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 as needed as per code regulations. Modifying and upgrading existing systems entails replacing components and materials to improve performance or reliability, and can be done during scheduled and unscheduled maintenance. Sometimes, vessels and components cannot be repaired and need to be replaced.
Boilermakers need to know when rigging, fitting and cranes are needed to accomplish the tasks.
Inspecting and testing are important to identify defective and worn components to ensure that the system has been constructed or repaired properly.
D-13.01 - Inspects vessels and components for defects
Essential Skills
Document Use, Thinking, Oral Communication
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 that permit requirements are met |
permit requirements are met before proceeding with the task at hand |
D-13.01.02P |
clean surfaces |
surfaces are cleaned for inspection by grinding, chipping or buffing |
D-13.01.03P |
recognize common vessel defects |
visual inspection is performed to recognize common vessel defects according to specifications |
D-13.01.04P |
recognize common component defects |
visual inspection is performed to recognize common component defects as confirmed by engineered drawings |
D-13.01.05P |
request non-destructive testing to verify material integrity |
material integrity is identified by non-destructive testing results |
D-13.01.06P |
report deficiencies and defects to the supervisor or quality control inspector |
deficiencies and defects are reported to the supervisor or quality control inspector |
Range of Variables
- permit requirements include: gas tests, hot and cold work, confined space entry, blanket permit, lock-out tag-out
- vessel defects include: dents, cracks, corrosion, gouges, weld defects, arc strikes, flat spots, crowning, wear
- component defects include: missing hardware, dents, cracks, corrosion, gouges, undercut, arc strikes, flat spots, dog legs, crowning, foreign objects
- non-destructive testing includes: ultrasound, magnetic particle inspection (MPI), hydrostatic, air testing, vacuum box testing, x-ray, phased array, liquid penetrant inspection (LPI), positive material identification (PMI), diesel testing
Knowledge
Reference Code |
Learning Outcomes |
Learning Objectives |
D-13.01.01L |
demonstrate knowledge of inspection procedures to detect defects in vessels and components |
list common vessel defects and component defects |
explain the causes of common vessel defects and component defects |
describe inspection procedures of the vessels and components |
identify material composition of a vessel or component |
Range of Variables
- vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters
- components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints
- vessel defects include: dents, cracks, corrosion, gouges, weld defects, arc strikes, flat spots, crowning, wear
- component defects include: missing hardware, dents, cracks, corrosion, gouges, undercut, arc strikes, flat spots, dog legs, crowning, foreign objects
- material includes: mild steel, stainless steel, galvanized steel, aluminum, alloy
D-13.02 - Prepares vessels and components for servicing
Essential Skills
Document use, Thinking, Working with Others
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 specifications |
D-13.02.02P |
identify site modification requirements to be performed |
site modification requirements to be performed are identified |
D-13.02.03P |
empty, depressurize, isolate and purge vessels |
vessels are emptied, depressurized, isolated and purged before maintenance begins |
D-13.02.04P |
create access or openings to work area |
access or openings to work area are created |
D-13.02.05P |
select tools, material and equipment |
tools, material and equipment are selected according to the task at hand |
D-13.02.06P |
set up tools, materials and equipment |
tools, materials and equipment are set up in a designated location |
D-13.02.07P |
pre-assemble components |
components to be installed are pre-assembled according to engineer-approved drawings and specifications |
Range of Variables
- modification requirements include: demolition, component removal and adjustments, site leveling, scaffold erection, lighting, power, ventilation
- equipment includes: scaffolding, maintenance decks, temporary work platforms, needle beams, welding machines, compressors, air movers, tripods, cranes, trolley beams
Knowledge
Reference Code |
Learning Outcomes |
Learning Objectives |
D-13.02.01L |
demonstrate knowledge of procedures used to prepare for service of vessels and components |
identify vessels and components to be serviced |
list tools needed to complete the task at hand |
describe vessel isolation procedures |
identify fasteners and fastening methods required to complete the task at hand |
interpret required changes as detailed in engineer-approved drawings and specifications of vessels and components |
Range of Variables
- vessel isolation procedures include: hot bolting, odd bolting, line-break, blanking/blinding, purging
- fastening methods include: bolting, welding, expanding, riveting
D-13.03 - Repairs vessels and components
Essential Skills
Working with Others, Thinking, Numeracy
D-13.03 - Repairs vessels and components
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Reference Code |
Performance Criteria |
Evidence of Attainment |
D-13.03.01P |
prepare parent material and repair pieces using tools and equipment |
work area is prepared for installation of new vessels and components by using preparation methods |
D-13.03.02P |
install components |
components are installed using hoisting/lifting and moving equipment according to job situation |
D-13.03.03P |
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-13.03.04P |
fasten components |
components are fastened to existing vessels and components using fastening methods |
D-13.03.05P |
reinstall components removed during repair preparation |
components removed during repair preparation are reinstalled |
Range of Variables
- tools and equipment include: see appendix (tools and equipment)
- vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters
- components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints
- preparation methods include: cleaning, grinding, chipping, buffing, welding, sand blasting, cutting, milling, gouging, water jet cutting, blanking/blinding
- hoisting/lifting and moving equipment includes: chainfall, come-along, Tirfor™, shackles, slings, crane, tugger, rope, gin wheel, lugs, engineered high line
- job situation includes: material of vessel or component, size of repair area, work area accessibility, product stored in vessel, job specification, QC requirements
- fitting tools include: dogs and wedges, screw dogs, bull pins, key plates, hickey bars, pinch bars, U-bars, drift pin, sledge hammer, finger bars, welder, level
