Upon Further Inspection

Upon Further Inspection welcomes Mark Bell back to the podcast with Part 2 of our discussion where he shares stories and insights from his decades of inspection and mechanical integrity experience.  As a member of the API/AFPM site assessment program, he has performed assessments and PSM audits across many companies. He highlights gaps he sees in smaller facilities: limited adoption of CCDs, IOWs, and effective RBI/IDMS use, often letting budgets drive wrong inspection techniques (e.g., spot UT instead of needed radiography). He recounts a 1988 explosion and other cases to stress how localized corrosion and unknown damage mechanisms can have catastrophic consequences, and argues for proactive corrosion engineers, field presence, mentoring, and a culture that rewards conservative shutdown decisions. He cautions that AI/RBI are only as good as their inputs and ownership. Listen now for practical, experience-based guidance on improving mechanical integrity and preventing repeat failures.If you missed part 1 “From Boilermaker to Expert”, please listen here.00:39 Why Sites Must Share01:09 Joining API APM Audits04:44 Assessment Takeaways05:41 Lessons from Site Explosion10:04 Modern Tools CCD IOW12:03 Mentors Who Shaped Me16:31 Building A Strong Program18:43 Budget Versus Right NDE25:13 Spot UT Limits and Future29:51 Corrosion Monitoring Debate31:02 Credible Damage Mechanisms33:02 CCDs Into Inspection Plans34:29 Culture and Recognition37:05 Hard Calls on Leaks41:33 Field Communication Matters43:11 AI Needs Good Data45:09 RBI Garbage In, Garbage Out49:31 RBI Horror Stories52:24 Ownership Over Tools Episode Acronyms & AbbreviationsAP – American Petroleum IndustryAFPM – American Fuel & Petrochemical ManufacturersCCDs – Corrosion Control DocumentsCMLs – Corrosion Monitoring LocationsDMRs – Damage Mechanism ReviewsIDMS – Inspection Data Management SystemsIOWs – Integrity Operating WindowsMOC – Management of ChangePSM – Process Safety ManagementRBI – Risk-based InspectionRT – Radiographic TestingUT – Ultrasonic TestingSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In this episode we welcome Mark Bell, a semi-retired fixed equipment consultant to the podcast. The animated discussion between Greg, Branden, and Mark provide a practical, experience-based look at how great inspectors are developed and how inspection quality is improved over time. Mark’s key takeaway is that effective mechanical integrity depends less on “having certifications” or flashy NDE outputs and more on disciplined learning, sound decision-making, qualified people, and repeatable data—especially for something as basic as UT thickness readings. He explains how mentorship, clear procedures, verification/testing of technician capability, and consistent practices (including global standardization and technical networks) can dramatically raise both the quality and usefulness of inspection data, helping plants move away from “hope is not a plan” toward reliable, trendable integrity decisions.01:36 From Boilermaker to Inspector05:16 Mentorship and Learning Culture07:01 Decision Making as Inspector08:37 Early NDE Tools and RT Focus12:27 Picking Locations and Intervals14:00 Three Wise Men Document17:58 School and Career Motivation21:13 API 510 Origins and First Test23:21 Certifications Change the Role24:34 Certs Versus Competence25:45 Early Welding and NDE Exams27:42 Spotting Fake Credentials29:37 NDE Tech Evolution32:07 PAUT Versus TOFD35:20 Explaining Results to Management36:30 Qualification and Performance Testing38:45 Better Thickness Data42:24 CML Trending Strategy44:26 Using All the Data46:18 Averaging to Reduce Error49:57 Global Best Practices at Shell54:26 Tech Networks and Productivity Episode Acronyms & AbbreviationsAPI 510 – Pressure Vessel Inspection CodeAPI 570 – Piping Inspection Code & Inspector CertificationAPI 571 – Damage Mechanisms Affecting Fixed EquipmentAPI 653 – Tank Inspection, Repair, Alteration, & ReconstructionCML – Corrosion Monitoring LocationsCWI – Certified welding inspectorEP – Engineering practiceEPRI – Electric Power Research InstituteIDMS – Inspection Data Management SystemsMFE – Multi-flow EvaluatorNDE – Non-Destructive EvaluationPAUT – Phased Array Ultrasonic TestingRT – Radiographic TestingSFI – Slurry fracture injectionTML – Thickness Monitoring LocationsTOFD – Time of Flight Diffraction TechniqueUT – Ultrasonic Testing Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In part 2 of our conversation with Brent Ray, we take a deeper look at his extensive work with industry codes and standards through API, ASME, and NBIC. Brent reflects on how reviewing a marked up draft of API 571 in 2003 helped launch a path that later included chairing API 581, API 580, the Subcommittee on Inspection and Mechanical Integrity, and the API Inspection Summit. Throughout the discussion, he discusses the challenge of writing standards that are both technically sound and accessible, and offers advice to young engineers trying to make sense of complex and overlapping guidance.Brent also gives listeners an inside look at the 10th API Inspection Summit coming to San Antonio in July 2026, including new divisions, expanded training, a charity golf tournament, and the much-anticipated “Gray Beards” panel. He shares candid career wisdom on navigating emerging standards like ASME Section 5 Subsection C, the challenge of bridging NBIC and fitness-for-service communities, and what he hopes his legacy will be: the engineer’s engineer.Whether you are active in codes and standards work, preparing to attend your first API Inspection Summit, or simply looking to strengthen your technical foundation, Brent's perspective offers valuable lessons on leadership, communication, and what it means to serve the broader industry. Subscribe today so you don't miss our next episode! If you missed part 1 "Curiosity, Caves, & Carbon Steel", you can listen here.00:00  Introduction and API engagement origins00:49  Brent’s early history with codes and standards02:55  First API meeting experience 05:39  Chairing API 581 and saving it from sunset07:07  ASME PCC involvement and API subcommittee leadership07:50  API Inspection Summit chair role and cross-industry communication10:35  NBIC, state boiler inspectors, and the evolving role of fitness for service13:52  ASME Section 5 Subsection C — new in-service NDE rules explained18:38  Advice for young engineers navigating codes and standards22:27  Critical thinking, connecting the dots, and avoiding hasty conclusions25:19  Quick glossary: API 578, API 751, ASME PCC 1/2/3, PTB-229:36  