About The Course

This training course is primarily intended for experienced O&M staff working in thermal power and process plants as well engineering and management staff at the corporate level. The objective is to give attendees all the essentials for effective determination of the root cause of failures that can occur in the boiler or associated steam balance-of-plant. The principal failure modes are reviewed, with focus on those occurring in the boiler, critical piping and other key components such as pressure vessels and condensers.


Major emphasis is placed on analyzing how upstream events in the steam cycle process can lead to failures in downstream components. Several actual failure case histories treated by our staff at plants around the world are presented, providing attendees with practical application of the presented concepts.

Learning Outcomes

  • Gain an overview of the most common damage mechanisms, either on the waterside or fire/gas/air-side, that can affect components in the steam cycle
  • Understand how to define the problem, collect the evidence and then identify the component failure mechanism, which is not the same as the failure root cause.
  • Acquire insight into the various root cause analysis methods, their respective merits and how several were applied in some actual case studies

Who Should Attend

Engineers of all disciplines, managers, technicians, design, maintenance and operations personnel, and other technical individuals who need a comprehensive introduction to practical optimization, operation and design considerations of a major combined cycle power plant.

Expert Course Faculty

Our key expert trained as a Nuclear Engineer, with a BS in Physics (1978), and MS in Nuclear Engineering (1980) from Rensselaer Polytechnic Institute (RPI) in Troy New York. After graduation, he started working in the Reactor Physics group of Combustion Engineering in 1980, designing reactor fuel enrichments for power generation reactors.


He later worked for Raytheon Co. on improving the survivability of electronics in nuclear environments. This was followed by several years at a small start-up developing control systems for diesel power plants. Since 1991, our key expert has been at his current company, where he is now a Managing Director and Principal Engineer of an European subsidiary.


His experience covers the entire steam cycle of combined cycle and conventional thermal power plants. This includes performing several hundred field missions to plant sites on 5 continents for boiler/HRSG inspections, and failure root cause analysis.


Our key expert’s current work is not focused on the practical and cost-effective application of thermo-hydraulic, mechanical and fluid flow simulations to predicting boiler and piping component degradation issues encountered in the field.


Selected publications:

  • Assuring Pressure Part Manufacturing & Repair Quality – has ticking the box become more important than the end product? Fabricius, A. Taylor, M. Malloy, J. Inspectioneering Journal, March/April 2019
  • Understanding Variations in Flow-Accelerated Corrosion Wear Rates in HRSG Evaporator Tubes Malloy, J. Rusaas, J., Taylor, M. International Conference on Flow Accelerated Corrosion, EdF, France and Power Plant Chemistry Magazine, 2017
  • HRSG Tube Failure Diagnostic Guide, 3rd edition; P. Jackson, D. Moelling, J. Malloy, M. Taylor, Tetra Engineering Group, Inc., 2016, ISBN-13 978-0-9719616-3-0
  • Role of Boiling Mode and Rate in Formation of Waterside Deposits in Heat Recovery Steam Generator Evaporator Tubes Moelling, D., Malloy, J. ASME POWER 2014 Conference, July, 2014
  • Evaluating Contributions of Flow-Accelerated Corrosion and Liquid Droplet Impingement to Pipe Thinning in HRSG Evaporator Tubes Malloy, J., A., Graham, Taylor, M., Fabricius, Moelling, D. EdF FAC Conference Avignon, May 2013 and Power Plant Chemistry 2013
  • Design factors for avoiding FAC erosion in HRSG low-pressure evaporators Malloy, J., Taylor, M., Fabricius, A., Graham, M., Moelling, D. July 2013, ASME POWER Conference, USA
  • HRSG Inspection Planning Guide, 2nd edition; P. Jackson, D. Moelling, J. Malloy, M. Taylor, Tetra Engineering Group, Inc., 2006, ISBN 0-9719616-2-X


Review of Steam Cycle Damage Mechanisms

Steam Cycle Components and Failure Modes

Collecting Evidence and Identifying the Failure Mechanism

Root Cause Analysis Methods

Sample Case Histories and Discussion

This training course has a limited attendance for up to 20 participants only. Sessions commence at 9am on all days, with short intervals at 10.30am and 3.30pm respectively. 
Refreshments will be provided in the short intervals. Lunch will be provided at 12:30pm for 1 hour. Sessions will end at 5pm on all days.

Unique Features with powerEDGE Training

• Pre-Course Questionnaire to help us focus on your learning objectives
• Detailed Course & Reference Manual for Continuous Learning and Sharing
• Practical Exercises & Case Examples to better understand the principles
• Limited class size to ensure One-to-One Interactivity
• Assessment at the end of the course to help you develop a Personal Action Plan