Boilermaker

Boilermakers operate a variety of equipment and machinery to create, repipe and retube hot water and steam boilers, producing them in all steps of the production process. They cut, gouge and shape the metal sheets and tubes for the boilers to size, using oxy-acetylene gas torches, assemble them by shielded metal arc welding, gas metal arc welding or gas tungsten arc welding, and finish them by the appropriate machine tools, power tools and coating.

Boilermakers typically do the following:

• Read blueprints to determine locations, positions, and dimensions of boiler parts
• Install small, premade boilers in buildings and manufacturing facilities
• Lay out prefabricated parts of large boilers before assembling them
• Assemble boiler tanks, often using robotic or automatic welders
• Test and inspect boiler systems for leaks or defects
• Clean vats with scrapers, wire brushes, and cleaning solvents
• Replace or repair broken valves, pipes, or joints, using hand and power tools, gas torches, and welding equipment.

Boilermakers do physically demanding work in cramped spaces inside boilers, vats, or tanks that are often dark, damp, noisy, and poorly ventilated. They frequently work outdoors in all types of weather, including extreme heat and cold.

Because dams, boilers, storage tanks, and pressure vessels are large, boilermakers frequently work at great heights. For example, they may be hundreds of feet above the ground when working on a dam.                                                                                                               

The work that boilermakers do can be dangerous. Workers must follow specific safety procedures to avoid injuries and illnesses and must be mindful of potential dangers to themselves and their coworkers. To reduce the risk of injury, boilermakers wear hardhats, earplugs, safety glasses, and other protective equipment. When working in enclosed spaces, boilermakers often wear a respirator.

Most boilermakers work full time, and work schedules may vary. Boilermakers may experience extended periods of overtime when equipment is shut down for maintenance or repair, or when necessary to meet construction or production deadlines. In contrast, because most field construction and repair is contract work, there may be periods of unemployment upon completion of a contract.

Boilermakers may travel to worksites and be away from home for extended periods.

The following job titles also refer to boilermaker:

boilermaker fitter
boiler fabricator
Boiler smith
welder boilermaker
pressure vessel maker
pressure vessel repairer
plater
boiler constructor
boiler retuber
pressure vessel mender
boiler mender
boiler repiper
boiler repairer
steam boilermaker
boiler fitter
steel fabricator,
pressure vessel fabricator

A high school diploma is generally required to work as a boilermaker.

Boilermakers typically learn their trade through an apprenticeship program. During training, workers learn how to use boilermaker tools and equipment on the job. They also learn about metals and installation techniques, blueprint reading and sketching, safety practices, and other topics.

ISCO skill level is defined as a function of the complexity and range of tasks and duties to be performed in an occupation. It is measured on a scale from 1 to 4, with 1 the lowest level and 4 the highest, by considering:

• the nature of the work performed in an occupation in relation to the characteristic tasks and duties
• the level of formal education required for competent performance of the tasks and duties involved and
• the amount of informal on-the-job training and/or previous experience in a related occupation required for competent performance of these tasks and duties.

Boilermaker is a Skill level 2 occupation.

These occupations, although different, require a lot of knowledge and skills similar to boilermaker.

drill press operator
screw machine operator
oxy fuel burning machine operator
riveter
chain making machine operator

These occupations require some skills and knowledge of boilermaker. They also require other skills and knowledge, but at a higher ISCO skill level, meaning these occupations are accessible from a position of boilermaker with a significant experience and/or extensive training.

pulp control operator
automated assembly line operator
metal production supervisor
container equipment assembly supervisor
machine operator supervisor

This knowledge should be acquired through learning to fulfill the role of boilermaker.

• Fuel gas: The various qualities, hazards and applications of gaseous fuels, such as oxy-acetylene, oxy-gasoline, oxy-hydrogen and others.
• Types of metal: Qualities, specifications, applications and reactions to different fabricating processes of various types of metal, such as steel, aluminium, brass, copper and others.
• Quality standards: The national and international requirements, specifications and guidelines to ensure that products, services and processes are of good quality and fit for purpose.
• Manufacturing of heating equipment: The manufacture of electrical ovens and water heaters by metalworking processes.
• Flammable fluids: The behaviour of liquids and gases that represent a serious explosion and fire danger, and their appropriate handling systems and effective storage.
• Metal smoothing technologies: The various technologies used for the smoothening, polishing and buffing of fabricated metal workpieces.

These skills are necessary for the role of boilermaker.