API Inspection Summit 10th anniversary preview — San Antonio, July 202638:35  Career edification and taking one nugget a day from Summit41:15  Wildest process units: FCC catalyst and the Cuming unit explosion43:48  Career legacy — the engineer’s engineer45:36  Conclusion and podcast credits+++++++++++Episode Acronyms & AbbreviationsAI — Artificial IntelligenceAMPP — Association for Materials Protection and PerformanceAPI — American Petroleum InstituteAPM — Asset Performance ManagementASME — American Society of Mechanical EngineersEAP — Enterprise AssetSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In part 1 of our interview with Brent Ray, Fixed Equipment & Mechanical Integrity Specialist at Marathon Petroleum, we explore the experiences and influences that helped shape his engineering perspective. After opening with a pair of gripping spelunking stories, Brent traces a career path guided by curiosity and opportunity—from studying materials science and chemical engineering to supervising melt operations and eventually joining Marathon in 2002 as a corrosion and metallurgical engineer.The conversation explores how his background in metallurgy gave him a fundamental understanding of why metals behave the way they do, and how that insight continues to guide his work addressing corrosion, damage mechanisms, and equipment reliability in refinery environments. We also discuss the importance of breaking down silos between fixed equipment, inspection, maintenance, operations, and tech service, and what it looks like when that culture of communication actually takes root.Whether you are early in your engineering career, managing a team of inspectors, or simply enjoy a good story about scrap metal and Levi’s rivets, Brent’s reflections offer thoughtful perspectives on curiosity, mentorship, and the importance of understanding how materials are actually made. Part 2 of our interview with Brent Ray is now available, you may listen here.00:00  Introduction and Spelunking Stories08:02  Growing Up in West Virginia and University of Kentucky11:02  Career at Inco Alloys / Special Metals14:26  Enron’s Ripple Effect on American Industry19:28  Engineering Degrees and Mentor Dr. George Crew20:21  Lessons from the Steel Mill 23:05  The Levi’s Button Contamination Story27:32  How the Steel Mill Prepared Him for Refinery Work33:17  Transition from Steel Mill to Refinery / Joining Marathon39:21  Mindset Shift: Seeing Process from the Outside In41:13  Think Like an Inspector46:12  Critical Thinking, Curiosity, and Mentoring Young Engineers47:39  Breaking Down Silos 52:13  Cultural Shift: Communication, Adaptability, and the "Easy Button"56:30  Sense of Family at Marathon and in the Industry+++++++++++Episode Acronyms & AbbreviationsASME - American Society of Mechanical EngineersASTM - American Society for Testing and MaterialsDRI - Direct Reduced IronFEMI - Fixed Equipment Mechanical IntegrityMI - Mechanical IntegrityMOC - Management of ChangeMT - Magnetic Particle TestingNDE - Nondestructive ExaminationPMI - Positive Material IdentificationPT - Liquid Penetrant TestingRBI - Risk-Based InspectionRCM - Reliability Centered MaintenanceRP - Recommended PracticeRT - Radiographic TestingSME - Subject Matter ExSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In this episode of Upon Further Inspection, we explore the most common missteps and best practices in RBI implementation, examining what separates programs that deliver lasting value from those that fall short. The discussion highlights the importance of defining clear goals before selecting technology, building a culture where risk-based language is spoken at every level of the organization, and avoiding tactical pitfalls around data inputs, corrosion circuit classification, and damage mechanism documentation.Whether you’re launching a new RBI program, troubleshooting an existing one, or looking to push a mature program to the next level, this episode offers valuable insights on mindset, cultural adoption, disciplined execution, and the emerging role of AI and enterprise data in unlocking even greater value from your inspection investment.00:00  Introduction to RBI Implementation01:02  The Biggest Missteps: Wrong Motives and Poor Technology Selection04:54  What the Best Programs Do Right07:49  Cultural Buy-In: Speaking the Same Language Across the Organization13:12  Champions, Ownership, and People-Driven Success14:29  Tactical Pitfalls in RBI Implementation19:35  Profiles of Success and Crossing the Chasm24:44  The Next Frontier: AI, Machine Learning, and Enterprise Data28:04  Conclusion and Final Thoughts+++++++++++Episode Acronyms & AbbreviationsAI – Artificial IntelligenceAPI – American Petroleum InstituteDMR – Damage Mechanisms ReviewFCC – Fluid Catalytic CrackingMI – Mechanical IntegrityNDE – Nondestructive ExaminationRBI – Risk-Based InspectionROI – Return on InvestmentRT – Radiographic TestingSME – Subject Matter ExpertSOHIC – Stress-Oriented Hydrogen Induced CrackingSRU – Sulfur Recovery UnitUT – Ultrasonic Testing+++++++++++Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In part 1 of our interview with Lionel Roberts, he reflects on his early career at Canadian refineries, where limited resources and mentorship pushed him to think creatively and build a strong professional network.The conversation delves into Lionel's experiences at independent refineries without access to major company resources, highlighting how he leveraged industry organizations like NACE (now AMPP) and API to build expertise. He discusses the critical role of codes and standards participation, not just for professional development but for gaining access to subject matter experts across the industry. Lionel also addresses the evolution of the inspection profession, comparing NDE-background inspectors with engineer-trained inspectors, and the importance of critical thinking over task completion. He offers valuable advice for young professionals on patience, networking, and the "80/20 rule" - that knowing where (and who) to find answers is more important than having all the answers yourself.Whether you are a young engineer starting your career or a seasoned professional, Lionel’s insights on moving beyond "box-checking" to embrace critical thinking provide a roadmap for long-term success in the field.00:00 Introduction and Guest Welcome00:45 Lionel's Background in Metallurgy02:47 Journey into Mechanical Integrity05:11 The Role of AI and Experience in Metallurgy07:42 Early Career and Learning Experiences16:20 Challenges and Growth at Irving Oil19:55 Importance of