Holley O L & Sons

Boilermakers assemble, install, and repair boilers, closed vats, and other large vessels or containers that hold liquids and gases.

Boilermakers typically do the following:

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

Boilers, tanks, and vats are used in many buildings, factories, and ships. Boilers heat water or other fluids under extreme pressure to generate electric power and to provide heat. Large tanks and vats are used to store and process chemicals, oil, beer, and hundreds of other products.

Boilers are made out of steel, iron, copper, or stainless steel. Manufacturers are increasingly automating the production of boilers to improve the quality of these vessels. However, boilermakers still use many tools in making or repairing boilers. For example, they use hand and power tools or flame cutting torches to cut pieces for a boiler. To bend the pieces into shape and accurately line them up, boilermakers use plumb bobs, levels, wedges, and turnbuckles.

If the plate sections are very large, large cranes lift the parts into place. Once they have the parts lined up, they use metalworking machinery and other tools to remove irregular edges so the parts fit together properly. They join the parts by bolting, welding, or riveting them together.

In addition to installing and maintaining boilers and other vessels, boilermakers help erect and repair air pollution equipment, blast furnaces, water treatment plants, storage and process tanks, and smokestacks. Boilermakers also install refractory brick and other heat-resistant materials in fireboxes or pressure vessels. Some install and maintain the huge pipes used in dams to send water to and from hydroelectric power generation turbines.

Because boilers last a long time--sometimes 50 years or more--boilermakers must regularly maintain them and upgrade parts. They frequently inspect fittings, feed pumps, safety and check valves, water and pressure gauges, and boiler controls.

Electricians install and maintain electrical systems in homes, businesses, and factories.

Electricians typically do the following:

• Read blueprints or technical diagrams before doing work
• Install and maintain wiring and lighting systems
• Inspect electrical components, such as transformers and circuit breakers
• Identify electrical problems with a variety of testing devices
• Repair or replace wiring, equipment, or fixtures using hand tools and power tools
• Follow state and local building regulations based on the National Electric Code
• Direct and train workers to install, maintain, or repair electrical wiring or equipment

Almost every building has an electrical system that is installed during construction and maintained after that. Electricians do both the installing and maintaining of electrical systems.

Installing electrical systems is less complicated than maintaining older equipment. This is because it is easier to get to electrical wiring during construction. Maintaining older equipment, however, involves identifying problems and repairing malfunctioning equipment that is sometimes difficult to reach. Electricians doing maintenance work may need to fix or replace outlets, circuit breakers, motors, or robotic control systems.

Electricians read blueprints, which are technical diagrams of electrical systems that show the location of circuits, outlets, and other equipment. They use different types of hand and power tools, such as pipe benders, to run and protect wiring. Other commonly used hand and power tools include screwdrivers, wire strippers, drills, and saws. While troubleshooting, electricians also may use ammeters, voltmeters, and multimeters to find problems and ensure that components are working properly.

Many electricians work independently, but sometimes they collaborate with others. For example, experienced electricians may work with building engineers and architects to help design electrical systems in new construction. Some electricians also may consult with other construction specialists, such as elevator installers and heating and air conditioning workers, to help install or maintain electrical or power systems. At larger companies, electricians are more likely to work as part of a crew; they may direct helpers and apprentices to complete jobs.

The following are examples of occupational specialties:

Inside electricians maintain and repair large motors, equipment, and control systems in businesses and factories. They use their knowledge of electrical systems to help these facilities run safely and efficiently. Some also install the wiring for businesses and factories that are being built. To minimize equipment failure, inside electricians often perform scheduled maintenance.   

Residential electricians install wiring and troubleshoot electrical problems in peoples' homes. Those who work in new-home construction install outlets and provide access to power where needed. Those who work in maintenance and remodeling repair and replace faulty equipment. For example, if a circuit breaker is tripped, electricians determine the reason and fix it.

Electrical engineers design, develop, test, and supervise the manufacturing of electrical equipment such as electric motors, radar and navigation systems, communications systems, or power generation equipment. Electrical engineers also design the electrical systems of automobiles and aircraft.

