring and pre-assembly |
| C-11.02.03P |
select and use tools and equipment |
tools and equipment are selected and used according to task at hand |
| 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 engineer-approved drawings and specifications |
| C-11.02.05P |
attach components |
components are attached using attachment methods |
Range of Variables
- tools and equipment include: levels, dogs, wedges, hammers, rigging, key plates, pry bars, strongbacks
- attachment methods include: bolting, clipping, tacking, welding, expansion of tubes, riveting, chemical bonding
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| C-11.02.01L |
demonstrate knowledge of the procedures to fit vessels and components and their associated tools and equipment |
identify and describe assembly requirements and procedures |
| describe fitting methods and procedures |
| list tools and equipment used to fit vessels and components and their functions and limitations |
Range of Variables
- tools and equipment include: levels, dogs, wedges, hammers, rigging, key plates, pry bars, strongbacks
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. A small component of this task may include working with fiberglass.
C-12.01 - Bolts components
Essential Skills
Document Use, Working with Others, Numeracy
C-12.01 - Bolts components
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-12.01.01P |
select bolts |
bolt types, grades and sizes for application are selected according to approved drawings and specifications |
| C-12.01.02P |
prepare components |
components are prepared prior to fastening using preparation methods |
| C-12.01.03P |
select approved gasket |
approved gasket is selected according to specifications |
| C-12.01.04P |
select approved lubrication |
approved lubrication is selected according to specifications |
| C-12.01.05P |
install hardware |
hardware is installed according to job specifications |
| C-12.01.06P |
select and use tools and equipment |
tools and equipment are selected and used according to job requirements |
| C-12.01.07P |
ensure final fit |
final fit is ensured before tightening bolts on vessels and components |
| C-12.01.08P |
torque or tension bolts |
bolts are torqued or tensioned according to specifications |
Range of Variables
- preparation methods include: approved lubrication, cleaning, buffing
- hardware includes: gaskets, bolts, nuts, washers, studs, rivets
- tools and equipment include: torque wrenches, impact wrenches, pneumatic torque guns, hydraulic torque wrenches, tensioning and torqueing equipment, hammer wrenches
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| C-12.01.01L |
demonstrate knowledge of the techniques used to bolt components and their associated tools and equipment |
identify types, grades and sizes of bolts |
| identify types of gaskets and flanges |
| identify types of lubricants |
| identify types of torqueing and tensioning equipment |
| describe bolting and torqueing sequence |
Range of Variables
- tools and equipment include: torque wrenches, impact wrenches, pneumatic torque guns, hydraulic torque wrenches, tensioning and torqueing equipment, hammer wrenches
- grades are specified by: CSA, ASTM, American Iron and Steel Institute (AISI), American National Standards Institute (ANSI), ASME
- torqueing and tensioning equipment includes: pneumatic torque wrench, hydraulic torque wrench, electric torque wrench, hydraulic tensioning system, pumps
C-12.02 - Expands tubes
Essential Skills
Document Use, Numeracy, Working with Others
C-12.02 - Expands tubes
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-12.02.01P |
select and use expansion tools and equipment |
expansion tools and equipment are selected and used according to manufacturers’ specifications |
| C-12.02.02P |
disassemble, clean, lubricate and reassemble rolling components |
rolling components are disassembled, cleaned, lubricated and reassembled to prevent damage to equipment |
| C-12.02.03P |
prepare surface |
surface is prepared by using tube reamer, grooving tool and tube brushes to buff and clean |
| C-12.02.04P |
roll tubes |
tubes are rolled according to job specifications |
| C-12.02.05P |
measure initial and final expansion |
final expansion is verified with initial calculations to confirm job specifications by using measuring instruments |
Range of Variables
- expansion tools and equipment include: rolling guns, mandrels, rolls
- measuring instruments include: outside micrometers, inside micrometers, gauges, telescopic gauges
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| C-12.02.01L |
demonstrate knowledge of the techniques used to expand tubes and their associated tools and equipment |
define expansion theory and describe techniques to expand tubes |
| define terms associated with tube hole arrangement |
| describe the process of tube rolling |
| 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 factors to consider in tube expanding procedures for condensers and exchangers |
| list the basic steps associated with tube installation |
| state the recommended tube expansion sequences with reference to tube sheet layout, its area and shape |
| describe how to measure the inside diameter of a tube |