Networking and Industry Participation27:36 Technical Discussions and Industry Standards34:53 Concluding Thoughts and Advice+++++++++++Episode Acronyms & AbbreviationsAFPM - American Fuel & Petrochemical ManufacturersAI - Artificial IntelligenceAMPP - Association for Materials Protection and PerformanceAPI - American Petroleum InstituteCCD - Corrosion Control DocumentIOWs - Integrity Operating Windows JIP - Joint Industry ProjectNACE - National Association of Corrosion Engineers NDE - Non-Destructive ExaminationNHT - Naphtha HydrotreaterPMI - Positive Material IdentificationRBI - Risk-Based InspectionRT - Radiographic TestingSME - Subject Matter ExpertSTG - Specific Technology GroupTUNS - Technical University of Nova ScotiaUT - Ultrasonic Testing+++++++++++Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In this episode of Upon Further Inspection, we explore the challenges and best practices for optimizing enterprise asset management systems while maintaining high availability and safety performance. The discussion highlights the importance of designing digital frameworks around organizational needs, supported by strong processes such as RBI, root cause analysis, and MOC programs, along with clear communication. Whether you're implementing a new enterprise system, struggling to optimize an existing one, or looking to improve cross-site reliability comparisons, this episode offers valuable insights on strategic planning, critical success variables, and the power of disciplined execution.00:00 Introduction to Enterprise Asset Management01:14 Challenges in Optimizing Asset Management Systems02:47 Designing Effective Digital Systems03:55 Case Study: Refining Corporation's Journey05:22 Integration Complexities and Solutions07:30 Importance of Design and Planning08:44 Balancing Availability and Cost10:41 Starting and Adjusting Asset Management Programs11:37 People-Centered Digital Transformation17:44 Continuous Improvement and Root Cause Analysis28:52 Communication and Flexibility in Implementation31:14 Conclusion and Final Thoughts+++++++++++Episode Acronyms & AbbreviationsAPI – American Petroleum InstituteCCD – Corrosion Control DocumentCMMS – Computerized Maintenance Management SystemERP – Enterprise Resource PlanningIDMS – Inspection Database Management SystemIOW – Integrity Operating WindowKPI – Key Performance IndicatorMI – Mechanical IntegrityMOC – Management of ChangeNPRA – National Petrochemical & Refiners AssociationRBI – Risk-Based InspectionRCA – Root Cause AnalysisRCM – Reliability Centered MaintenanceSME – Subject Matter Expert+++++++++++Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In the 20th episode, we mark a significant milestone, reflecting on our past guests and their diverse insights. We express gratitude to our guests and their employers for the invaluable conversations that have helped broaden the podcast’s scope, including Andri Orphanides, John Reynolds, Lynne Kaley, Bobby Wright, Clay White, and Alexander Gonzalez. We highlight the importance of networking, communication, and the evolution of industry standards, and we also emphasize our excitement about future episodes, listener engagement, and continuous progress in the industry. We look forward to more enriching conversations in 2026, especially at the upcoming API Inspection & Mechanical Integrity Summit in San Antonio, and we urge our global community of listeners to stay connected and contribute to upcoming topics.00:00 Introduction and Milestone Celebration00:45 Reflecting on the Journey02:11 Acknowledging Guests and Employers03:04 Key Themes and Surprises05:13 Technological Advances and Industry Insights13:34 Looking Ahead to 202615:22 Closing Remarks and Gratitude16:24 Credits and Legal Disclaimer+++++++++++Episode Acronyms & AbbreviationsAI – Artificial IntelligenceAPI – American Petroleum InstituteASME – American Society of Mechanical EngineersIT – Information TechnologyMI – Mechanical IntegrityNDE – Nondestructive ExaminationRBI – Risk-Based Inspection+++++++++++Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In part 2 of our interview with Alex Gonzalez, we dive into the challenges and opportunities of implementing mechanical integrity programs in modern facilities. Alex shares his experiences rolling out RBI and inspection management platforms across an enterprise, discussing the critical importance of breaking down organizational silos and securing executive buy-in for successful implementation.The conversation explores the evolving role of AI and machine learning in mechanical integrity, with Alex offering thoughtful perspectives on augmenting rather than replacing human expertise. He addresses concerns about the knowledge gap created by retiring experienced professionals and emphasizes the need for structured knowledge transfer programs. Alex also discusses the importance of viewing RBI as one tool in a larger toolkit, cautioning against over-reliance on any single methodology.Whether you're implementing new MI platforms, navigating digital transformation, or preparing the next generation of professionals, Alex's insights on change management, continuous improvement, and keeping focused on end goals provide valuable guidance for practitioners at all levels.If you missed part 1 "From Tropics to Tundra", please listen here.00:00 Introduction and Initial Role in Canada00:54 Transition to Mechanical Integrity Projects04:29 Challenges and Successes in Mechanical Integrity05:36 Importance of Cross-Department Collaboration12:23 Adapting to Rapid Technological Changes31:48 Advice for Future Engineers36:27 Conclusion and Final Thoughts+++++++++++Episode Acronyms & AbbreviationsAI - Artificial IntelligenceAPI - American Petroleum InstituteAPM - Asset Performance ManagementEAM - Enterprise Asset ManagementESOP - Employee Stock Ownership PlanFMEA - Failure Mode and Effects AnalysisGPT - Generative Pre-trained TransformerIOW - Integrity Operating WindowKPPL - Key Performance Parameter ListMI - Mechanical IntegrityMOC - Management of ChangePHA - Process Hazard AnalysisRBI - Risk-Based InspectionRCM - Reliability Centered MaintenanceR&D - Research and DevelopmentSME - Subject Matter Expert+++++++++++Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In part 1 of our interview, we welcome Alex Gonzalez, an asset performance management specialist with extensive experience in the mechanical integrity field. Alex traces his career from his studies in materials engineering and metallurgy in Venezuela through his current work in Canada's oil and gas sector. The discussion covers his focus on corrosion