Preparing for the Boilermaker Trade

Sue Grecki

Teresa Phillips

Library and Archives Canada Cataloguing in Publication

Grecki, Sue, 1956 Preparing for the boilermaker trade / Sue Grecki, Teresa Phillips.

ISBN 978-1-926584-07-2

1. Numeracy. 2. Workplace literacy. 3. Boiler-makers--Training of. 4. Mathematics--Problems, exercises, etc.I. Phillips, Teresa, 1968- II. SkillPlan (Program) III. Title.

QA141.15.G7433 2011 513 C2011-907124-X

Copyright © 2012

To order copies of this publication, please contact:SkillPlan - BC Construction Industry Skills Improvement Council

Suite 405, 3701 Hastings StreetBurnaby, BC, V5C 2H6

Order online: www.skillplan.ca

This material is intended for individual use. The price of this publication is below market value to make it affordable for individual apprentices and to encourage purchase of class sets. No part of this material may be reproduced, repackaged or used for any commercial purpose or sold by any organization without permission in writing from SkillPlan.

iPreparing for the Boilermaker Trade – SkillPlan

About SkillPlan

SkillPlan, a joint labour and management initiative of the BC construction industry, was established as a not-for-profit society in March 1991. The Council is the industry’s response to an evolving workplace that requires greater writing, numeracy, problem solving and oral communication skills. SkillPlan believes that a solid foundation of these skills are part of an adult ’s life not only at work but in their unions and the wider community.

SkillPlan’s Workplace Educators are privileged to tutor hundreds of building trades apprentices and interact with technical instructors, training coordinators and the contractors who employ them. SkillPlan publications are dependent on this network to accurately reflect the Essential Skills needed on the job. Our thanks are extended to those organizations who allowed us to reprint their materials.

ii Preparing for the Boilermaker Trade – SkillPlan

iiiPreparing for the Boilermaker Trade – SkillPlan

Contents

Introduction ........................................................................................... v

Section 1: Math Foundations Using Your Calculator .................................................................... 1 Whole Numbers ............................................................................ 2 Decimals ....................................................................................... 5 Fractions ....................................................................................... 9 Ratio/Proportion ..........................................................................15 Percent .........................................................................................18 Averages .......................................................................................25 Measurement ................................................................................26 Perimeter ......................................................................................41 Area ............................................................................................44 Volume .........................................................................................46 Estimating Weight Loads ..............................................................49 Complex Shapes ...........................................................................52 Pythagorean Theorem ...................................................................58 Answer Key ..................................................................................61

Section 2: Word Problems Using a Strategy to Solve Word Problems ......................................82 Answer Key ..................................................................................89

Section 3: Problem Sets Problem Set 1: Chain Slings ............................................................. 92 Problem Set 2: Atmospheric Hazards ............................................94 Problem Set 3: Hydrogen Sulphide MSDS .....................................97 Problem Set 4: Personal Fall Protection ....................................... 100 Problem Set 5: Hazardous Process Chemicals in Pulp Processing .. 103 Problem Set 6: Boiler Air Flow ................................................... 106 Answer Key ................................................................................ 108

iv Preparing for the Boilermaker Trade – SkillPlan

Introduction

vPreparing for the Boilermaker Trade – SkillPlan

IntroduCtIon

Who Should Use This Publ icat ion?If you are interested in entering a Boilermaker apprenticeship and want to practice your skills in Reading, Document Use and Numeracy, then this workbook is for you. The purpose of this publication is to give you a quick review of these three Essential Skills.

What are Essential Ski l ls?Essential Skills are skills that allow workers in every occupation to get the job done. They are not technical skills but the foundation or underlying skills people need to acquire knowledge and complete workplace tasks and daily activities. The nine Essential Skills are Reading, Document Use, Numeracy, Writing, Oral Communication, Working with Others, Thinking Skills, Computer Use and Continuous Learning.

What Ski l ls Does This Publ icat ion Cover?Preparing for the Boilermaker Trade provides practice using Reading, Document Use and Numeracy skills for typical applications in Boilermaking. This publication will help you to successfully prepare for trade assessments which are part of intake requirements for further training.

For example, in one jurisdiction you may be asked to write the Boilermaker Trade Assessment. This assessment, like many others, does not require specific background knowledge about the boilermaker trade.

After you have completed Preparing for the Boilermaker Trade, you are ready to write most assessment tests. If you need more practice, go to Publications at www.skillplan.ca. Measurement and Calculation for the Trades is a helpful resource.

BTA-1

The Ironworkers Local 97 Apprenticeship and Training Society (DBA - Trade Improvement Committee) was established through the collective agreement process to provide training and skills upgrading to Local 97 members.

The Trade Improvement Coordinator, on behalf of the Society, is responsible for recruitment of apprentices and trainees and for provision of trade counselling from intake to completion of registered apprenticeships. The Society also assists in the development, design and validation of new programs and curriculum, and participates in provincial and national committees that set standards for the Ironworker trade.

