About The Course

Efficient and thorough inspections are a key factor in assuring long-term asset integrity.  This course will give attendees comprehensive insight into how to efficiently plan, execute and document inspections of Heat Recovery Steam Generators and directly associated steam-cycle balance of plant equipment such as steam drums and power piping.


Each attendee of this training course will receive a copy of the book HRSG Inspection Planning Guide, 2nd Edition, ISBN 0-9719616-2-X (163 pages) that is published by Tetra Engineering.

Learning Outcomes

  • Understand the basic process and design features of various HRSG designs and how they influence risk of damage and consequently the scope of inspections
  • Gain an overview of the most common damage mechanisms, either on the waterside or fire/gas/air-side, that can affect components in the HRSG and associated steam cycle
  • How to plan “judicious” inspections within time and budget constraints and thereby assure the best quality data for your O&M
  • Review the available inspection techniques and technologies, their benefits and limitations
  • Know the essential elements of writing clear and concise inspection reports

Who Should Attend

Although this training course is primarily aimed at O&M staff working in the plants, the content is also very relevant to corporate engineering and plant management staff that are concerned with assuring asset reliability and integrity.

Expert Course Faculty

He is currently Director of European Operations of a leading engineering and inspection consultancy in the power generation sector. Activities are now concentrated on the steam cycle in combined cycle plants, but included projects for coal, oil, diesel and nuclear plants in the past. Areas of specialization are instrumentation and controls (I&C) as well as materials science.


CRE S.A., Sophia Antipolis, France (1987-1991)

Lead Engineer, worked on the design and development of real-time systems for controlling diesel generators and turbines. One application involved the development of a complete monitoring system under subcontract to a major European diesel manufacturer, which was subsequently installed on a new black start diesel at a US nuclear plant.


Raytheon Company, Development Laboratory, Sudbury, MA. USA (1983-1987)

Engineering and analyses to improve resistance of defense electronic systems to spatial environments and effects of nuclear radiation. This involved designing custom test circuitry and carrying out the tests at both Raytheon and US government facilities.


Combustion Engineering Inc., Nuclear Division, Windsor CT. USA (1980-1982)

Worked in the design group responsible for the nuclear fuel reloading (enriched uranium) for the St Lucie 1 and BG&E Calvert Cliffs plants. Used radiation transport programs for simulating the physics of the reactor during a cycle.


Recent Project Experience:

  • HRSG Inspections ( more than 50 in last six years)
  • Computer Simulation of Boiler and Steam Plant Performance
  • API/ASME FFS-1 Fitness for Service Analysis on HRSG Components
  • Coal Boiler Inspection and Life Assessments
  • HRSG and Radiant Boiler Failure Analyses
  • HRSG Training (annual public courses and closed session at client sites



  • “An Advanced Model for the Prediction of the Total Burnup-Dependent Self-Powered Rhodium Detector Response,” T. G. Ober and J. W. Malloy, Proc. Int. Conf. on Mathematics and Computations, Reactor Physics and Environmental Analysis, vol. 2, 22-31, Portland, Oregon (1995).
  • “Cycling Experience of Large HRSG’s in the New England ISO”, D.S. Moelling, F.J. Berte, P. Jackson, J. Malloy. presented at POWERGEN Europe Brussels 2001.
  • HRSG Inspection Planning Guide, 2ndedition; P. Jackson, D. Moelling, J. Malloy, M. Taylor, Tetra Engineering Group, Inc., 2006.
  • “Computer Simulation of HRSGs Can Improve O&M”, J.W. Malloy, C. Daublebsky, M.
  • Taylor, Power Magazine, Jun 1 , 2009



US Patent 5,044,992, Sept 3, 1991, “Printed circuit injection molded connector with removable bifurcated contacts capable of high temperature exposure” (assigned to Raytheon Co.)


HRSG Design and Process Essentials

Background Planning and Preparation for Inspection

Inspection Technology

HRSG Components and Their Inspection

Reporting & Inspection Data Management 

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