science, the role political circumstances played in his relocation, and his experience developing a career in two different countries. Alex provides insights on effective networking practices, explains how API certifications serve as a common language in the global industry, and discusses the value of taking initiative in career advancement.Whether you're early in your MI career, navigating your own transition, or looking to strengthen your professional network, Alex's story offers valuable lessons on resilience, adaptation, and continuous learning. Part 2 of our conversation with Alexander Gonzalez is now available, listen now!00:00 Introduction to the Mechanical Integrity Podcast00:38 Meet Alex Gonzalez: Asset Performance Management Specialist01:12 Alex's Journey into Mechanical Integrity01:36 College Days and Early Career08:56 Networking and Professional Growth20:52 Challenges and Adaptations in Venezuela25:00 Relocating to Canada: New Beginnings27:06 Cultural and Professional Adjustments43:38 Conclusion and Podcast Credits+++++++++++Episode Acronyms & AbbreviationsAPI – American Petroleum InstituteMI – Mechanical IntegrityNBIC – National Board Inspection CodeR&D – Research and DevelopmentTAN – Total Acid NumberTML – Thickness Measurement Location+++++++++++Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

Part 2 of our interview with Bill Valerioti, a semi-retired petrochemicals and chemical industry SME, is now available! We dive right in with an interesting comparison between the chemical and refining industries. Bill draws on his extensive experience to emphasize the abundance of information available in refining compared to the more secretive nature of chemical manufacturing. Bill also contrasts the differences and overlaps between industry associations, such as NACE/AMPP, API, and MTI. From start to finish, this conversation offers several valuable lessons and underscores the critical nature of adhering to quality and safety standards in the industry.If you missed Part 1 of our interview with Bill, you can listen to the episode today. 00:28 Differences Between Refining and Chemical Industries04:14 The Role of Industry Organizations07:09 Value of Continuous Learning on Career Success13:53 Future of Knowledge Transfer18:42 Welding: A Practical Perspective 26:59 The Emotional Impact of Industrial Incidents29:34 Advancements in Inspection Technology31:31 The Future of Non-Invasive Inspections36:58 The Critical Role of Skill and Qualification in NDE+++++++++++Episode Acronyms & AbbreviationsAIChE – American Institute of Chemical EngineersAPI – American Petroleum InstituteAMPP – Association for Materials Protection & Performance  ASME – American Society of Mechanical EngineersASNT – American Society for Non-destructive TestingCUI – Corrosion under InsulationGTAW TIG Welding – Gas Tungsten Arc Welding-Tungsten Inert Gas WeldingGMAW MIG Welding – Gas Metal Arc Welding-Metal Insert Gas Welding HF Alki – Hydrofluoric Alkylation unitsMTI – Materials Technology InstituteNACE – National Association of Corrosion Engineers, now known as AMPP (Association for Materials Protection & Performance)  NDE – Non-destructive EvaluationQA-QC – Quality Assurance-Quality ControlRBI – Risk-Based InspectionSME – Subject Matter ExpertTIG – Tungsten Inert Gas Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

We have a deep dive into materials engineering and corrosion this time around! In part 1 of our interview, we welcome Bill Valerioti, a semi-retired petrochemicals and chemical industry SME. From his early days in chemical engineering to finding his passion for materials engineering and corrosion – Bill shares insight into his passion for materials failure analysis, mechanical integrity, and chemical plant operations. Bill also emphasizes the importance of effective communication, mentorship, understanding process operations, and continuous learning in the field. His contributions have spanned various roles, including materials engineer, maintenance superintendent, and operations superintendent, offering a comprehensive view of the industry's evolution and challenges.If you work in mechanical integrity or engineering, this episode is a must-listen. Part 2 of our conversation with Bill Valerioti is now available, listen today!01:12 Bill Val's Educational Journey02:09 Early Career and Internship Experience03:18 Professional Growth at Phillips Petroleum05:10 Transition to Equipment Inspection08:39 Lessons from Mentorship and Operations15:07 Importance of Communication and Soft Skills23:32 Technical Insights and Industry Evolution29:10 Encouragement for Continuous Learning35:26 Building Trust and Relationships in Operations+++++++++++Episode Acronyms & AbbreviationsAPI – American Petroleum Institute DMR – Damage Mechanism ReviewHTHA – High-Temperature Hydrogen AttackMPC – Materials Properties Council (subsidiary of the WRC)NACE – National Association of Corrosion Engineers, now known as AMPP (Association for Materials Protection & Performance)  NDE – Non-destructive Evaluation NDT – Non-destructive Testing NPC – National Petroleum CouncilRBI – Risk-Based InspectionWRC – Welding Research CouncilSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

We’re excited to welcome Clay White to the podcast!In this episode, Clay shares personal experiences and incidents that fueled his dedication to improving industry safety standards. He reflects on historical events, including the polypropylene reactor leak, and how these shaped his approach to safety. The conversation explores challenges in data management, the critical role of Damage Mechanism Reviews (DMRs), and limitations of inspection technologies. Clay also highlights common industry hurdles, such as ineffective RBI implementation and the need for careful planning when transitioning IDMS platforms. Tune in for insights on best practices, emerging trends in inspection, and the ongoing evolution of Risk-Based Inspection programs.If you missed Part 1 of our discussion with Clay White, catch up here or wherever you get your podcasts.00:22 Motivation and Early Career01:06 Significant Incident and Lessons Learned05:21 Discussion on Industry Failures and Data Analysis10:40 Best Practices for Mechanical Integrity18:44 Challenges in Changing IDMS Programs ++++++++++Episode Acronyms & AbbreviationsAFPM – National Petrochemical & Refiners Association (USA)API RBI – Desktop RBI software available through Equity Software CCDs – Corrosion Control DocumentsCML – Condition Monitoring LocationDMR – Damage Mechanism ReviewEPRI – Electric Power Research InstituteHTHA – High-Temperature Hydrogen AttackIDMS – Inspection Data Management SystemIOW – Integrity Operating WindowsMI – Mechanical IntegrityMOC – Management of ChangePCMS – Mechanical Integrity Software available through MISTRASPRDs – Pressure Relief DevicesRBI – Risk-based InspectionUT – Ultrasonic Testing Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