The purpose of the Ironworkers Local 97 Apprenticeship and Training Society is to develop and promote apprenticeship and training of Ironworkers within British Columbia.

This assessment is intended to gauge the readiness of candidates for a registered apprenticeship. By participating in this process, candidates gain an awareness of expectations for the trade and have an opportunity to prepare for technical training. The Society is committed to the successful completion of every indentured apprentice in their programs.

Copyright © 2011Boilermakers’ Apprenticeship and Training Society

?????????????????Burnaby, BC

V5C 3W5

>>>>>>>>>>>>>, Trade Improvement Coordinator

No part of this assessment may be reproduced or used by any person other than the owner’s representative.

SkillPlan, the BC Construction Industry Skills Improvement Council, in collaboration with the Boilermakers’ Apprenticeship and Training Society, designed this assessment.

For more information about the companion publication, Preparing for the Boilermakers’ Trade visit www.skillplan.ca.

BOILERMAKER Trade Assessment

Name:_ ____________________________________________________

_ Date:_ _____________________________________________________

Introduction

vi Preparing for the Boilermaker Trade – SkillPlan

ReadingReading means reading material that is in the form of sentences and paragraphs. Some examples of Reading are memos, bulletins, textbooks, detailed work orders, reports, journals and manuals. Different trades use specialized trade terms, vocabulary and jargon which makes the reading boilermakers are required to do more complex.

Boilermakers:

• read brief summaries of toolbox safety meetings to review the issues discussed.

• read Material Safety Data sheets (MSDS) to locate information about the safe handling of a substance.

• read reference books (e.g. IPT’s Metal Trades Handbook) to review technical procedures, mathematical explanations, first aid instructions, and safety guidelines.

The following box is an example of the kind of text a boilermaker might have to read on the job or during technical training.Section 3

102 Preparing for the Boilermaker Trade – SkillPlan

below the work• must include an adequate fixed support; the harness

must be connected to it via a lifeline, or via a lanyardand a lifeline

• must prevent a falling worker from hitting the groundor any object or level below the work

• must not subject a falling worker to a peak fall-arrestforce greater than 8 kilonewtons.

The construction regulation (O. Reg. 213/91) requires that• all fall protection equipment must be inspected for

damage, wear, and obvious defects by a competentworker before each use

• any worker required to use fall protection must betrained in its safe use and proper maintenance.

Any defective component should be replaced by one thatmeets or exceeds the manufacturer’s minimumperformance standards for that particular system.The regulation also requires that any fall-arrest systeminvolved in a fall be removed from service until themanufacturer certifies all components safe for reuse.For any worker receiving instruction in fall protection, themanufacturer’s instructions for each piece of equipmentshould be carefully reviewed, with particular attention towarnings and limitations.ComponentsCanadian fall protection standards are regularly updatedto incorporate the most current changes to fall protectionsystems. The following is a list of current CSA standardsfor personal fall protection equipment:- CAN/CSA-Z259.1-M99 – Body Belts and Saddles for

Work Positioning and Travel Restraint - CAN/CSA-Z259.10-06 – Full Body Harnesses - CAN/CSA-Z259.11 – Energy Absorbers and

Lanyards - CAN/CSA-Z259.12 – Connecting Components for

Personal Fall Arrest Systems (PFAS) - CAN/CSA-Z259.14 – Fall Restrict Equipment for

Wood Pole Climbing - CAN/CSA-Z259.2.1 – Fall Arresters, Vertical Lifelines

and Rails - CAN/CSA-Z259.2.2 – Self-Retracting Devices for

Personal Fall-Arrest Systems - CAN/CSA-Z259.2.3 – Descent Control Devices

For any component not covered by these standards,confirm with the manufacturer that the component issuitable for the particular system being considered.The minimum strength of fall-arrest components dependson whether or not the system uses a shock absorber.

• In systems without shock absorbers, all components,including lifeline and lifeline anchorage, must be ableto support a static load of at least 8 kilonewtons (1800pounds) without exceeding the allowable unit stress ofthe materials used for each component.

• In systems with shock absorbers, all components,including lifeline and lifeline anchorage, must be ableto support a static load of 6 kilonewtons (1350pounds) without exceeding the allowable unit stress ofthe materials used for each component.

In designing both systems, it is recommended that asafety factor of at least two be applied to the stated

minimum load capacity. In practical terms, anchorageshould be strong enough to support the weight of a smallcar (about 3600 pounds).

Lifelines

There are three basic types of lifelines:1) vertical 2) horizontal 3) retractable.

All lifelines must be inspected daily to ensure that they are

- free of cuts, burns, frayed strands, abrasions, andother defects or signs of damage

- free of discolouration and brittleness indicating heat orchemical exposure.

