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. The course is one day long.

Learning Outcomes

  • 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

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 the 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


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, 2ndedition; P. Jackson, D. Moelling, J. Malloy, M. Taylor, Tetra Engineering Group, Inc., 2006, ISBN 0-9719616-2-X


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