Welcome to the world of mechanical integrity! In part 1 of our interview, we welcome Clay White to the podcast. Take a listen as Clay takes us through his career journey, from earning a welding and metallurgy degree to becoming a recognized expert in mechanical integrity, corrosion, and materials engineering – including his contributions to API 581. Our discussion explores the evolution of Risk-Based Inspection (RBI) models, flaws in the Generic Failure Frequencies (GFF), the critical role of Damage Mechanism Reviews (DMR), and how statistical analysis can sharpen inspection strategies. We wrap up with Clay’s perspective on Artificial Intelligence (AI), emphasizing the need for transparency, data accuracy, and responsible implementation.If you work in mechanical integrity or engineering, this episode is a must-listen. Part 2 of our conversation with Clay White will be published on October 16 – subscribe today!00:26 Background and Early Career02:57 Development of RBI Programs07:12 Challenges with GFF and Data Accuracy10:56 AI and the Future of Mechanical Integrity15:29 Continuous Improvement and Data Management18:33 CML Optimization and Inspection Strategies22:30 Importance of Data Tracking and Optimization25:26 Collaboration Between Engineers and Data Scientists28:39 Case Studies: Heater Failure and Corrosion Rates 32:26 The Role of AI in Data Analysis: Transparency & Reliability+++++++++++Episode Acronyms & AbbreviationsAPI 581 – Risk-Based Inspection Technology (Recommended practice developed & published by API)API RBI – Desktop RBI software available through Equity SoftwareASME – American Society of Mechanical EngineersCML – Condition Monitoring LocationsDMR – Damage Mechanism ReviewsGFF – Generic Failure FrequenciesIDMS – Inspection Data Management SystemISO – International Organization for StandardizationMI – Mechanical IntegrityQA – Quality AssuranceQRA – Quantitative Risk AssessmentRBI – Risk-based InspectionRCM – Reliability Centered MaintenanceSME – Subject Matter ExpertTMLs – Thickness Measurement Location Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In Episode 13, we are pleased to welcome industry veteran Bobby Wright to the podcast! From his beginnings working summers on an assembly line in Arkansas to becoming a business strategist and mentor, Bobby shares the valuable lessons learned and experiences that shaped his path. He discusses pivotal moments, including his roles at refineries and handling emergencies, like tornadoes. Key highlights include Bobby's involvement with coker units, advanced inspection methods, and the significance of a collaborative and well-rounded approach in achieving industry success.Reflecting on relationships forged, professional growth, and the importance of teamwork, Bobby's insights provide a comprehensive look into a dynamic and evolving career. Tune in to hear about resilience, leadership, and the future of engineering from someone who has lived it all. 01:43 Refinery Experience and Lessons05:09 Transition to DNV – Innovations, Achievements, and meeting Greg Alvarado07:12 Acoustic Emission Testing18:58 Reflections on Technological Advancements21:00 Technological Advancements and AI23:06 Journey into the Coker World29:06 Catastrophic Failures and Safety Concerns33:24 Team Collaboration and Reliability36:16 Institutionalizing Best Practices40:29 Personal Reflections and Career Influences45:51 Building Effective Teams +++++++++++Episode Acronyms & AbbreviationsAE – Acoustic EmissionsAutomated UT – Automated Ultrasonic TestingEPA – Environmental Protection Agency (USA)FEA – Finite Element AnalysisH2S – Hydrogen SulfideNDT – Non-Destructive TestingOSHA – Occupational Safety and Health Administration (USA)PSM – Process Safety Management RBI – Risk-based Inspection Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

Part 2 of our interview with Lynne Kaley is now live. In episode 12, ‘We’re Over-Inspecting’, we welcome risk-based inspection (RBI) expert, Lynne Kaley back to the show. Listen now and hear more about our small yet incredibly interconnected world of mechanical integrity professionals. Branden, Greg, and Lynne discuss the significant shift in the mechanical integrity industry over the years and how it has evolved from merely preventing failures to managing risk and reducing waste.During the conversation, Lynne hypothesizes about the “Kaley Refinery” and how high-level risk assessments and the transition to more data-driven quantitative analyses would prevail at her hypothetical plant. In addition, Lynne shares details about her extensive experience in the field, including offering practical advice and reflections on significant career milestones. This was the final segment of our interview with Lynne Kaley. You may find part 1 “Startups & New Developments” wherever you get your podcasts. 00:44 Evolution of Mechanical Integrity Practices01:11 Challenges in Mechanical Integrity and Reliability02:22 Over-Inspection and Cost Management06:11 Innovations in Inspection Techniques08:30 Starting a New Refinery: Risk-Based Approach17:19 Reflections on Career and Industry Contributions20:56 Personal Influences and Career Highlights+++++++++++Episode Acronyms & Abbreviations581 Committee – API RP 581, Risk-Based Inspection Technology API – American Petroleum InstituteBRD – Base Resource DocumentCML – Condition Monitoring LocationsP&IDs – Piping & Instrumentation DiagramPFDs – Process Flow DiagramsRBI – Risk-based InspectionTML – Thickness Monitoring Locations Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In episode 11, 'Startups & New Developments’, we welcome risk-based inspection (RBI) expert, Lynne Kaley to the show. Listen now and hear more about our small yet incredibly interconnected world of mechanical integrity professionals.In part 1 of this two-part series, Lynne discusses her journey in the industry, starting from her early days at Amaco Oil and DNV to her contributions on the API 581 committee. This conversation highlights the various challenges and opportunities she faced throughout her career, including her transition from microbiology to metallurgical engineering, and her role in creating the principles of RBI. Lynne shares her perspective on the evolution of the industry, the