Study each topic below — these are the core knowledge areas tested in Year 1. Build a solid foundation here before advancing to Year 2 material.
💡Pressure Vessel Fundamentals
- Boiler definition: vessel producing steam for power/heat
- Pressure vessel categories: low-pressure, high-pressure, specialty
- Safety devices: pressure relief valves, water level controls
- Construction materials: carbon steel, stainless, copper
- Design pressures vs maximum allowable working pressures
📋ASME Code Section I - Power Boilers
- ASME Section I: boilers generating steam over 15 psi
- Design requirements: thickness calculations, stress limits
- Material specifications and allowable stresses
- Joint efficiencies and radiography requirements
- Documentation: nameplate data and compliance records
📋ASME Code Section VIII - Pressure Vessels
- Section VIII Division 1: unfired pressure vessels up to 3000 psi
- Design pressure and maximum working pressure calculations
- Minimum wall thickness and corrosion allowance
- Opening reinforcement and nozzle design
- Inspection, testing, and certification procedures
⚙️Welding Procedures & Qualification
- WPS (Welding Procedure Specification) development and documentation
- PQR (Procedure Qualification Record) testing and acceptance
- Welder qualification through test coupons
- Heat input control and preheat requirements
- SMAW, GMAW, FCAW processes for boilermaker applications
⚙️Tube Rolling & Installation
- Tube-to-tubesheet connections: expanded and rolled
- Rolling equipment operation: hydraulic and pneumatic
- Tube expansion tools and mandrel selection
- Pressure testing of tube joints post-installation
- Tube bundle arrangement and tube sheet layout
💡Refractory Installation Fundamentals
- Refractory materials: brick, castable, firebrick types
- High-temperature insulation for furnaces and boilers
- Refractory lining application and curing procedures
- Thermal expansion and movement in refractory systems
- Surface preparation and adhesive application
📖Non-Destructive Examination
- Visual inspection for surface defects and cracks
- Liquid penetrant testing (PT) for surface discontinuities
- Magnetic particle testing (MT) for ferrous materials
- Radiographic examination (UT) for internal defects
- Acceptance standards and documentation requirements
📖Boiler Operation & Maintenance
- Daily startup and shutdown procedures
- Water level control and sight glass maintenance
- Blowdown procedures for sediment removal
- Steam and water quality monitoring
- Safety interlocks and emergency shutdown systems