Electronics engineers design and develop electronic equipment such as broadcast and communications systems, from portable music players to global positioning systems (GPS). Many also work in areas closely related to computer hardware.

Electrical engineers typically do the following:

• Design new ways to use electrical power to develop or improve products
• Do detailed calculations to compute manufacturing, construction, and installation standards and specifications
• Direct manufacturing, installing, and testing to ensure that the product as built meets specifications and codes
• Investigate complaints from customers or the public, evaluate problems, and recommend solutions
• Work with project managers on production efforts to ensure projects are completed satisfactorily, on time, and within budget

Electronics engineers typically do the following:

• Design electronic components, software, products, or systems for commercial, industrial, medical, military, or scientific applications
• Analyze electrical system requirements, capacity, cost, and customer needs and then develop a system plan
• Develop maintenance and testing procedures for electronic components and equipment
• Evaluate systems and recommend repair or design modifications
• Inspect electronic equipment, instruments, and systems to make sure they meet safety standards and applicable regulations
• Plan and develop applications and modifications for electronic properties used in parts and systems to improve technical performance

Electronics engineers who work for the federal government research, develop, and evaluate electronic devices used in diverse technologies, such as aviation, computing, transportation, and manufacturing. They work on federal electronic devices and systems, including satellites, flight systems, radar and sonar systems, and communications systems.

The work of electrical engineers and electronics engineers is often similar. Both use engineering and design software and equipment to do engineering tasks. Both types of engineers must also work with other engineers to discuss existing products and possibilities for engineering projects.

Engineers whose work is related exclusively to computer hardware are considered computer hardware engineers. For more information about this occupation, see the profile on computer hardware engineers.

Assemblers and fabricators assemble both finished products and the parts that go into them. They use tools, machines, and their hands to make engines, computers, aircraft, toys, electronic devices, and more.

Assemblers and fabricators typically do the following:

• Read and understand detailed schematics and blueprints
• Use hand tools or machines to assemble parts
• Conduct quality control checks
• Work closely with designers and engineers in product development 

Assemblers and fabricators have an important role in the manufacturing process. They assemble both finished products and the pieces that go into them. The products encompass a full range of manufactured products, including aircraft, toys, household appliances, automobiles, computers, and electronic devices.

Changes in technology have transformed the manufacturing and assembly process. Modern manufacturing systems use robots, computers, programmable motion-control devices, and various sensing technologies. These systems change the way in which goods are made and affect the jobs of those who make them. Advanced assemblers must be able to work with these new technologies and use them to produce goods.

The job of an assembler or fabricator ranges from very easy to very complicated, requiring a range of knowledge and skills. Skilled assemblers putting together complex machines, for example, read detailed schematics or blueprints that show how to assemble the machine. After determining how parts should connect, they use hand or power tools to trim, shim, cut, and make other adjustments to fit components together and align them properly. Once the parts are properly aligned, they connect them with bolts and screws or weld or solder pieces together.

Quality control is important throughout the assembly process, so assemblers look for faulty components and mistakes in the assembly process. They help to fix problems before defective products are made.

Manufacturing techniques are moving away from traditional assembly line systems toward lean manufacturing systems, which use teams of workers to produce entire products or components. Lean manufacturing has changed the nature of the assemblers' duties.

It has become more common to involve assemblers and fabricators in product development. Designers and engineers consult manufacturing workers during the design stage to improve product reliability and manufacturing efficiency. Some experienced assemblers work with designers and engineers to build prototypes or test products.

Although most assemblers and fabricators are classified as team assemblers, others specialize in producing one type of product or do the same or similar tasks throughout the assembly process.

The following are types of assemblers and fabricators:

Aircraft structure, surfaces, rigging, and systems assemblers fit, fasten, and install parts of airplanes, space vehicles, or missiles, such as wings, fuselage, landing gear, rigging and control equipment, or heating and ventilating systems.

Coil winders, tapers, and finishers wind wire coils of electrical components used in a variety of electric and electronic products, including resistors, transformers, generators, and electric motors.

