Welding and Cutting for Boilermakers
Cutting and welding as boilermakers use them, followed through a spring season with Ironbridge Industrial out of Port Allen, Louisiana: oxyfuel track cuts on a tank shell, plasma membrane splits and mechanical tube cutting, air carbon arc back-gouging, SMAW on plate in all positions and FCAW in the field, tube end preparation and fit-up, GTAW and SMAW boiler tube welds and membrane walls, window and pad welds, preheat and PWHT for carbon and chromium-molybdenum tubes under ASME and NBIC repair rules, and weld quality, NDE and repair, ending with a capstone that replaces a section of waterwall tube from repair package to hydrostatic test.
BLR-210 12 lessons · 3 h 52 min ▶ Video lessons coming soon
Offered by HSM University · Boilermaking
This is the American version of this course. See the Canadian version.
What you'll learn
- Describe the cutting and welding processes boilermakers use, where each fits, and how pressure welding is regulated through procedures, welder qualification, continuity and inspection
- Prepare equipment that has held product for hot work and make oxyfuel track cuts, bevels and attachment removals on vessels and tanks, planning the gas and the acetylene withdrawal rate
- Split membrane bars with plasma and cut boiler tubes mechanically, plugging and recording tube ends and freeing a section before the final square cuts
- Back-gouge double-V joints and excavate defects with air carbon arc gouging and grinding, confirming sound metal by examination
- Weld plate in the flat, horizontal, vertical and overhead positions with low-hydrogen electrodes and check heat input against the WPS
- Choose between SMAW, gas-shielded FCAW and self-shielded FCAW in the field, and control wind, stickout and fume
- Prepare tube ends with end prep machines, clean them, cut a replacement section to length and check root opening and high-low at fit-up
- Describe how boiler tube butt welds are made from the GTAW root to the SMAW cap in fixed positions, and how membrane walls are closed
- Plan tube replacements, window welds and pad welds, and assemble a repair package for inspector acceptance
- Select preheat, interpass and PWHT from the base metal group and thickness, confirm alloys by PMI, and describe field heat treatment and Grade 91 controls
- Recognize weld discontinuities, match them to the NDE methods that find them, apply acceptance rules and carry out a weld repair
- Carry a waterwall tube section replacement from repair package to signed record, including examination, repair and the hydrostatic test
Course content
12 lessons · 3 h 52 min total · final exam
- 1 Welding and cutting in boilermaker work 21 min · quiz
- 2 Oxyfuel cutting on vessels and in the field 19 min · quiz
- 3 Plasma cutting and tube cutting tools 20 min · quiz
- 4 Air carbon arc gouging and back-gouging 20 min · quiz
- 5 SMAW on plate in all positions 19 min · quiz
- 6 FCAW in the field 19 min · quiz
- 7 Tube end preparation and fit-up 19 min · quiz
- 8 Boiler tube welding and membrane walls 19 min · quiz
- 9 Pad welds, window welds and tube replacements 19 min · quiz
- 10 Welding on pressure parts: procedures, preheat and PWHT 19 min · quiz
- 11 Weld quality, NDE and repair 19 min · quiz
- 12 Capstone: replacing a section of waterwall tube 19 min · quiz
- E Final exam 20 questions
Requirements
Recommended background. You can start any course at any time.
Description
Cutting and welding as boilermakers use them, followed through a spring season with Ironbridge Industrial out of Port Allen, Louisiana: oxyfuel track cuts on a tank shell, plasma membrane splits and mechanical tube cutting, air carbon arc back-gouging, SMAW on plate in all positions and FCAW in the field, tube end preparation and fit-up, GTAW and SMAW boiler tube welds and membrane walls, window and pad welds, preheat and PWHT for carbon and chromium-molybdenum tubes under ASME and NBIC repair rules, and weld quality, NDE and repair, ending with a capstone that replaces a section of waterwall tube from repair package to hydrostatic test.