Red Seal Boilermaker study plan

List the ten highest-frequency hazard classes in boiler shop and field work (confined space, hot work, suspended loads, stored energy, silica and fume exposure, pinch points, hand and power tool hazards, arc flash, hydrostatic test energy, working at height) and write the control measure you would apply to each

Walk through the lockout/tagout and confined-space entry sequence for a vessel repair step by step, naming who authorizes, who tests atmosphere, who attends, and what triggers an evacuation

Demonstrate the parallel line and perpendicular bisector constructions on paper with dividers and trammel points, then explain how each is used to establish a true centerline on a plate

Compute circumference, chord length, and arc length from a given diameter and included angle without a reference sheet, showing each formula you used

Develop a full flat pattern for a truncated cone and for a square-to-round transition using radial line and triangulation methods, labeling every station line and true-length line

Calculate bend allowance, setback, and bend deduction for 90-degree and non-90-degree bends in 10 mm and 6 mm plate, then verify against a physical test bend

Lay out and cut a hole pattern on scrap plate using dividers, a trammel, and a center punch, checking square and center-to-center distances with a tape and a square

Identify the correct allowance for a rolled cylinder seam and explain how plate thickness and rolling direction change the finished diameter

Describe the setup and operating limits of plate rolls, press brake, and ironworker, and state the safety interlock and pinch-point checks before each is energized

Explain the effect of heat input, preheat, interpass temperature, and cooling rate on distortion and hardness in carbon steel and low-alloy steel, and state when preheat is required

Match the SMAW electrode classification (E7018, E6010, E6013, E11018) to its intended service, position capability, and storage or reconditioning requirement

Set up a root pass, hot pass, fill, and cap sequence for a groove weld on plate and state the defect each pass is most likely to produce if run wrong

Calculate weld metal volume and deposition rate for a given joint, then convert to arc time and total labor hours using an operating factor

Identify weld discontinuities from written descriptions (porosity, slag inclusion, lack of fusion, undercut, crater crack, lamellar tear) and state the process or handling cause and the correction

Compute the tension in each sling leg for a two-leg and four-leg bridle at a stated included angle, and state the capacity loss at 60, 90, and 120 degrees

Select shackles, hooks, and slings for a given load with the correct working load limit derating, and identify the inspection rejection criteria for each

Plan a lift from scratch: determine load weight including rigging, locate the center of gravity, choose the hitch, verify crane capacity at radius, and list the exclusion zone and tagline plan

Explain the difference between a fired pressure vessel, unfired pressure vessel, and a power boiler in terms of code jurisdiction, inspection interval, and the fittings each must carry

Trace the water and steam path through a firetube and a watertube boiler and state the failure mode each design is prone to (overheating from low water, tube sheet cracking, caustic embrittlement, scale)

Identify the safety valve, relief valve, gauge glass, low-water cutoff, and try-cock functions and state the test each receives

Compute the required thickness of a cylindrical shell and a hemispherical head for given design pressure, allowable stress, joint efficiency, and corrosion allowance, and state the formula basis for each

Explain postweld heat treatment: when it is required by thickness and material, how temperature is measured and controlled, and what happens if the soak or cooling rate is wrong

Lay out and fit a beam-to-column connection and a stiffener plate using a tape, square, and level, and state the tolerance for square, plumb, and camber

Identify the structural shapes (W, S, C, HSS, angle, channel) and state how each is oriented for strong-axis bending and how holes are located from a gauge line

Describe the sequence for erecting a structural bay: anchor bolts, column plumb, beam fit, temporary bracing, final bolt torque, and when temporary bracing may be removed

Explain pipe schedule, nominal size versus actual outside diameter, and how to select the correct flange rating, gasket, and bolt grade for a given service

Trace a piping system from source to use and identify where expansion loops, guides, anchors, and supports belong and why

State the alignment tolerances for a flange joint and the bolt tightening sequence for a four-bolt and an eight-bolt flange

Explain radiographic, ultrasonic, magnetic particle, dye penetrant, and visual testing in terms of what each detects, its limitations, and when each is specified

Describe a hydrostatic test: fill, vent, pressurize in steps, hold time, temperature requirement, inspection points, and the safe distance and barricade rule

Build a quality control hold-point list for a vessel job from material receiving through final test, naming the record produced at each hold point

Rehearse the safety and code content of the two heaviest domains under timed conditions and correct every missed item with a written explanation