Applicants

Selection of Applicants

Applicants for the training program must be one of the following:

• Apprentice

• Journeyman

• Helper

• Potential Recruit

Qualifications

Applicants must meet one of the following criteria:

• Must pass a weld test with one signatory contractor

• Must pass a weld test conducted by the Director of Training or a designee of the Director of Training

Agreement

All applicants must sign an agreement issued by the Boilermakers National Apprenticeship Program, agreeing to the terms and conditions of this training, before beginning the program.  Applicants will not be allowed to participate in training until all required paperwork is complete.

All hours earned by apprentices during this training will be applied to their welding curriculum apprenticeship hours. 

 

 

Evaluation – SMAW & FCAW Processes

Orientation

Location:        Classroom

Hours:            One

Topics:           Safety

Expectations

Procedures

Review of machines and tools

 

Preparation

Location:        Shop

Hours:            Two

Details:           Students will prep and fit-up plates for testing

• 12 plates

• 6 backing bars

 

Practice

Location:        Shop

Hours:            Five

Details:           Students will practice SMAW/FCAW processes

 

Review

Location:        Classroom

Hours:            One

Details:           Students will return to the classroom to review procedures and expectations.

                        Open discussion will be led by the class instructor(s).

 

 

Evaluation Testing

Testing Time Limits

Students will perform the following processes within the given testing time limits:

Process:         SMAW

Time limit:      Three hours

 

Process:         FCAW

Time limit:      Two hours

Testing Criteria

Students will be given two opportunities on each procedure which will be graded by the instructor on the following:

• Time

• Quality

• Ability to learn

• Conduct

• Craftsmanship

 

After evaluation testing, students will be selected to start the program.

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SMAW Weld Training

SMAW Class Structure and Curriculum

Day 1 – Introduction and Prep

• The Instructor will give orientation of the SMAW process and the expectations of the program

• Students will be given all materials and tools needed for the class.  It is the responsibility of the student to control all materials provided.

• Students will prep all materials

  • Each class will use 60 plates and 30 backing strips.

 

Day 2 Curriculum – Setup and Fit-up

• Proper machine setup

• Coupon fit-up on 2G, 3G, and 4G positions

• 10 sets of coupons

 

Day 3 Curriculum – Setup and Root Pass

• Setup plates in position

• Begin root pass until proficient

  • If student fails to show proficiency after three days, he/she will be dismissed from the class

 

Day 4 Curriculum – Proper Fill

• Proper fill of SMAW process with 3/32” 7018

 

Day 5 Curriculum – Proper Fill

• Proper fill of SMAW process with 1/8” 7018

 

Day 6 Curriculum – Timed Testing

• Start to finish weld out of SMAW process 3/32” root, 1/8” fill, and 3/32” cap

• Students will be timed by the instructor

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Day 7 Curriculum – Full Procedure

• Preparation

• Fit-up

• Tack

• Root

• Fill

• Cap

• Students will have four hours to complete the test.

• Students will be given two chances to perform the test.

• If a student fails, it will be left to the discretion of the instructor if the student can continue in the program.

 

Day 8 (Morning) – Material Prepping; Start of Proficiency Testing

• 3 sets:

  • 18 plates

  • 9 backing

 

Days 8 (Afternoon), 9 & 10 – Proficiency Testing

• Proficiency testing for SMAW process

• Students must pass all three tests consecutively

• Upon completion of testing, students must recut all materials and set up for the next class.

 

 

 

 

FCAW Weld Training

 

FCAW Class Structure and Curriculum

Day 1 – Introduction and Prep

• The Instructor will give orientation of the FCAW process and the expectations of the program

• Students will be given all materials and tools needed for the class.  It is the responsibility of the student to control all materials provided.

• The Instructor will give each student a hands-on test, which will include:

  • Setting up a MIG machine

  • Maintenance of equipment for the FCAW process

 

Day 2 – Material Prep and Fit-up

• Students will prep all materials and fit-up for the FCAW process, including:

  • 10 sets

  • 60 plates

  • 30 backing bars

 

Day 3 – Fit-up and Root Pass

• Proper fit-up and root passes of the FCAW process on all testing sets of coupons

• All work will be documented in writing by the Instructor

 

Day 4 – Fill

• Students will properly fill previously rooted coupons

 

Day 5 – Cap

• Students will cap coupons previously filled with the FCAW process

 

Day 6 – Cutting and Re-prepping Materials

• Students will cut and re-prep all materials for continued training

• As tasks are completed, students will continue the program

 

Days 7 & 8 – Practice

• Students will root, fill, and cap two sets of coupons each day by the end of scheduled class, for a total of four sets over the course of two days

 

Days 9 & 10 – Proficiency Testing

• Proficiency testing on the FCAW process

• Students must complete three sets of coupons consecutively within the time frame of the procedure.

• Upon completion of testing, students will recut all materials and set up for the next class.

 

 

 

Evaluation of GTAW/SMAW Process

Orientation

Location:        Classroom

Hours:            One

Topics:           Safety

Expectations

Procedures

Review of machines and tools

 

Preparation

Location:        Shop

Details:           Students will prep two sets of practice coupons for the GTAW process

Practice

Location:        Shop

Hours:            Four

Details:           Students will take one set of coupons and perform the GTAW/SMAW process in the 6G position. The Instructor will critique and document the student’s weaknesses and strengths.  These critiques will be reviewed and the end of the student’s evaluation. Students will than be selected to perform the GTAW/SMAW training.
 

 

GTAW/SMAW Weld Training

 

FCAW Class Structure and Curriculum

Day 1 – Introduction, Prep & Fit-up

• The Instructor will give orientation of the GTAW/SMAW process and the expectations of the program

• Students will be given all materials and tools needed for the class.  It is the responsibility of the student to control all materials provided.

• Students will begin prep of materials, consisting of 20 tube coupons (10 sets)

• As students complete the prep of materials, they will begin proper fit-up

 

Day 2 – Root Process

• The student will begin the root process

• Each student will complete all 10 sets of coupons by the end of the scheduled day

 

Day 3 – Root Pass Testing

• Students will re-prep coupons, and will have five chances to perform a proper root pass for the Instructor

• If a student cannot successfully complete the task, it will be left to the discretion of the instructor if the student can continue in the program.

 

Day 4 – Root & Hot Pass

• Students will perform root and hot pass of all 10 sets of coupons

 

Days 5 & 6 – Fill

• Students will perform fill of coupons with the SMAW process

 

Days 7 & 8 – Cap

• Students will perform capping of coupons

 

Day 9 – Prep, Fit-up & Proficiency of Root Pass

• Students will prep and fit-up 10 sets of tube coupons

• Students will begin proficiency testing of root pass in all coupons

 

Day 10 – Proficiency Testing – Hot Pass & Fill

• Students will test for SMAW proficiency on hot pass and fill process on all coupons

 

Day 11 – Hot Pass & Fill

• Continuation of hot pass and fill activities

 

Day 12 – Proficiency Testing – Capping

• Students will begin proficiency testing for capping of all tubes

 

Days 13 & 14 – Buddy Welding

• Students will be paired and will begin buddy welding activities

 

Days 15 & 16 – Water Wall

• Paired students will be given task with water wall panel to complete

 

Days 17 & 18 – GTAW/SMAW Proficiency Testing

• Students will begin proficiency testing on GTAW/SMAW tube test as individuals in the 6G position

• Each student must successfully complete three consecutive tube tests for the Instructor

 

Days 19 & 20 – Wall Panel Proficiency Testing

• Students will be paired and will begin proficiency testing on a five-tube wall panel in position