• Apply arc welding techniques: Apply and work with a variety of techniques in the process of arc welding, such as shielded metal arc welding, gas metal arc welding, submerged arc welding and flux-cored arc welding.
• Record production data for quality control: Keep records of the machine’s faults, interventions and irregularities for quality control.
• Operate welding equipment: Use welding equipment to melt and join together pieces of metal or steel; wear protective eyewear during the working process.
• Troubleshoot: Identify operating problems, decide what to do about it and report accordingly.
• Operate precision measuring equipment: Measure the size of a processed part when checking and marking it to check if it is up to standard by use of two and three dimensional precision measuring equipment such as a caliper, a micrometer, and a measuring gauge.
• Perform test run: Perform tests putting a system, machine, tool or other equipment through a series of actions under actual operating conditions in order to assess its reliability and suitability to realise its tasks, and adjust settings accordingly.
• Handle gas cylinders: Grip gas cylinders in a safe manner and ensure they are compliant with safety and health regulations.
• Wear appropriate protective gear: Wear relevant and necessary protective gear, such as protective goggles or other eye protection, hard hats, safety gloves.
• Read standard blueprints: Read and comprehend standard blueprints, machine, and process drawings.
• Ensure equipment availability: Ensure that the necessary equipment is provided, ready and available for use before start of procedures.
• Operate oxy-fuel cutting torch: Operate a cutting torch fueled by oxyacetylene gas safely to perform cutting processes on a workpiece.
• Apply precision metalworking techniques: Comply with precision standards specific to an organisation or product in metalworking, involved in processes such as engraving, precise cutting, welding.
• Smooth burred surfaces: Inspect and smooth burred surfaces of steel and metal parts.
• Ensure correct metal temperature: Ensure the necessary, usually constant, temperature of processed metal workpieces during metal fabrication processes.
• Operate soldering equipment: Use soldering equipment, such as a soldering gun, a soldering torch or a gas-powered iron, to melt and join together pieces of metal or steel.
• Select filler metal: Select optimal metal used for metal joining purposes, such as zinc, lead or copper metals, specifically for welding, soldering or brazing practices.

This knowledge is sometimes, but not always, required for the role of boilermaker. However, mastering this knowledge allows you to have more opportunities for career development.

• Riveting machine types: The various types of machines used for riveting purposes, their qualities and applications, such as the impact riveting machine, radial riveting machine, orbital riveting machine, rollerform riveting machine, and others.
• Cutting technologies: The variety of cutting technologies, such as software or mechanics, guiding cutting processes through lasering, sawing, milling etc.
• Ferrous metal processing: Various processing methods on iron and iron-containing alloys such as steel, stainless steel and pig iron.
• Metal forming technologies: The variety of technologies and techniques, such as forging, pressing, stamping, rolling and others, used for the forming processes of metal product manufacturing.
• Types of metal manufacturing processes: Metal processes linked to the different types of metal, such as casting processes, heat treatment processes, repair processes and other metal manufacturing processes.
• Rivet types: The various types of rivets used in manufacturing, such as solid head rivets, blind rivets, drive rivets, semi-tubular rivets, oscar rivets, flush rivets, and others.
• Casting processes: The various practices used in the casting of metal, plastics and other cast materials, including mould filling, solidification, cooling, and others, all relating to varying approaches in case of different types of material.
• Types of drill press oils: Types of oil such as (sulphurarised) cutting oils, WD-40, 3-IN-ONE and others used in the drilling process to function as a lubricant that facilitates a smooth drilling process, keeps the drill bit cool and increases its durability.
• Manufacturing of steam generators: The manufacture of steam or other vapour generators, the manufacture of auxiliary plant for use with steam generators: condensers, economisers, superheaters, steam collectors and accumulators. The manufacture of nuclear reactors, parts for marine or power boilers. Also the production of pipe system construction comprising further processing of tubes generally to make pressure pipes or pipe systems together with the associated design and construction work.

These skills and competences are sometimes, but not always, required for the role of boilermaker. However, mastering these skills and competences allows you to have more opportunities for career development.

• Repair heating equipment: Repair boilers, heat exchangers, fired heaters, tanks, reactors and other pressure vessels by use of welding techniques applied to cut and formed metal sheets.
• Cast metal: Pour liquid metal into the hollow cavity of a mould, which contains the future product’s desired shape, place it into a furnace and then cool it and let it solidify.
• Supply machine with appropriate tools: Supply the machine with the necessary tools and items for a particular production purpose.
• Monitor gauge: Oversee the data presented by a gauge concerning the measurement of pressure, temperature, thickness of a material, and others.
• Spot metal imperfections: Observe and identify various kinds of imperfections in metal workpieces or finished products. Recognise the best fitted manner of fixing the problem, which could be caused by corrosion, rust, fractures, leaks, and other signs of wear.
• Perform product testing: Test processed workpieces or products for basic faults.
• Dispose of cutting waste material: Dispose of possibly hazardous waste material created in the cutting process, such as swarf, scrap and slugs, sort according to regulations, and clean up workplace.
• Monitor automated machines: Continuously check up on the automated machine’s set-up and execution or make regular control rounds. If necessary, record and interpret data on the operating conditions of installations and equipment in order to identify abnormalities.
• Tend punch press: Tend a punch press, monitor and operate it, according to regulations.
• Perform machine maintenance: Perform regular maintenance, possibly including corrections and alterations, on a machine or machine tool to ensure it remains in a proper productive state.
• Operate drill press: Operate a semi-automated, semi-manual drill press to drill holes in a work piece, safely and according to regulations.
• Supply machine: Ensure the machine is fed the necessary and adequate materials and control the placement or automatic feed and retrieval of work pieces in the machines or machine tools on the production line.
• Consult technical resources: Read and interpret such technical resources such as digital or paper drawings and adjustment data in order to properly set up a machine or working tool, or to assemble mechanical equipment.
• Keep records of work progress: Maintain records of the progress of the work including time, defects, malfunctions, etc.
• Set up the controller of a machine: Set up and give commands to a machine by dispatching the appropriate data and input into the (computer) controller corresponding with the desired processed product.

7213 – Sheet-metal workers

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References

1. Boilermaker – ESCO
2. Boilermakers : Occupational Outlook Handbook – U.S. Bureau of Labor Statistics
3. Featured image: By Alfred T. Palmer – This image is available from the United States Library of Congress’s Prints and Photographs division under the digital ID fsac.1a35230.