| determine the recommended percentage wall reduction for ferrous and non-ferrous materials |
| list recommended lubricants |
| identify the optimum length of expanded seat |
| describe the reason for grooved seats |
| list and describe the uses and limitations of tube equipment |
| identify the factors affecting the quality of an expanded joint |
| describe the operational relationship of the mandrel and rolls |
| describe the purpose of bell rolls |
| describe the purpose and process of tube beading |
| identify and define the propulsive type of expander |
| explain the principle involving explosive tube expansions |
| describe tube flaring using flaring tools |
| C-12.02.02L |
demonstrate knowledge of calculations required when expanding a tube |
calculate the expanded diameter (final ID) of a tube |
Range of Variables
- terms include: circumferential pitch, ligament space, removal space, longitudinal pitch, diagonal pitch
- exchanger heads include: channel and removable cover, bonnet, channel integral with tube sheet, pull through and floating head, outside packed floating head
- factors to consider in tube expanding include: tube sheet layout, number of tubes, type of metals, length of tubes, diameter of tube (OD), material wall thickness (MWT) tube sheet or header thickness, expansion required, lubrication
- tube equipment includes: tube guide, compressor, air motor, electric motor tube end mills, tube expanders, fly cutters, tube cutters, tube cleaners, tube removal tools, micrometers, gauges, torque wrench
- factors affecting the quality of an expanded joint include: surface of hole, roundness of hole, cleanliness of hole, expansion past the inner edge of tube sheet, overheating, roller speed, mechanical properties of tube and tube sheet, lubrication or lack of it, overexpansion
C-12.03 - Lays up fiberglass
Essential Skills
Document Use, Thinking, Continuous Learning
C-12.03 - Lays up fiberglass
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Skills
| Reference Code |
Performance Criteria |
Evidence of Attainment |
| C-12.03.01P |
select and use tools and equipment, and PPE |
tools, equipment and PPE are selected and used according to jurisdictional regulations and SDS |
| C-12.03.02P |
prepare surface |
surface is prepared by grinding, sanding and cleaning |
| C-12.03.03P |
mix fiberglass resins |
fiberglass 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 |
| C-12.03.06P |
store and dispose of fiberglass materials |
fiberglass materials are stored and disposed of according to SDS |
Range of Variables
- tools and equipment include: power cutter (circular saw), power disc sander, extension cords, rags, heat lamps, rollers and brushes
- PPE include: disposable coveralls, safety goggles, full-faced respirator, chemical-resistant gloves, organic vapour cartridges, butyl rubber gloves, face shields
- lay-up techniques include: rolling, brushing, spraying
- malformations include: air bubbles, delamination, impurities
Knowledge
| Reference Code |
Learning Outcomes |
Learning Objectives |
| C-12.03.01L |
demonstrate knowledge of the procedures used to lay up fiberglass and the associated tools and materials |
describe procedures involved in fiberglass lay-up |
| identify types and grades of fiberglass materials |
| describe mixing and curing procedures |
| identify accelerators, retarders and promoters |
| identify certification requirements |
| describe the handling and storage process for the chemicals required to assemble fiberglass pipe and vessels |
| describe the process of drilling |
| describe the process of bolting |
| describe process for handling and mixing resins, catalysts and associated chemicals |
| describe safety considerations for handling and mixing resins, catalysts and associated chemicals |
| describe the process of cutting |
| describe the process of grinding |
| describe the process of laminating glass |
| identify and describe the resins and fiberglass materials required for lay-up and repairs |
| describe the uses of fiberglass in tanks, silos, stacks, scrubbers, breeching and piping |
| define the purpose of fiberglass materials |
| describe the process to facilitate repairs on round and flat surfaces |
| list and describe the tools and materials used for preparation and assembly |
| list and describe measuring equipment |
| list and describe lay-up equipment |
| C-12.03.02L |
demonstrate knowledge of drawing interpretation |
interpret specification drawings |
Range of Variables
- procedures involved in fiberglass lay-up include: tight fit-up, sanding saturate mat, stagger cut lengths, mix resin and catalyst, apply surface veil, remove air, sand entire weld, apply resin and air dry mix application method, hand lay-up, spray lay-up, cutting, fitting, surface preparation, hot patches
- types and grades of fiberglass materials include: cloth, resins, fillers
- fiberglass materials include: polyester resins, catalysts, promoters, surfacing veil, mat, woven roving, acetone, methylene chloride, air dry additive, filler
- measuring equipment includes: paper or plastic mixing cups, mixing sticks, plastic bucket graduated for measuring resin, glass for measuring promoters and catalysts, mixing pails
- lay-up equipment includes: surfacing veil, matting, woven roving