1) Vertical Lifelines Vertical lifelines must comply with the current edition ofthe applicable CSA standard and the following minimumrequirements:- Only one person at a time may use a vertical lifeline.- A vertical lifeline must reach the ground or a level

above ground where the worker can safely exit.- A vertical lifeline must have a positive stop to prevent

the rope grab from running off the end of the lifeline.Vertical lifelines are typically 16-millimetre (5/8-inch)synthetic rope (polypropylene blends).

2) Horizontal Lifelines The following requirements apply to any horizontal lifelinesystem:- The system must be designed by a professional

engineer according to good engineering practice.- The design can be a standard design or specifically

engineered for the site.

The design for a horizontal lifeline system must✓ clearly indicate how the system is to be arranged,

including how and where it is to be anchored✓ list and specify all required components ✓ clearly state the number of workers that can safely be

attached to the lifeline at one time✓ spell out instructions for installation, inspection, and

maintenance

PERSONAL FALL PROTECTION

19 – 2

36383 19_Fall Protection 9-19 3-23_CSAO Responsibilities/Health 10-11-02 2:00 PM Page 2

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Introduction

viiPreparing for the Boilermaker Trade – SkillPlan

Document UseDocument Use tasks involve different information displays. Words, numbers and icons are given meaning by their spatial arrangement. Some examples of Document Use are reading prints, drawings, signs, labels, lists and tables.Boilermakers:

• read tables showing the weights and sizes of steel bars to locate a specific bar size.• interpret American Welding Society standard welding symbols on blueprints

to identify the recommended welding technique.• interpret blueprints to determine what tasks must be completed and to

review material lists.The following box is an example of the kind of document a boilermaker might refer to on the job or during technical training.

112 Preparing for the Boilermaker Trade – SkillPlan

6 The forced draft (FD) fans pull in outside air at the beginning of the process. The induced draft (ID) fans create a vacuum effect on the boiler side that helps to move the air and flue gases through the boiler.

Reading Text (Level 3): Located and integrated multiple pieces of information.

7 Precipitator

Scrubber

Air Heater

Reading Text (Level 3) and Document Use (Level 2): Located and integrated multiple pieces of information. Used a process of elimitation to identify required information.

ITP

Publ

ishin

g & T

rain

ing L

td. R

eprin

ted w

ith pe

rmiss

ion.

Introduction

viii Preparing for the Boilermaker Trade – SkillPlan

NumeracyNumeracy refers to using numbers and thinking in quantitative terms on the job and during technical training. On the job, math is used to solve problems that get the work done accurately the first time.

Boilermakers:

• compare pressure gauge readings to stated norms to determine whether pressure adjustments must be made.

• calculate the Working Load Limit for a variety of wire and fibre rope types using a formula to determine which size and type of rope to use when hoisting a load.

• use geometry, such as bisecting angles and constructing a circle from chords, to lay out materials for pressure vessels.

• estimate the load weight to ensure safe rigging operations are being used.The following box is an example of a document a boilermaker uses to estimate the weight of the load on the sling legs.

Chain SlingS grade a (8) alloy Steel

Chain Size

(inches)

Working load limit (Wll) in PoundS

Single Vertical

Hitch

Single Choker Hitch

Single Basket Hitch

(Vertical Legs)

2-Leg Bridle Hitch & Single Basket Hitch with Legs Inclined

60° 45° 30°

14

2,800 2,100 5,600 4,850 3,959 2,800

38

5,680 4,260 11,360 9,838 8,032 5,680

12

9,600 7,200 19,200 16,627 13,574 9,600

58

14,480 10,860 28,960 25,079 20,475 14,480

34

22,640 16,980 45,280 39,212 32,013 22,640

78

27,360 20,520 54,720 47,388 38,687 27,360

SlingAngle

Introduction

ixPreparing for the Boilermaker Trade – SkillPlan

How is Preparing for the Boi lermaker Trade Organized?There are three sections in Preparing for the Boilermaker Trade. Each section is followed by an Answer Key for that section.

• Section 1: Math FoundationsSection 1 provides a review of basic math foundations and examples of whole numbers, decimals, fractions, ratio/proportion, percent, averages, measurement, perimeter, area, volume, estimating weight loads and Pythagorean Theorem that you will need during technical training and on the job. There are practice questions for each topic. The Answer Key gives step by step solutions. The material in this section provides practice of skills that you may have forgotten because you have not used them in a long time. You may need to refer to other resources to relearn some topics.

• Section 2: Word ProblemsSection 2 demonstrates how to solve word problems. A strategy for locating information and rearranging numbers to set up the problem is included. Practice questions are provided. The Answer Key gives step by step solutions.

• Section 3: Problem SetsSection 3 provides practice in Reading, Document Use, and Numeracy. Questions are grouped with documents you might encounter during technical training or in a work situation. All the information needed to answer the questions can be located in the document provided. The Answer Key is included at the end of the section.