importance of being proactive in solving problems, and the critical role of research and development in maintaining mechanical integrity.Stay tuned for part 2 "We're Over Inspecting" is now available wherever you get your podcasts.00:44 Lynne's Early Career Journey05:43 Experience in the Field and Transition to DNV14:14 Innovative Projects and Industry Challenges22:48 Expertise and Crack Propagation24:37 Failure Analysis and RBI Development25:28 Pilot Studies and Software Development30:36 The Golden Years at DNV38:37 Challenges and Innovations in RBI +++++++++++Episode Acronyms & Abbreviations 581 Committee – API RP 581, Risk-Based Inspection Technology AE – Acoustic Emission Testing API – American Petroleum InstituteBRD – Base Resource DocumentHIC – Hydrogen Induced CrackingHIC-SOHIC – Hydrogen Induced Cracking-Stress Oriented Hydrogen Induced Cracking HTHA – High-Temperature Hydrogen AttackJIP – Joint Industry ProjectNDT – Non-Destructive TestingPTA – Purified Terephthalic AcidRBI – Risk-based InspectionSOHIC - Stress Oriented Hydrogen Induced CrackingUT – Ultrasonic TestWet H2S – Wet Hydrogen SulfideSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

Here's a sneak peek of our conversation with Lynne Kaley. You will get a taste of our lively discussion, the shared camaraderie, and potentially learn something too.  Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In episode 10, ‘Brilliant Whiz Kid,' Branden and Greg continue their conversation with industry legend John Reynolds. Join us as we look to the future of mechanical integrity and the integration of artificial intelligence. In the final part of this three-part series, listen to an in-depth discussion that starts with the application of artificial intelligence in fixed equipment mechanical integrity (FEMI) and ends with insights into the value of networking and building competency improvement plans. Once again, John Reynolds uses his extensive career to highlight the value of engaging with colleagues across the industry and within your company to help you grow professionally. Remember, your education will continue well beyond the completion of a university degree.This was final segment of our interview with industry legend, John Reynolds. You may find part 1 “The Mountains We Still Need to Climb” and part 2 “RBI Was the Way of the Future” wherever you get your podcasts. 00:45 AI and Big Data in Mechanical Integrity05:58 Why Everyone Should Network10:09 Developing Competency Improvement Plans16:36 Participation in Process Safety & MI Audits+++++++++++Episode Acronyms & AbbreviationsAI - Artificial IntelligenceAPI – American Petroleum InstituteASME – American Society of Mechanical Engineers FEMI – Fixed Equipment Mechanical IntegrityNACE – National Association of Corrosion Engineers, now known as AMPP (Association for Materials Protection & Performance)NLP – Natural Language ProcessingRBI – Risk-based InspectionSCI – API Subcommittee on InspectionSMEs – Subject Matter Experts Send a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In episode nine, 'RBI Was the Way of the Future,' Branden and Greg continue their conversation with industry legend John Reynolds. Join us and hear about the evolution of mechanical integrity practices through John’s shared experiences and expertise. In part two of this three-part series, the discussion traces the history of risk-based inspection (RBI), detailing its evolution from the nuclear power sector to its codification in API 580 and API 581 standards. Discussing the early days of RBI in the 1990s, the transition from time-based and condition-based inspection to RBI's formalized process. John shares insights from his tenure as the API 581 committee chair, recounts how he advocated for the shift towards RBI to improve industry reliability and safety. This episode also touches upon the challenges inspectors face with data overload and emphasizes the need for effective data analysis to prevent major incidents.The final episode, "Brilliant Whiz Kid" is now available, also if you missed part 1, "The Mountains We Still Need to Climb", please listen here. 00:25 Early Days of RBI03:35 The Evolution and Impact of Risk-Based Inspection08:29 Challenges in Data Analysis for Inspectors14:14 Conclusion +++++++++++Episode Acronyms & Abbreviations API 580 – Risk-Based InspectionAPI 581 – Risk-Based Inspection TechnologyAPI RBI – Equity Software’s RBI desktop software available through PlantManagerCBI – Condition-based InspectionCML – Condition Monitoring LocationsFEMI – Fixed Equipment Mechanical IntegrityMI – Mechanical IntegrityPSSAP – Process Safety Site Assessment ProgramRBI – Risk-based InspectionTBI – Time-based InspectionTML – Thickness Monitoring LocationsSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In episode eight, 'The Mountains We Still Need to Climb,' we welcome industry legend John Reynolds to the podcast. Join us and hear about the evolution of mechanical integrity practices through John’s shared experiences and expertise. In part 1 of this three-part series, John shares how he became a renowned expert in Fixed Equipment Mechanical Integrity (FEMI). Starting his career with Shell in 1968, John recounts pivotal moments including his contributions to the Inspectioneering Journal and his involvement in API standards development. He discusses the impact of major industry incidents and the evolution of standards like API 510 and 570. John also shares personal anecdotes about his love for mountain climbing and the great outdoors, how these activities have provided a balance to his professional life, and his current life in the Rocky Mountains. If you enjoyed this episode, make sure to listen to the rest of our interview with John Reynolds: "RBI Was the Way of the Future" (part 2) and "Brilliant Whiz Kid" (part 3). 00:38 Meet John Reynolds02:03 Early Career and Shell Experience04:56 Transition to Consulting and Legal Defense10:46 Passion for Mountain Climbing18:00 The Three Wise Men and API Standards30:13 Significant Industry Incidents and Lessons Learned+++++++++++Episode Acronyms & AbbreviationsAPI 510 – Pressure Vessel Inspection CodeAPI 570 – Piping Inspection CodeAPI 571 – Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI 578 – Material Verification for New & Existing AssetsBSME – Bachelor of Science, Metallurgical EngineeringCMLs – Condition Monitoring LocationsFEMI – Fixed Equipment Mechanical IntegrityNDE – Non-destructive Examination PSSAP – Process Safety Site Assessment ProgramSCIMI – Subcommittee Inspection Mechanical IntegrityTMLs – Thickness Monitoring LocationsWOSA – World Outside of AmericaSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