- fastening methods include: bolting, welding, gluing, riveting, tack welding
Knowledge
Reference Code |
Learning Outcomes |
Learning Objectives |
D-13.03.01L |
demonstrate knowledge of procedures to prepare vessels and components for repair |
explain and select preparation methods |
D-13.03.02L |
demonstrate knowledge of procedures to hoist material into place in order to repair vessels and components |
list hoisting/lifting and moving equipment and explain the advantages and drawbacks of each piece of equipment for a repair situation |
D-13.03.03L |
demonstrate knowledge of procedures to fit material to vessels and components for repair |
describe fitting tools and methods used to fit new components for a repair and explain the advantages and drawbacks of each method for a repair situation |
D-13.03.04L |
demonstrate knowledge of procedures to fasten material to vessels and components for repair |
describe fastening methods used to fasten new components for a repair and explain the advantages and drawbacks of each method for a repair situation |
Range of Variables
- preparation methods include: cleaning, grinding, chipping, buffing, welding, sand blasting, cutting, milling, gouging, water jet cutting, blanking/blinding
- vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters
- components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints
- hoisting/lifting and moving equipment includes: chainfall, come-along, Tirfor™, shackles, slings, crane, tugger, rope, gin wheel, lugs, engineered high line
- fitting tools include: dogs and wedges, screw dogs, bull pins, key plates, hickey bars, pinch bars, U-bars, drift pin, sledge hammer, finger bars, welder, level
- fastening methods include: bolting, welding, gluing, riveting, tack welding
D-13.04 - Performs preventative maintenance and upgrades
Essential Skills
Thinking, Oral Communication, Working with Others
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 at hand |
D-13.04.02P |
remove contaminants and corrosion on vessels and components |
contaminants and corrosion on vessels and components are removed using cleaning methods |
D-13.04.03P |
plug tubes to isolate them from system |
tubes are plugged to prevent further damage to the system |
D-13.04.04P |
install shielding materials to prevent excessive wear on vital components |
shielding materials are installed to prevent wear |
D-13.04.05P |
pull tube bundle from heat exchanger for cleaning and inspection |
tube bundles are pulled, cleaned and inspected and defects identified |
D-13.04.06P |
repair defects |
defects are repaired according to specifications |
D-13.04.07P |
reinstall or replace tube bundles |
tube bundles are reinstalled or replaced |
D-13.04.08P |
tighten loose components and replace missing hardware according to job specifications |
components are in place and are tightened to specifications |
Range of Variables
- tools and equipment include: chipping guns, buffers, grinders, bundle puller
- contaminants include: lead, asbestos, silica, kaol
- vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters
- components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints
- cleaning methods include: scraping, buffing, chipping, high pressure washing (chemical, water), media blasting, grinding, sweeping, vacuuming
Knowledge
Reference Code |
Learning Outcomes |
Learning Objectives |
D-13.04.01L |
demonstrate knowledge of preventative maintenance and upgrade procedures |
identify vessels and components to be maintained |
describe preventative maintenance procedures |
describe upgrading procedures |
describe cleaning methods and their advantages and drawbacks |
identify tube defects |
identify compatible materials when selecting replacement hardware or components |
Range of Variables
- vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters
- components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints
- cleaning methods include: scraping, buffing, chipping, high pressure washing (chemical, water), sandblasting, grinding, sweeping, vacuuming
- tube defects include: wear, dents, bends, corrosion, leaks, cracks, legs, rupture
D-13.05 - Tests materials, vessels and components
Essential Skills
Thinking, Document Use, Digital Technology
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 test procedure |
D-13.05.02P |
perform visual test (VT) |
VT is completed to confirm that work appears to be free of surface 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 to confirm the existence and location of defects, and internal weld or structure defects |
Range of Variables
- tools and equipment include: wrenches, impact wrenches, gauges, air lines, manifolds, waterlines, purge cables, cleaning pigs, borescopes, pressure gauges, pumps, hydraulic torqueing and tensioning equipment
- surface defects include: poor surface weld integrity, misalignment, improper fit up, thread protrusion, missing hardware, hardware not identified, undercut
- components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints
- testing equipment includes: test blinds, pumps, gauges, vent lines, trees, vacuum box, magnets, films, LPI fluid, radiation source, digital equipment
- advanced testing procedures may include (depending on work location and training of tradesperson): liquid penetrant inspection (LPI), magnetic particle inspection (MPI), ultrasonic test (UT), radiographic test, phased array ultrasonic testing (PAUT), pneumatic test, hydrostatic test
- defects include: cracks, undercut, pinholes, cold laps, thinning of material
- internal weld or structure defects include: lack of fusion, porosity, lamination, inclusions, material makeup, lack of penetration, excessive penetration
Knowledge
Reference Code |
Learning Outcomes |
Learning Objectives |
D-13.05.01L |
demonstrate knowledge of procedures to test materials, vessels and components |
describe types of destructive testing (DT) |
describe types of non-destructive testing (NDT) |
explain the difference between DT and NDT |
identify vessels and components to be tested |
identify inspection methods and procedures |
describe the process, application, end results, advantages and drawbacks of NDT |
Range of Variables
- destructive testing includes: tensile test, impact test, bend test
- non-destructive testing includes: visual, magnetic particle, radiographic, ultrasonic, dye penetrant, hydrostatic, vacuum box, pneumatic
- vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters
- components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints
Task D-14 Removes vessels and components
Task Descriptor
Boilermakers remove vessels and components to be repaired or replaced. Removing equipment, vessels and components allows easier access and facilitates maintenance and repairs. Obsolete vessels and components also need to be dismantled, demolished or removed.