Electrical and electronic equipment assemblers build products such as electric motors, computers, electronic control devices, and sensing equipment. Automated systems have been put in place because many small electronic parts are too small or fragile for human assembly. Much of the remaining work of electrical and electronic assemblers is done by hand during the small-scale production of electronic devices used in all types of aircraft, military systems, and medical equipment. Production by hand requires these workers to use devices such as soldering irons.

Electromechanical equipment assemblers assemble and modify electromechanical devices such as household appliances, computer tomography scanners, or vending machines. The workers use a variety of tools, such as rulers, rivet guns, and soldering irons.

Engine and machine assemblers construct, assemble, or rebuild engines, turbines, and machines used in automobiles, construction and mining equipment, and power generators.

Structural metal fabricators and fitters cut, align, and fit together structural metal parts and may help weld or rivet the parts together.

Fiberglass laminators and fabricators laminate layers of fiberglass on molds to form boat decks and hulls, bodies for golf carts, automobiles, or other products.

Team assemblers work on an assembly line, but they rotate through different tasks, rather than specializing in a single task. The team may decide how the work is assigned and how different tasks are done. Some aspects of lean production, such as rotating tasks and seeking worker input on improving the assembly process, are common to all assembly and fabrication occupations.

Timing device assemblers, adjusters, and calibrators do precision assembling or adjusting of timing devices within very narrow tolerances.

Electrical and electronics installers and repairers install, repair, or replace a variety of electrical equipment in telecommunications, transportation, utilities, and other industries.

Electrical and electronics installers and repairers typically do the following:

• Prepare cost estimates for clients
• Refer to service guides, schematics, and manufacturer specifications
• Repair or replace defective parts, such as motors, fuses, or gaskets
• Reassemble and test equipment after repairs
• Maintain records of parts used, labor time, and final charges

Electrical and electronics installers and repairers work on complex pieces of electronic equipment.

Automated electronic control systems are becoming increasingly complex. As a result, repairers use software programs and testing equipment to diagnose malfunctions. Among their diagnostic tools are multimeters--which measure voltage, current, and resistance--and advanced multimeters, which measure the capacitance, inductance, and current gain of transistors.

Repairers also use signal generators, which provide test signals, and oscilloscopes, which display signals graphically. In addition, repairers use handtools such as pliers, screwdrivers, soldering irons, and wrenches to replace faulty parts and adjust equipment.

Commercial and industrial equipment electrical and electronics repairers repair, test, adjust, or install electronic equipment, such as industrial controls, transmitters, and antennas.

Electrical and electronics installers and repairers of transportation equipment install, adjust, or maintain mobile communication equipment, including sound, sonar, security, navigation, and surveillance systems on trains, watercraft, or other vehicles.

Powerhouse, substation, and relay electrical and electronics repairers inspect, test, maintain, or repair electrical equipment used in generating stations, substations, and inservice relays. These workers may be known as powerhouse electricians, relay technicians, or power transformer repairers.

Electric motor, power tool, and related repairers--such as armature winders, generator mechanics, and electric golf cart repairers--specialize in installing, maintaining, and repairing electric motors, wiring, or switches.

Electronic equipment installers and repairers of motor vehicles install, diagnose, and repair sound, security, and navigation equipment in motor vehicles. Motor vehicle installers and repairers work with an increasingly complex range of electronic equipment, including DVD players, navigation systems, and passive and active security systems.

Electrical and electronic installers and repairers may specialize, according to how and where they work:

Field technicians often travel to factories or other locations to repair equipment. When equipment breaks down, field technicians go to a customer's site to repair the equipment. Because repairing components is a complex activity, workers on the factory floor usually remove and replace defective units, such as circuit boards, instead of fixing them. Defective units are discarded or returned to the manufacturer or a specialized shop for repair.

Bench technicians work in repair shops in factories and service centers, fixing components that cannot be repaired on the factory floor. These workers also locate and repair circuit defects, such as poorly soldered joints, blown fuses, or malfunctioning transistors.