Upon Further Inspection is pleased to welcome back Andri Orphanides, API’s Director of ICP. We had such a great conversation going with Andri that we extended our chat and split her interview into two parts. Here’s part 2:Part two of our conversation with Andri is centered around the need for developing programs and educational pathways to attract younger generations, particularly Gen Z, to the industry. She highlights the concerning trend of Gen Z's (and Gen Alpha’s) lack of interest in mechanical integrity and the challenges it poses for the future workforce. The discussion includes ideas for integrating certifications with academic degrees, creating mentorship programs, and using modern advertising methods to engage younger audiences. The discussion also touches upon the importance of mentorship programs, onboarding processes, and continual learning to foster a growth-oriented culture. Finally, you’ll get a sneak peek into some of the 2026 API Mechanical Integrity and Inspection Summit planning. NOTE – the abstract submission deadline is coming up in August!If you missed Part 1 of our interview with Andri, listen to “Episode 6: It All Starts with the Standards” today.00:00 Introduction 00:37 Evolution of Inspection Practices01:29 Addressing Workforce Challenges03:12 Engaging the Next Generation04:21 The Role of Certifications10:01 Mentorship and Career Pathways20:19 Expanding Industry Opportunities21:27 API Mechanical Integrity & Inspection Summit 202624:46 Conclusion and Acknowledgements++++++++++++Episode Acronyms & ICP CertificationsAPI – American Petroleum InstituteCert - CertificationICP – Individual Certification ProgramsISO – International Organization of StandardsSTEM – Science, Technology, Engineering, Mathematics1169 – Pipeline Construction Inspector1184 – Pipeline Facility Construction Inspector510 – Pressure Vessel Inspector570 – Piping Inspector571 – Corrosion and Materials576 – Inspection of Pressure Relieving Devices580 – Risk Based Inspection653 – Aboveground Storage Tank Inspector936 – Refractory Personnel982 – Refractory InspectorSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

Upon Further Inspection is pleased to welcome our first podcast guest, Andri Orphanides, API’s Director of ICP. We had such a great conversation with Andri that we split her interview into two parts. In Episode 6, Greg, Branden, and Andri discuss her 14-year journey with API from an exam coordinator to a director. Andri shares insights into the evolution of the ICP certification programs, the career pathways they offer, and the importance of international standards. She highlights the growth from 11 to 21 API certification programs and new initiatives like the bolted joint program. The conversation also touches on industry changes, technology integration, and the importance of creating opportunities for veterans and newcomers to the field.Part 2 "An Education Task Force", is now available wherever you get your podcasts. 01:10 Journey into API Certification04:31 Challenges and Growth in the Credentialing World07:23 API Certification Numbers and Their Significance09:50 Expanding API Certification Programs13:40 Global Standards and Future Initiatives23:57 Career Pathways and Opportunities30:44 Conclusion and Closing Remarks++++++++++++Episode Acronyms & ICP CertificationsAPI – American Petroleum InstituteCert - CertificationICP – Individual Certification ProgramsSTEM – Science, Technology, Engineering, Mathematics1169 – Pipeline Construction Inspector1184 – Pipeline Facility Construction Inspector510 – Pressure Vessel Inspector570 – Piping Inspector571 – Corrosion and Materials576 – Inspection of Pressure Relieving Devices580 – Risk Based Inspection653 – Aboveground Storage Tank Inspector936 – Refractory Personnel982 – Refractory InspectorSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In this episode of Upon Further Inspection, hosts Branden Stucky and Greg Alvarado discuss the evolution of mechanical integrity, exploring its transition from past practices to our current standards and regulations. They recount a couple historical failures (the Union Oil Lemont refinery explosion in 1984 and the Shell Norco explosion in 1988) that highlight the importance of developing stringent inspection codes. The discussion touches upon the role of standards, the shift from localized to holistic thinking, the integration of technology, and the critical importance of mentoring and the role of generalists in the industry.  The hosts conclude this episode with some advice for new engineers – be passionate about your work, seek to understand the link between data and wisdom, and ask guidance from experienced mentors.00:00 Introduction to Mechanical Integrity Podcast02:08 Historical Events Shaping Mechanical Integrity04:47 Evolution of Codes and Standards08:59 Understanding Recommended Practices vs. Standards12:28 Regulatory Bodies and Their Roles17:31 Boiler Inspections and Heat Treatment25:19 Technological Advancements in PMI28:06 Evolution of Mechanical Integrity Programs29:06 The Role of Generalists and Specialists33:12 Challenges in Implementing Predictive Models44:24 Advice for New Asset Integrity Engineers48:35 Conclusion and Final Thoughts +++++++++++++Episode Acronyms & Abbreviations1910.119 - OSHA's process safety management of highly hazardous chemicalsANSI - American National Standards Institute (USA)API - American Petroleum Institute (USA)RP - recommended practiceASME - American Society of Mechanical Engineers (USA)ERP - enterprise resource planning softwareFEA - finite element analysisLNG - liquid natural gasNACE - National Association of Corrosion Engineers (now called AMPP - the Association for Materials Protection & Performance, USA)NBIC - National Board Inspection Code (USA)OSHA - Occupational Health & Safety Administration (USA)P&IDs - piping and instrumentation diagramPMI - positive materials identificationRBI - risk-based inspection (API RP 581)SME - subject matter expertSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In this episode of Upon Further Inspection, hosts Branden Stucky and Greg Alvarado discuss the concepts of qualitative and quantitative Risk-Based Inspection (RBI). They talk about the history of the API 581 RBI project from the early 1990s and explore how the methodologies have evolved from qualitative to quantitative approaches. The conversation highlights the benefits of both methods, the importance of systematic documentation, and the role of advancing technology in