D-14.01 - Dismantles vessels and components
Essential Skills
Working with Others, Thinking, Document Use
D-14.01 - Dismantles vessels and components
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Skills
Reference Code |
Performance Criteria |
Evidence of Attainment |
D-14.01.01P |
prepare a plan for which vessels and components are to be dismantled |
a plan for which vessels and components are to be dismantled has been made according to job requirements, site conditions and sequence |
D-14.01.02P |
select and use tools and equipment |
tools and equipment are selected and used according to task at hand |
D-14.01.03P |
identify vessels and components to be salvaged |
vessels and components to salvage are numbered, match-marked or tagged |
D-14.01.04P |
prepare components for dismantling |
components are prepared for dismantling using procedures according to plan |
D-14.01.05P |
coordinate work with other trades |
work with other trades is coordinated to ensure efficient and safe removal of components |
D-14.01.06P |
unbolt, unfasten or cut vessels and components |
vessels and components are unbolted, unfastened or cut according to plan and site conditions |
D-14.01.07P |
separate components to be salvaged (reused or recycled) |
components to be salvaged are placed in secure area for storage and cleaning |
Range of Variables
- vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters
- components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints
- tools and equipment include: CAC-A (gougers), torches, wrenches, impact wrenches, hydraulic nut splitters, mechanical lifting devices, cranes
- procedures include: installing lifting lugs, pre-cutting, removing obstructions
Knowledge
Reference Code |
Learning Outcomes |
Learning Objectives |
D-14.01.01L |
demonstrate knowledge of dismantling procedures related to vessels and components |
describe dismantling methods and procedures |
describe demolition methods and procedures |
identify vessels and components that can be re-used |
describe lifting, hoisting, handling and storage methods and procedures |
D-14.01.02L |
demonstrate knowledge of safe work practices related to the dismantling of vessels and components |
identify hazards and describe safe work practices when dismantling vessels and components |
list factors to consider when analyzing the integrity of components or attachment points |
Range of Variables
- vessels include: furnaces, boilers, condensers, tanks, vats, bins, exchangers, reactors, towers, stacks, penstocks, economizers, precipitators, scrubbers, drums, evaporators, digesters and air heaters
- components include: curtains, electrodes, tubes and tube bundles, headers, trays and hardware in towers, stairways, support structures, screens, hoppers, ductwork, platforms, ladders, breeching and expansion joints
- safe work practices include: tie off tools, follow rigging plan, plan access to the work, establish lift zone around vessel, ensure isolation points of vessels or equipment to be removed
- factors include: steel strength, rust, corrosion, weight of vessel (buildup of residue, fly ash, water retention)
D-14.02 - Removes materials
Essential Skills
Document Use, Working with Others, Thinking
D-14.02 - Removes materials
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Reference Code |
Performance Criteria |
Evidence of Attainment |
D-14.02.01P |
plan material and scrap removal |
material and scrap removal is planned according to material being removed, hazards, job requirements and site conditions |
D-14.02.02P |
select and use tools and equipment |
tools and equipment to remove material are selected and used according to work plan |
D-14.02.03P |
select PPE to execute work plan |
PPE to remove material is selected and used according to work plan |
D-14.02.04P |
sort and dispose of material |
material to be removed is sorted and disposed of according to work plan and jurisdictional requirements |
Range of Variables
- tools and equipment include: torches, gougers, hammers, rigging equipment, mobile equipment, oxygen lances
Knowledge
Reference Code |
Learning Outcomes |
Learning Objectives |
D-14.02.01L |
demonstrate knowledge of procedures related to the removal of materials |
describe the process to plan the removal of material |
describe process and factors for sorting material to be removed |
D-14.02.02L |
demonstrate knowledge of regulatory requirements pertaining to the disposal of waste materials |
dispose of waste material according to work plan and jurisdictional requirements |