improving inspection processes. Key topics include the development of risk management tools, the transition from hand calculations to computer-based models, and the impact of RBI on damage mechanism reviews and corrosion control.00:00 Introduction to Mechanical Integrity Podcast00:20 Hosts Introduction and Episode Overview00:52 Qualitative vs Quantitative RBI01:18 Historical Context of RBI Development03:59 Evolution of RBI and Technological Advances06:48 Impact of RBI on Industry Practices08:33 Documentation and Software in RBI09:42 Future of RBI and AI Integration12:25 Closing Remarks and Podcast Credits ++++++++++++Episode Acronyms & AbbreviationsAPI - American Petroleum InstituteCCDs - corrosion control documentsCML - corrosion monitoring locationsIDMS - inspection data management systemIOWs - integrity operating windowsJIP - joint industry projectNDE - non-destructive examination (or evaluation)RBI - risk-based inspectionTML - thickness management locationsSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In Episode 3 of Upon Further Inspection, co-host Greg Alvarado continues to share stories of his career and experiences, particularly focusing on his time with DNV and the significant projects he was involved in. The episode covers detailed case studies on Hydrogen Induced Cracking (HIC) and Stress-Oriented Hydrogen Induced Cracking (SOHIC), including breakthrough practices and tests from the 1980s and 1990s. The discussion also touches on advancements in automated ultrasonic testing (UT) and the progression of metallurgical lab work to understand and mitigate material failures in the industry.00:00 Introduction to Mechanical Integrity Podcast00:22 Greg's Background and Early Career01:25 Industry Burst Tests and HIC-SOHIC Insights03:22 DNV Projects and HTHA Discoveries06:10 Automated UT and Technological Advances11:41 Pioneering Work and Industry Collaborations16:57 Concluding Remarks and Credits +++++++++++++++++++++Episode Acronyms & AbbreviationsAE Test - acoustic emission testingHIC - hydrogen induced crackingHTHA - high-temperature hydrogen attackMAWP - minimum allowable working pressureNDE - non-destructive evaluation (or examination)PSA - pressure swing adsorptionSOHIC - stress-oriented hydrogen induced crackingUT - ultrasonic testing AUT = automated ultrasonic testingSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In this episode of Upon Further Inspection, Branden asks Greg about his extensive career in mechanical integrity and reliability, starting as a chief chemist at Dutch Boy Paints to becoming a key figure at Monsanto, DNV, and finally, at Equity Engineering. Throughout the episode, Greg discusses his passion for chemistry and metallurgy, the evolution of risk-based inspection (RBI), and the technological advancements in non-destructive evaluation (NDE). He shares insights on the importance of mentoring, the integration of safety, environment, and profitability in the industry, and the educational mission behind Inspectioneering. Greg’s experience is so varied and extensive that we had to divide up his introduction into two parts, listen to episode three for the next chapter in Greg’s history. 00:00 Introduction to the Mechanical Integrity Podcast00:45 Greg's Background and Career Beginnings01:47 Transition to Monsanto and Early Career Challenges05:05 Learning and Mentorship at Monsanto14:19 The Evolution of Mechanical Integrity and RBI23:28 Navigating Regulatory Challenges and Industry Changes26:43 Regulator Types and Early Career Moves27:47 Developing the Lotus Tool and Founding Inspectioneering29:21 Educating the Industry and Regulator Training34:45 Return to DNV and the Rise of RBI38:45 Equity Engineering and Industry Collaborations45:31 Exploring IT and Software in the Industry47:36 Reflecting on Inspectioneering's Impact and Future Goals49:14 Podcast Goals and Future Discussions54:13 Conclusion and Credits +++++++++++Episode Acronyms & Abbreviations:ABSA - Alberta Boiler Safety Association (Canada)API - American Petroleum Institute API RBI - Equity Software RBI software productASME - American Society of Mechanical Engineers (USA)BRD - base resource documentCML - condition monitoring locationsHTHA - high-temperature hydrogen attackNDE - non-destructive examination (or evaluation)QA/QC - quality assurance & quality controlOSHA - Occupational Safety & Health Administration (USA)Cal OSHA - California OSHA (see above)PSM - process safety management29 CFR 1910.119 - PSM standard for highly hazardous chemicalsRBI - risk-based inspection (API 581 code)SAGE - Equity Software fitness-for-service software product (SagePlus)UT - ultrasonic testingSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.

In the inaugural episode of Upon Further Inspection, hosts Branden Stucky and Greg Alvarado kick things off with a conversation about their journeys in mechanical integrity and why this podcast exists. From the power of mentorship to the future of technology, they chat about what’s shaping the reliability and inspection world. They also explore how the industry continues to balance safety, environmental responsibility, and profitability. It’s an honest, insightful start to a series built on sharing knowledge and elevating the people behind the work.00:00 Introduction to the Podcast00:41 Meet the Hosts: Branden and Greg02:04 Branden's Journey into Mechanical Integrity07:27 The Role of Technology in Mechanical Integrity10:41 Challenges and Future of the Industry18:23 Goals and Vision for the Podcast31:21 Conclusion and Final Thoughts ++++++++++++++Episode Acronyms & AbbreviationsAPI - American Petroleum Institute (USA)CML - condition monitoring locationsERP - enterprise resource planningOSHA - Occupational Safety & Health Administration (USA)PSM - process safety management (USA)RBI - risk-based inspectionROI - return on investmentSend a text & tell us what you think!Thank you for listening to Upon Further Inspection! If you enjoyed this episode, be sure to follow or subscribe so you don’t miss the next one.  We’d love to hear from you—connect with us on LinkedIn and share your thoughts on the episode. Have ideas for future topics or guests? Email us at [email protected] us next time, wherever you get your podcasts. Until then, stay safe and stay informed.Note:  The views and opinions expressed by the guest are their own and do not necessarily reflect those of the hosts or the Upon Further Inspection podcast. This podcast is for informational purposes only and does not constitute legal or professional advice. Listeners should seek their own qualified advisors for guidance.